emo milano 2009

VOLUME XI NUMBER 7 AN ACCESS COMMUNICATIONS INC. PUBLICATION SEPTEMBER 2009

A Tool Steel for Use in HighlyStressed Mould ComponentsDeutsche Edelstahlwerkes new PH 42 Supra toolsteel is well suited for complex plastic-injectionmould components, such as manifolds. 35

A zero-pointclamping system fromHainbuch provides arigid solution that can bechanged in seconds.

Your guide to EMO2009, the biggestmachine tool fairin the world.

30

49

Case Study: How 3DPrinting Cuts Costs

Spindle Innovationsin Micromilling

IN THIS ISSUE

For more product information visit www.tool-moldmaking.com

Special Quarterly Supplement

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The global financial crisis has taken itstoll on most industries. And becausetools and moulds are used to makealmost everything, our industry and itssuppliers have been hit especially hard.From reading and conversations, I havethe impression that, for most of us, itwill take several years to get back to the

business levels of 2007 and 2008. But, though battered now,the tool and mould making industry can look forward toimprovement in 2010.

Things are not good at the moment. However, in navi-gating the business waters, one has to identify the likeliestareas of clear sailing and chart a coursethat is, form a busi-ness planthat exploits those areas that will enable you tomake the most progress.

So, what will be important to the tool and mould mak-ing industry in 2010? New products introduced by manu-facturers will drive growth, because to bring these productsto market in most cases will require new tools and moulds.Therefore, demand for new products will be a big help.

Also, diversity in terms of industries served will beimportant, because companies now largely dedicated tomature industries such as automotive will surely be lookingto get into more-dynamic industries. Industries such asmedical technology, sustainability manufacturing, renew-able energy, and aerospace are predicted to show sustainedgrowth over the next few years.

Trade fairs can help you understand growth industriesbetter. You should consider attending COMPAMED in Dssel-dorf, MEDTEC in Stuttgart, and a new congress about sus-tainability that will run alongside AMB in Stuttgart, calledNachhaltigkeits Kongress. The AMB congress will be organ-ized by SellersMedia. On the metalworking side, in additionto AMB, the major show that can make a difference for youwill be METAV in Dsseldorf; on the plastics side will be thebiggest plastics fair in the world, the K show in Dsseldorf.

Even in a depressed market, we must carry on. Keep youreyes on the bright spots appearing on the horizon of 2010.

Douglas SellersMANAGING DIRECTOR/EDITOR-IN-CHIEF

Seize the Opportunities to Rebound in 2010

Editors MessageEditors Message

September 2009 European Tool & Mould Making 3


http://www.delcam.commailto:[email protected]://www.etmm.info/2009/09/002

September 2009

11 Mec-Spe Survey Reveals an OptimisticMechanical Engineering Industry

11 Sandvik Coromants New GlobalPresident Is a Seasoned Veteran

12 Industry News in Brief

EuroMold News14 EuroMold 2009 Designates Poland, a

Leading Mould Making and ToolingMarket for Germany, as Host Country

14 Successful EuroMold Concept BeingExported to America: Amerimold2010 to Be Held in Cincinnati, Ohio,Next May

ISTMA News17 13th ISTMA World Conference Set for

June 2010 in Canada

Technology18 Synchronous Motors and Shaft Cooling

Are Among Spindle System InnovationsThat Support Micromilling

18 Multithreading Capability in NewCAD/CAM Suite Takes Advantage ofMultiprocessor Computing Advances

Case Studies22 Reports from the field: a detailed look

at how different shops resolved theirreal-world problems

Spotlight:Cutting Tools26 New insert grades, microdrills for titanium,

tool selection software, and more

Spotlight:MachiningAccessories30 A zero-point clamping system, a

CNC simulator, and a patented newfiltration system for cutting fluids usedin grinding and lapping machines

Products & Services32 Recently introduced equipment and

services from all over

Table of ContentsTable of Contents

Industry News7 Mould Industry Convenes in Turkey for

Mould Eurasia and the Annual SpringMeeting of ISTMA Europe

8 Preparations Are Under Way for 26thBIEMH, Scheduled for Bilbao in theLate Spring of 2010

8 Fixturing System Manufacturer HorstWitte Gertebau Celebrates 40thAnniversary of Its Establishment

10 Through Corporate Acquisition,Mcanumric Integrates DCBDigitalControl Water-Jet Cutting Business

10 Nineteenth International PlasticsIndustry Fair Plast Eurasia Istanbul2009 to Take Place in November

40

8

Erowa AGBoth machine and operator are

better protected when using thisdatum-point tooling system.

Horst Witte GertebauBarskamp KGThe fixturing system manufacturercelebrates its 40th anniversary inbusiness.

Leica Geosystems AGLaser trackers equipped with improved vision

technology eliminate a major problem inmeasuring moving targets.

52

CNC Software Inc.The multithreading capability in a new CAD/CAM suitetakes advantage of multiprocessor computing advances.

21

4 European Tool & Mould Making September 2009

Volume XI Number 7

EDM Europe41 The Autumn 2009 issue of our

quarterlymagazinefor users of electrical dischargemachining technologies

EMO Milano 200949 The World of Machine Tools is held

every other year,and its comingsoon to Milan,Italy. Ourexclusive guideshows tool andmould makerswhat to look forat the show

Quick Sourcing Grid:MachiningEquipment60 Just in time for EMO 2009, a handy

table of companies supplyingmachining equipment to thetool/mould industry

Company Index66

48

31

DP Technology EuropeOne American EDM shop learns how CAMsoftware can help it improve electrodeprogramming and cycle time.

NEXT ISSUENEXT ISSUE

NUM AGA cutting head and CNC

simulator allows machine toolbuilders to extend performance.

DMG Vertriebs-und Service GmbHA big display of high-techmachine tools at EMO willinclude seven world firsts.

59


Trk+Hillinger GmbH78532 Tuttlingen Germany

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Tool & Mould Suppliers Guide Fakuma Focus on Hot Runners

and Tool/Mould Components Spotlight: Materials

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European Headquarters, Comeniusstr.2, 40670 Meerbusch, Germany.Tel +49 2159 91890 email [email protected]

CHOOSE JAPANS NO. 1

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V O L U M E X I N U M B E R 7 S E P T E M B E R 2 0 0 9

EUROPEAN TOOL & MOULD MAKINGAn Access Communications Inc. publication

Contract-published 9 times per year by SellersMedia

PUBL ISHER

Clay [email protected]

EUROPEAN AGENCY

SELLERSMEDIA*Otto-von-Guericke-Ring 3A, 65205 Wiesbaden, Germany

Tel: +49 6122 95590 Fax: +49 6122 [email protected]

MANAGING DIRECTOR/EDITOR- IN-CHIEF

Douglas Sellers*[email protected]

OPERATIONS MANAGER

Robert Bonds*[email protected]

PRODUCTION, C IRCULATION & INFORMATION SERVICES MANAGER

Sylvia Zwick*[email protected]

GRAPHIC DESIGNER

Jason Sellers*[email protected]

INFORMATION TECHNOLOGY SPECIAL IST

Markus Mller*[email protected]

SALES MANAGER EUROPE

Britta Solloway*[email protected]

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Evelyne Gisselbrecht33 Rue du Puy-de-Dme, 63370 Lempdes, France


REPRESENTATIVE AGENT FOR TAIWAN, CHINA & HONG KONG

Robert Yu, Worldwide Services Co. Ltd.11F-B, No. 540 Wen Hsin Road, Section 1, Taichung 408, Taiwan


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EDITORIAL CONTRIBUTIONS: Product/service information bulletins and press releases should besubmitted in English and should be accompanied by a colour photograph or transparency. Thepublishers assume no responsibility for return of artwork, photographs, or manuscripts. NOTICE:Every precaution is taken to ensure accuracy of contents; however, the publishers cannot acceptresponsibility for the correctness of the information supplied or advertised or for any opinionexpressed herein.

SUBSCRIPTIONS: European Tool & Mould Making is published 9 times per year, plus the supplementalEDM Europe Buyers Guide, and is distributed free of charge to qualified readers in Europe.

Nonqualified readers in Europe: US$100 (1 year), US$175 (2 years)Readers outside Europe: US$150 (1 year), US$275 (2 years)Single copies: US$25. Payments to be made in US dollars.

Subscription inquiries, back issues, address changes: send your request to EUROPEAN TOOL & MOULD MAKINGby e-mail to [email protected] or by fax to +49 6122 51090.

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Printed at: Kssinger AG, www.koessinger.de

Copyright 2009 ACCESS COMMUNICATIONS INC. ALL RIGHTS RESERVED

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Tyap Bursa Fair Inc. and Prestij Pub-lishing (Mould World Magazine) collab-orated to organize a trade event com-prising three fairs that was stagedsuccessfully in Bursa, Turkey, in May.Some 16,000 people visited MouldEurasia 2009, Bursa Autotechnic2009, and Bursa Sheet MachiningTechnologies 2009. Mould Eurasia fea-tured 275 exhibiting companies from20 countries and drew visitors fromTurkeys many industrial centres.

Mould Eurasia was the third editionof the mould technologies and sub-industries fair to take place in Bursa,an industrial city in western Turkeythat is the home of automotive manu-facturers and their supply industries.The mould making fair and the twoassociated events were held in theTyap Bursa International Fair andCongress Centre and supported byUKUB (the Tool Manufacturers Associ-ation of Turkey), the city governmentof Bursa, and the Bursa Chamber ofIndustry.

The spring meeting of the Europeanbranch of the International Special

Mould Industry Convenes in Turkey for Mould Eurasia and the Annual Spring Meeting of ISTMA Europe


Industry NewsIndustry News

Tooling & Machining Association(ISTMA) was convened in Bursa simul-taneously with Mould Eurasia 2009.ISTMA meeting attendees and showvisitors interested in developments inthe mould making and mouldingindustries were able to acquire valu-able information from mould semi-nars presented at Mould Eurasia inparallel to the exhibition.

Mould Eurasia 2009BURSA, TURKEY



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The joint organizers of BIEMH 2010,the Spanish Association of MachineTool Manufacturers and the BilbaoExhibition Centre (BEC), have begunpromoting the next edition of thebiennial international machine toolexhibition held in Bilbao, Spain. Re-sponding to the impact they know thecurrent economic contraction has had

This past summer, HorstWitte Gertebau Bars-kamp KG marked the40th anniversary of itsfounding. The companyoriginally began as a sub-contractor that producedhigh-accuracy aerospaceparts, but today it is aninternationally respectedmanufacturer and suppli-er of a range of fixturingsystems for measuringand machining. Wittenow employs a workforceexceeding 200 people.Since 1969, more than100 apprentices havecompleted their trainingat the company, andmost of them stayed onas full employees.

The recruiting of qual-ified technical personnel

starts at home, explains Horst Wittehimself, the company founder. Themanufacturing of accurate, sometimescomplicated, partsmostly made inhigh-tensile aluminiumrequires con-siderable expertise. Our training man-agement greatly contributes to secur-ing and maintaining our high qualitystandards.

Horst Witte Gertebau Barskamphas long been known for its Alufixmodular fixturing system which, inaddition to various vacuum clampingtechnologies that Witte has devel-oped, is marketed through subsidiariesand partners worldwide. Continuousdevelopment of new products andproduct enhancements is Wittes strat-egy for retaining its market leadershipin the area of measurement and ma-chining fixtures.

on capital goods manufacturers, theorganizers decided to hold standrental rates for 2010 at the same levelas for the previous BIEMH. They areoffering exhibitors extra features basedon the amount of space rented, alongwith preferential reservation options,easy payment terms, and special pack-age deals for stand decoration.

Most significant, the 26th BIEMHwill not take place in March, ashas been traditional. The datesinstead are May 31June 5, 2010,to allow more time for an eco-nomic recovery to commence.

The 25th edition of BIEMH in2008 brought together manufac-turers and purchasers from 36countries, and occupied all sixexhibition halls at the BEC. Thatfair had 1,761 exhibitors and wel-comed 50,712 trade visitors.

BIEMH 2010 will be organizedto present displays in the areas ofcutting and shaping machine

tools; other machinery, includingequipment for welding, flame-cutting,and surface treatment; tools for ma-chine tools; parts, components, andaccessories; production automation;and metrology and quality control.

Preparations Are Under Way for 26th BIEMH,Scheduled for Bilbao in the Late Spring of 2010

Fixturing System Manufacturer Horst Witte Gertebau Celebrates 40th Anniversary of Its Establishment

BIEMH 2010BILBAO, SPAIN


Horst Witte Gertebau Barskamp KGBLECKEDE, GERMANY

www.etmm.info/2009/09/008Company founder Horst Witte.

http://www.etmm.info/2009/09/007http://www.etmm.info/2009/09/008

Find out more about the new NBV series on: www.mag-ias.com/nbv

NBV More than the sum of its parts.

, Modular DesignDesigned to enable a range of table and spindle combina-tions in either 3-, 4-, 5-axisand millturn configurations, the NBV platform provides the ideal machine performance to meetthe demands of your application requirements.

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Mcanumric S.A.ALBI, FRANCE


Plast Eurasia Istanbul 2009ISTANBUL, TURKEY


Through Corporate Acquisition, Mcanumric IntegratesDCBDigital Control Water-Jet Cutting Business

Nineteenth International Plastics Industry Fair Plast Eurasia Istanbul 2009 to Take Place in November

At the beginning of thisyear, Mcanumric S.A.acquired the businessof DCBDigital Con-trol, a well-establishedFrench manufacturer ofcutting equipment thatuses jets of pure wateror abrasive water. Thelatter technology hasapplication in variousmechanical industries,among others. DigitalControl production ac-tivity is being trans-ferred to Mcanumr-ics main site in Albi, insouthern France, and anew equipment rangewill soon be launched.Digital Control very-high-pressure (VHP)generators will be pro-gressively replaced bythose of the worldwide leader KMT.

Since its creation more than 15years ago, says company CEO ArthurPas, Mcanumric has been building

Turkeys plastics indus-try now holds a 1.6%share of the worldwideindustry. In terms of itsprocessing capacity to-day, Turkey ranks sixthamong European coun-tries. Its European rank-ing in synthetic-fibreproduction is secondand in window profilesis third. Annual plasticmaterial consumptionin Turkey has increasedby 12% on average overthe past five years, and that rate isexpected to increase to at least 15% incoming years. Turkey is where theglobal plastics industry will meet inNovember for Plast Eurasia Istanbul2009, the 19th International IstanbulPlastic Industries Fair.

Fair dates are November 1922,2009, and the venue is the Tyap FairConvention and Congress Centre inBykekmece, just west of the Istan-bul metropolis.

The organizer has been promotingthe event heavily through domestic

and international in-dustry publications andtrade shows, so a suc-cessful fair can be antic-ipated. At its most re-cent edition, in 2008,Plast Eurasia featured arecord-breaking num-ber of exhibitors (1,018,from 42 countries) andvisitors (27,018, includ-ing 3,391 from 60 for-eign countries).

A noteworthy aspectof the 2008 meeting of

Plast Eurasia was that around $100million worth of business in plastics-processing machinery was conducteddespite the recession.

its success by combining strong inter-nal development, through an integrat-ed research department, very wellstructured purchasing department, and

highly reactive after-sales service net-work, with selective and controlledexternal growth. Through the acqui-sition of DCB, which Pas calls a greatopportunity, Mcanumric reinforcesits international position.

Mcanumric is the only world-wide producer with expertise in all thetechnologies necessary to design, pro-duce, install, and maintain complete,customized solutions for cutting byVHP water jetas well as by addition-al cutting processes, such as milling,plasma, laser, knife, and ultrasonics,Pas explains.

The Mcanumric group of compa-nies includes Charlyrobot SAS, amilling machine specialist, and ICTechnologie SARL, which offers cus-tomized vacuum-forming and dryingequipment, in addition to Mcanu-mric S.A. Several subsidiaries and anetwork of exclusive distributors ex-tend the Mcanumric presence tomore than 60 countries worldwide.




Mec-Spe 2010PARMA, ITALY



Mec-Spe Survey Reveals an OptimisticMechanical Engineering Industry

Sandvik Coromants New Global President Is a Seasoned Veteran

The six themed trade fairs of Mec-Spe2010, the international exhibition forspecialized mechanics organized bySenaf S.r.l., will come to the Parma Fair-grounds March 2527. In preparationfor the event, and in recognition of theeconomic situation affecting major seg-ments of the global manufacturingindustry, Senaf sponsored a spring sur-vey, the results of which suggested thatItalian mechanical engineering compa-nies were strong and optimistic.

The Marketing Centre of Milan sur-veyed the industry and its supply sec-tors, analyzing responses gleaned from348 Italian companies. Results indicat-

The cutting tool and tooling systemsspecialist Sandvik Coromant appoint-ed a new president this summer. Takingup the position on September 1 wasTom Erixon, who left behind his role aspresident of Sandvik Hard Materials, aproduct area within Sandvik Tooling.

Erixon had held that job since 2003. Hecontinues to be a member of the Sand-vik Tooling Executive Group.

Erixon, 48, has occupied variouspositions within the Sandvik Group,and previously with the Boston Con-sulting Group. He obtained a law de-gree at Lund University in Sweden, andthen went on to earn an MBA at theUniversity of Navarras IESE BusinessSchool in Barcelona.

Outgoing Sandvik Coromant presi-dent Kenneth Sundh was appointedexecutive vice president of SandvikTooling. He now has responsibility forglobal strategic projects. Both manage-rial changes are seen by the SandvikGroup as further steps in the develop-ment of its Tooling business area.

ed that Italian manufac-turers in mechanical engi-neering had some doubtsabout future turnover andorders but generally ex-pected to keep operatingat current levels.

Italian companies feltthe downturn principallyin customer relationships:the worst consequences ofthe economic crisis for

62% of them were customer insolven-cies and delays in receiving payments.Reduced investment in machines andproduction processes was a critical issuefor 47%, while 35% cited the difficultyof access to credit.

Most companies would wait for mar-ket stabilization before rethinking busi-ness strategies, according to the survey.Half of those surveyed had no particu-lar plan for getting through the reces-sion, while 31% intended to reorganizecompany structure to optimize costs.

Sandvik Coromant EuropeZAVENTEM, BELGIUM


Tom Erixon, global president of Sandvik Coromant.

http://www.etmm.info/2009/09/012http://www.etmm.info/2009/09/013http://www.rosmould.comhttp://www.etmm.info/2009/09/014


Industry News in BriefIndustry News in Brief

When European mould and die mak-ers want to purchase polishing stones,mounted points, industrial sharpeningstones, diamond compounds, or otherproducts from the North Americanspecialist supplier Boride EngineeredAbrasives, they need not wait weeks,or even days, for their order to arrive.Boride, headquartered in Michigan,USA, and a leading manufacturer ofbonded abrasive products for themould and die industry, is seeking tobe known as much for its global distri-bution and world-class service as forthe performance of its products.

Customers increasingly expect dieand mould shops to produce low-costtools with short lead times. Borideand its network of industrial distribu-tors help make that happen, offeringnext-day delivery to manufacturers inmore than 30 countries. The supplieremphasizes speed, product quality,and competitive pricing and aims toenable mould and die shops to fulfilltheir customers requirements on timeand within budget.

The 2nd EPLA International Fair ofPlastics and Rubber Processing will beheld in Poznan, Poland, February 24,2010. EPLA 2010 will be staged in themost modern complex of pavilions atthe fairgrounds. These pavilions fea-ture full technical infrastructure toaccommodate even the most demand-

Boride AbrasivesDelivered Next Day

Plastics Trade Fair Coming to Poznan

Haas Automation has made its ma-chine tool CNC control, designed forease of use, more powerful than everby giving it the capability to translateand run most Fadal-specific CNC pro-grammes without reposting or manualediting. Long known for its operator-friendly interface and intuitive pro-gramming systems, the Haas control

Haas Control NowSpeaks Fadal

Fanuc GE CNC Europe S.A.ECHTERNACH, LUXEMBOURG

www.etmm.info/2009/09/018Boride Engineered AbrasivesTRAVERSE CITY, MI, USA


The 2009 European Cutting Tool Con-ference, organized by the EuropeanCutting Tools Association (ECTA),takes place on October 7 in Milan, inconjunction with the metalworkingtrade fair EMO Milano 2009. Numer-ous delegates from Europe and guestsfrom America and Asia will be attend-ing. Its international aspect ensuresthat the 2009 ECTA conference willaddress the global, not merely Euro-pean, challenges the cutting toolsindustry confronts.

The conference represents an im-portant networking opportunity forthe industry. Because the sector islinked with all areas of the global man-ufacturing industry through the sup-ply of cutting tools and holding fix-tures and related services, a variety ofexperiences from many different in-dustries will be shared. ECTA expectsthat participants will go away withideas for getting through the currenteconomic crisis and securing a promis-ing future for their businesses.

ECTA ConferenceScheduled in Milan

GE and Fanuc are dissolving the GEFanuc Automation Corp. joint ven-ture, the European headquarters ofwhich is Fanuc GE CNC Europe S.A.in Luxembourg. Their agreement letseach company refocus investments soas to grow existing businesses and pur-sue core industry expertise. Under itsterms, Japan-based Fanuc will retainand reinforce its CNC portfolio andUS-headquartered GE will continue toinvest globally in industrial automa-tion and process control systems, soft-ware solutions, and embedded com-puting. The dissolution should becompleted by the end of 2009, subjectto customary closing conditions.

Established in 1986 through jointGE and Fanuc investment, GE FanucAutomation grew to become a leadinghigh-performance technology compa-ny serving a wide array of industriesworldwide. The partnership delivershardware and software solutions, serv-ices, automation, embedded comput-ing systems, and CNC products.

GE Fanuc Ends Joint Venture

European Cutting Tools AssociationFRANKFURT/MAIN, GERMANY


EPLA 2010POZNAN, POLAND



ing exhibitors and are joined by glazedwalkways. The fair will display process-ing machines, tools and equipment;finished and semifinished products;additives; computer software and hard-ware; and much else. In addition tothe exposition, the organizer is plan-ning a rich programme of conferenceevents, including seminars, panel dis-cussions and lectures.

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The manufacturing technology tradefair TIME 2009 takes place October 29through November 1 at the CNR Expoin Istanbul, Turkey. Exhibits of ma-chines and auxiliary technology willattract industrial professionals lookingto equip their production facilities fora competitive global arena. TIME isorganized and staged by Istanbul TradeFairs, which expects more than 25,000

visitors from Europe and the MiddleEast, as well as Turkey, to attend.

TIME 2009 features more than 200exhibitors from Turkey, Asia, NorthAmerica, and Europe. In the active ex-hibition area, which measures some30,000 m2, visitors will see machinesand devices for sheet metal processing,welding, surface processing, and metalmoulding and casting; industrial ro-bots, automation technology, and hy-draulic and pneumatic systems; CAD/CAM systems; measuring and qualitycontrol devices; cutting lubricants;and many related products.

owned by a group of investors led byAvenue Capital Group and DDJ Capi-tal Management LLC. Completion ofthe purchase enables the Milacronbusinesses to emerge from Chapter 11bankruptcy and puts them in astronger competitive position than atany time in the past decade.

Milacron LLC is a new, privatelyheld entity with a strong balancesheet: it has over $500 million less inliabilities, including roughly 80% lessdebt than the previous company. Ithas also secured a $55-million revolv-ing credit facility, and a $75-millionsecond-lien term loan facility has beenprovided by the new group of in-vestors led by Avenue Capital.

Milacron LLC is headed by Presi-dent and CEO Dennis Smith, an exec-utive with an impressive turnaroundtrack record.

The new companys business struc-ture retains the global brands ofMilacron Injection and Extrusion,Uniloy, D-M-E, and Cimcool.Milacron LLC has completed its previ-

ously announced purchase of substan-tially all of the businesses and assets ofMilacron Inc. The new company is

TIME 2009 OpensOct. 29 in Istanbul

Milacron ExitsChapter 11

Milacron LLCBATAVIA, OH, USA


TIME 2009ISTANBUL, TURKEY



now expands on its reputation byallowing machine operators to convertFadal-specific programme formats andcodes to standard Haas format andcodes right at the control in a matterof seconds. In cases where editing isnecessary to remove ambiguities, thecontrol alerts the user to the section inquestion.

Haas Automation Europe N.V.ZAVENTEM, BELGIUM


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With Poland as the designated hostcountry, EuroMold 2009, the leadingtrade fair for mould making and tool-ing, design, and application develop-ment, is placing a dedicated emphasison one of the key states in EasternEurope and a neighbour whose econo-my is soaring. EuroMold organizerDEMAT GmbH is exerting considerableeffort in marketing Poland as a grow-ing mould making and tooling centre.

At this years EuroMold, takingplace December 25 in Frankfurt, Ger-many, Polish organizations such as theBydgoszcz Industrial Cluster, with astand in Hall 9.0, will introduce them-selves to fair visitors. To promote andreinforce business contacts, EuroMold2009 will be offering a first-time inter-national cooperative exchange calledMoldMatch, with a focus on Poland.International Synergy Exchange Po-land is another EuroMold featureDEMAT has under development.

With the premiere of Amerimold2010 next May 1113 in Cincinnati,Ohio, USA, DEMAT GmbH will launchits successful EuroMold trade fair con-cept in America. Organized in coopera-tion with Gardner Publications Inc., avenerable producer of industry maga-zines, websites and events, Amerimoldis intended to be the leading NorthAmerican fair for mould making andtooling, design, and application devel-opment. Following the EuroMold pat-tern, Amerimold will highlight theworld of moulds and tools, includingrelated technologies such as rapid pro-totyping and rapid manufacturing.

Having started successfully in Asia,we now are pleased to have the oppor-tunity to bring the EuroMold conceptand experience to the North Americanmarket, said Dr. Eberhard Dring,director of DEMAT GmbH, in announc-ing the agreement of cooperationbetween DEMAT and Gardner at NPE2009 in Chicago in June. Our target is to

create the most important marketplacefor mould making, tooling, and prod-uct development in North America.

Since 2006, DEMAT has been trans-ferring the EuroMold fair concept tokey foreign markets. EuroMold pavil-ions have been established at Ros-Mould (the next is June 24, 2010, inMoscow) and at Diemould India (com-

ing March 1820, 2010, in Mumbai).In addition, DEMAT organizes the tradefair Asiamold in cooperation withMesse Frankfurt. The next edition ofAsiamold is being held September1618, 2009, in Guangzhou, China.

Poland is the largest market amongthe new EU countries, with an econo-my that has registered stable growthfor more than 10 years. An increase ingross national product is expectedeven for 2009. Wage development,employment, and consumption and

investment are all trending positively.According to industry estimates, thePolish moulding and tooling sector,including raw material suppliers andplastics processors, consists of morethan 800 companies, with about halfof them operating in the regionaround Bydgoszcz.

Industry experts certify that the Pol-ish tool and mould making sector hasenormous growth potential. Compa-nies interacting with Polish firmsreport that the business climate inPoland is hospitable and that agree-ments reached are fair and binding.

Poland has already become anappealing market for the Germanmould making and tooling industry,attested Marko Schlken, CEO ofWerkzeugbau Ruhla, at a EuroMold-related press conference.

EuroMold 2009 Designates Poland, a Leading Mould Makingand Tooling Market for Germany, as Host Country

Successful EuroMold Concept Being Exported to America: Amerimold 2010 to Be Held in Cincinnati, Ohio, Next May

Amerimold 2010CINCINNATI, OH, USA


EuroMold 2009FRANKFURT/MAIN, GERMANY


EuroMold NewsEuroMold News

At the announcement of cooperation between DEMAT and Gardner (left to right): Gardner Publications Inc. CEORichard Kline, DEMAT GmbH director Eberhard Dring, and Amerimold managing director Lisa Dodge.


Wilhelm-Maier-Str. 3 D-73257 Kngen Phone +49- (0 )7024/98385-0 Fax +49- (0 )7024/98385-30 e-mail: [email protected] www.matec.de

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ISTMAISTMA

The International Special Tooling &Machining Association (ISTMA) is awell-established international organi-zation representing some two dozennations special tooling and machin-ing organizations on three continents:North America, Europe, and Asia.

ISTMA Europe represents the indus-try in matters concerning industrialrelations in the European Union.Among its many activities, it conducts

a dynamic schedule of exchanges ontechnical subjects in the special tool-ing and machining sector; promotescommunication among its memberson a wide variety of industry concerns;maintains an information pool ontechnical investigation subjects; trans-fers performing management actionsamong its member associations; andsupports European fairs and exhibi-tions focusing on special tooling.

For information, contact:Mr. Fausto RomagnaniSecretariat, ISTMA Europec/o Cefamol Av. D. Dinis 17, Aptdo. 2572430-263 Marinha Grande, PortugalTel. +351 244 575150 Fax +351 244 [email protected]

CZECH REPUBLICTool Factories AssociationMr. Vaclav Klicka [email protected] NastrojarenCeskoslovenske Armady 118156215 Usti nad OrliciTel. +420 465 557101 Fax +420 465 525128www.svaz-nastrojaren.cz

ESTONIAEstonian Special Tooling AssociationMr. Andres [email protected] tee 1 74001 Viimsi vald, Harjumaa Tel. +372 620 5902 Fax +372 620 5901www.emliit.ee

FINLANDTechnology Industries of FinlandMr. Veli Matti [email protected] 10 00130 HelsinkiTel. +358 9 1923373 Fax +358 9 624462www.techind.fi

FRANCEAFIM (Association Franaise desIndustries du Moule, Modle et Maquette)Mrs. Catherine [email protected]/41 Rue Louis Blanc 92400 CourbevoieTel. +33 1 47176412 Fax +33 1 47176360www.afim-france.com

GERMANYVDMA Die and MoldDr. Wolfgang [email protected] Strasse 18 60528 Frankfurt/MainTel. +49 69 66031251 Fax +49 69 66032251www.vdma.org

HUNGARYSZMSZ (Hungarian Toolmakers Association)Dr. Sndor Markos [email protected] u. 31/C 1139 BudapestTel. +36 1 3402972 Fax +36 1 3295425www.szmsz.hu

ITALYUCISAP (Unione Costruttori ItalianiStampi & Attrezzature Precisione)Mrs. Fausta Antinori [email protected] Fulvio Testi, 12820092 Cinisello Balsamo (MI)Tel. +39 02 26255392 Fax +39 02 26255214www.ucisap.it

LATVIALatvian Tool and Prototype ProducerAssociationMrs. Natlija Ivanova [email protected] str. 2c Riga 1046Tel. +371 678 07794 Fax +371 678 07780www.lipra.lv

POLANDStowarzyszenie Techniczne - Tworzywa SztuczneMr. Maksymilian [email protected], ul. Graniczna 1005-816 MichalowiceTel. +48 22 7233812 Fax +48 22 7235201www.stts.com.pl

PORTUGALCefamol (Associaao Nacional da Industria de Moldes)Mr. Manuel [email protected]. D. Dinis 17, Aptdo. 257 2430-263 Marinha GrandeTel. +351 244 575150 Fax +351 244 575159www.cefamol.pt

SLOVENIAChamber of Commerce and Industry ofSlovenia (Metal Processing Association)Ms. Janja [email protected] 9 1504 Ljubljana Tel. +386 158 98308 Fax +386 158 98100www.posvet-orodjarstvo.com

SOUTH AFRICAToolmaking Association of South Africa(TASA)Mrs. Alet Balaam [email protected] Alexander Road, WestmeadKwazulu Natal P.O. Box 661 3600 PinetownTel. +27 31 7005563 Fax +27 31 7005562www.tasaweb.co.za

SPAINFEAMM (Federacin Espaola de AsociacionesEmpresariales de Moldistas y Matriceros)Mr. Josep Font [email protected] Tecnolgic del Valls, Ceramistes 208290 Cerdanyola del Valls (Barcelona)Tel. +34 93 5944747 Fax +34 93 5944737www.feamm.com

SWEDENSvensk Industrifrening (SINF)Mr. Niklas Eidersjo [email protected] 14, P.O. Box 22307104 22 StockholmTel. +46 8 4401170 Fax +46 8 4401171www.sinf.se

SWITZERLANDSwissmem (Swiss Mechanical and Electrical Engineering Industries)Mr. Peter Vogel [email protected] 4, 8032 ZrichTel. +41 44 3844811 Fax +41 44 3844846www.swissmem.ch

TURKEYTool Manufacturers Association of Turkey (UKUB)Mrs. Solmaz Ugurlar [email protected] Karaer Cad. Cigdem 2 Sok. PK:41 DOSAB, BursaTel. +90 224 2615892 Fax +90 224 2615893www.ukub.org.tr

UNITED KINGDOMGTMA (Gauge and Tool Makers Association)Mrs. Julia Moore [email protected] Forge House, Summerleys RoadPrinces Risborough, Bucks HP27 9DTTel. +44 1844 274222 Fax +44 1844 274227www.gtma.co.uk

Listing of ISTMA Europe Member Associations

mailto:[email protected]://www.svaz-nastrojaren.czmailto:[email protected]://www.emliit.eemailto:[email protected]://www.techind.fimailto:[email protected]://www.afim-france.commailto:[email protected]://www.vdma.orgmailto:[email protected]://www.szmsz.humailto:[email protected]://www.ucisap.itmailto:[email protected]://www.lipra.lvmailto:[email protected]://www.stts.com.plmailto:[email protected]://www.cefamol.ptmailto:[email protected]://www.posvet-orodjarstvo.commailto:[email protected]://www.tasaweb.co.zamailto:[email protected]://www.feamm.commailto:[email protected]://www.sinf.semailto:[email protected]://www.swissmem.chmailto:[email protected]://www.ukub.org.trmailto:[email protected]://www.gtma.co.ukmailto:[email protected]://www.istma-europe.com


The 2010 World Tooling & Machining Conferencethe13th International Meeting of the International SpecialTooling & Machining Association (ISTMA)will take placenext June 2024 at the Windsor Convention Centre & Casi-no in Windsor, Ontario, Canada. The host member is theCanadian Tooling & Machining Association (CTMA),which will be sharing the duties of organization with its US-based partner, the National Tooling & Machining Associa-tion (NTMA).

This next ISTMA World will be the 13th opportunitythat members of the Europe, Asia, and Americas branches ofISTMA have had to meet in general session. Its theme isGlobal Opportunities for Special Tooling & MachiningCompanies. With an anticipated attendance of 300 to 500delegates from around the world, the 2010 ISTMA WorldConference is the first in the series to be held in Canada.

The 13th ISTMA World will be accompanied by the 11thInternational Pattern-Model Makers Congress. Both confer-ences are convened every three years in order for memberassociations and companies to get together, exchange in-formation, and explore new and better methods for cross-border or global collaboration.

ISTMA is an international association representing some30 national special tooling and machining associations inits three regional branches. Collectively, ISTMA memberassociations represent in excess of 8,000 companies whoseannual sales add up to more than $50 billion.

CTMA is inviting companies that belong to memberassociations to be corporate sponsors for the 2010 WorldTooling & Machining Conference. Sponsorship provides thecompany with an opportunity to showcase and promote itsproducts directly to company owners and senior staff execu-tives from around the world at a high-profile industryevent. In addition to being listed as a corporate sponsor inall printed and electronic promotional materials, sponsorsmay mount a tabletop exhibition in the conference hoteland will receive one complimentary registration to all con-ference events, plus other perks.

13th ISTMA World ConferenceSet for June 2010 in Canada


CHRI

STO

PHER

JON

ES

Canadian Tooling & Machining Association (CTMA)CAMBRIDGE, ON, CANADA


http://www.istma-europe.comhttp://www.etmm.info/2009/09/027http://www.etmm.info/2009/09/028

Steady progress in the miniaturizationof industrial parts has made micro-milling an ever more important manu-facturing process. Medical devices, op-tical component housings, and EDMtooling are typical micromilling appli-cations. To meet demanding perform-ance expectations requires use of theright spindles. Thus, a new generationof micromilling spindles offered byFischer AG Przisionsspindeln setsimproved market benchmarks for reli-ability, speed and precision.

Synchronous MotorsWhether a synchronous motor is to bepreferred for an ultra-high-precisionapplication depends on the outcomeof an accurate analysis of specific ap-plication requirements. Both asyn-chronous and synchronous motors arevery robust. However, improper para-meterization of the converter systemdriving the spindle can cause a fatalerror. Consideration of the total

mechatronic system (spindle includ-ing motor, plus converter) is crucial forensuring that micromilling cutting re-quirements are met.

Asynchronous motors offer hightemperature resistance, but their per-manent magnets demagnetize at oper-ating temperatures above 150C. Thiscritically stresses the rotor band. Syn-chronous motors higher power densi-ty is a major advantage; having agreater centre bore results in betterstatic stiffness and spindle dynamics.Disadvantages of synchronous motors

have been their smaller constant-power range and the mandatory inclu-sion of an encoder system. However, amajor breakthrough by the FischerPrecise Group enables synchronousmotors to be driven without an en-coder. Thus, their benefits are availablefor micromilling applications.

Owing to lower rotor temperatures,which lessens thermal axial growth ofthe spindle shaft, spindles with syn-chronous motors achieve better tool-centre-point repeatability. While theinfluence of mechanical forces onaxial growth remains constant regard-less of the speed chosen, synchronousmotors lower rotor temperatures dohave a beneficial impact.

Tests performed on a grease-lubri-cated 100-mm-OD HSK-E25 spindlewith a top speed of 50,000 rpm com-pared an asynchronous and a synchro-

nous motor in terms of their influenceon spindle growth (see graph at left).Using a synchronous motor decreasedspindle rotor temperature by about 20K, which resulted in turn in 14 m lessaxial growth, or a reduction of 26%.Considering only thermal expansion(subtracting mechanical growth fromtotal axial growth), synchronous-motor-originated spindle growth isonly half that caused by an asynchro-nous motor.

Shaft CoolingThe temperature behaviour of spindlesmatters a great deal in micromillingapplications. Not only the temperaturebut the saturation time has to be mini-mized. Here, Fischers shaft coolingsystem (image at top) sets a standard.The complete shaft, including rotorand bearing inner rings, is cooled withwater flowing through a series of chan-nels and supplied via a special three-channel rotary joint that can also beconfigured as a regular rotary joint forsending coolant through the centre ofthe shaft to the tool tip.

When such major heat sources asthe rotor and bearings are cooleddirectly, tests show, up to 2 kW in loss-es from the spindle shaft can be elimi-nated. Consequently, spindle warm-uptime is reduced by 80%, and less heatmigrates into the machine.

Synchronous Motors and Shaft Cooling Are AmongSpindle System Innovations That Support Micromilling


Fischer AG PrzisionsspindelnHERZOGENBUCHSEE, SWITZERLAND


TechnologyTechnology

The Fischer shaft cooling system.

Axial growth of spindles with asynchronous and synchronous motors compared.

http://www.etmm.info/2009/09/029

For complex applications:CNCs from Fanuc GEWe not only do simple applications: Fanuc GE high-end CNCs control 5-axis-machines, complex turning machines, transfer machines or compound machines without problems. All this with the lowest failure rate. Statistics have demonstrated that the fi rst failure may not happen until 10 years after installation. Your benefi t: highest reliability for the highest productivity.

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GEF_5Achsen_210x297_UK_RZ.indd 1 14.07.09 11:42


http://www.etmm.info/2009/09/030http://www.fanucge.co.ukmailto:[email protected]

Hotset Heizpatronen und Zubehr GmbH

Hueckstrae 1658511 LdenscheidGermany

Tel.: +49 2351 43020Fax: +49 2351 430225

[email protected]

www.hotset.de

ADVERTISEMENT

hotset has been developing andproducing heating elements since thecompanys formation in 1973. hotsetssuccess at home and abroad is a directresult of the company placing customerneeds at the centre of its operationdeveloping heating elements for a widevariety of industrial applications.

hotset is synonymous with product qualityand manufacturing expertise, as well asprofessional, solution-oriented consultancy.In Germany and in over 30 other countries,hotset customers have confidence in thecompanys ability to consistently deliverinnovative, effective solutions. You will seeand experience it. Thats a promise!

hotrod

Cartridge heaters (types HHPand LHT) Driving quality!

In the tradition of all hotrod products,hotrod cartridge heaters have beendesigned to offer the ultimate infunctionality and product quality.Application-specific power distribution,integrated thermocouples, numerousconnection options, and a wide range ofaccessories enable hotrod cartridge heatersto be adjusted to almost any application.

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Coil heaters (type WRP)One step ahead, safely!

The innovative hotspring coil heaterrange offers a wide variety of products. Allof them can be adapted for specificapplication requirements. The innovationsintroduced with these coil heaters, as wellas their humidity resistance according toIP65, demonstrate that they were designedto meet new challenges.

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Allowing a very small bending radius,hotflex tubular heaters can be bentmanually and then easily inserted into amilled groove.

Relative to traditional heating devices(e.g., cartridge heaters), the three-dimensional bending of the hotflex offersengineers greater flexibility.

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Where an application requires a specifictemperature to be achieved precisely,hotslot offers a reliable, space-efficientsolution for providing the needed level ofheating.

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During the product lifetime of Master-cam X3 CAD/CAM software for milling,turning, wire-cut electrical dischargemachining, modelling, and othertasks, CNC Software Inc. carried outdevelopment work based on the po-tential of newer computer hardware.Computer systems with multiple pro-cessors or cores are now common andreflect a trend. With this in mind,CNC Software will roll out Mastercamsupport for multiple cores and proces-sors starting with high-speed multisur-face tool paths and multiaxis toolpaths during the X4 product life cycle.An example of the latest-generationsoftwares capabilities is provided bythe multithreadingfunction in the Millmodule of Master-cam X4.

Mastercam X4 Millincludes an optionthat lets the user turnthe multithreadingcapability on or off.With multithreadingturned on, a toolpath will be pro-cessed in a multi-threaded mode aslong as the tool-pathtype is supported.(Tool paths that can-not be supported bymultithreading will be processed nor-mally.) The multithreading managerdirects the supported tool paths totheir own processor or core for pro-cessing or regeneration in separatethreads as the processors are available.

During this processing, MastercamX4 Mill is free to continue working onother tasks. The user has control overthe number of processors to use andthe priority of operations that are be-ing processed, and can pause or cancel

the processing of anyoperation.

The new multi-threading capabilitydelivers benefits intwo ways. First, userscan continue work-

ing in Mastercam while the multi-threading manager is processing. Pre-viously, without the ability to domultithreading, users have had to runmultiple Mastercam sessions so thatother work could continue during thewait for Mastercam to process a toolpath. Targeting the surface high-speedand multiaxis tool paths first enabledCNC Software to provide the greatestpossible benefit here.

The second advantage provided bythe technology is dramatically fastertool-path processing. Users will see thebenefits when they view the time sav-ings recorded in the Mastercam EventLog after trying the multithreading

capability. In beta-cycle tests, a scallopmould with five high-speed multisur-face tool paths required 44% less timeto process completely when the multi-threaded mode was used. And a Flow5ax part with 83 surfaces was able tobe completed in just 41% of the timeneeded when processed without multi-threading capability.

Multithreading Capability in NewCAD/CAM Suite Takes Advantage of Multiprocessor Computing Advances


FISCHER AGPrzisionsspindelnPostfach 313360 HerzogenbuchseeP +41 62 956 22 22F +41 62 956 22 [email protected]

FISCHER, PRECISE und FORTUNA schnell und przise fr Ihren Erfolg

Unter den Marken FISCHER, PRECISE und FORTUNA entwickelt, produziert und vertreibt die FISCHER PRECISE Gruppe Standard und spezialisierte Spindelsysteme fr die Luftfahrtin-dustrie, den Werkzeug und Formen-bau, die Przisions und Mikrozerspa-nung, die Leiterplattenindustrie, die Medizintechnik sowie die Automobil-industrie.

Durch unsere Tochtergesellschaften in Deutschland, USA, Frankreich, Japan und China bieten wir kompetente An-sprechpartner und einen qualifizier-ten Service vor Ihrer Haustr.

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Besuchen Sie uns auf der EMO 2009: Halle 1, Stand A04

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CNC Software Inc.TOLLAND, CT, USA


http://www.fischerprecise.chhttp://www.etmm.info/2009/09/032mailto:[email protected]://www.etmm.info/2009/09/033

Case StudiesCase Studies


Rosell Werkzeugbau & StanztechnikGmbH, a metal-stamping tooling com-pany, serves the automotive industrymainly, but also other sectors. Work-ing closely with the customer is animportant part of tool developmentfor Rosell. That was more difficult afew years ago, when the companycommunicated with clients throughA0 drawings. Seeking design and man-ufacturing software that would betterrepresent the toolmakers ideas in cus-tomer meetings, Rosell settled on theVISI integrated CAD/CAM systemfrom Vero Software plc. The compa-ny credits its business progress since2003 in part to its use of VISI products.

Explains Franz Rosell, managingdirector of Rosell GmbH: Once theorder has been received, we complete astrip layout and preliminary design forall forming stations and present thedata to our customer. Back when suchpresentations centred on drawings,they didnt really make very clear tothe customer how the tool wouldoperate. These days, the meeting lastslonger, but the 3D representation of

the tool that is shown gives the cus-tomer a much clearer idea of the toolmechanics. Technical discussions con-ducted at this stage now can go intomuch greater detail.

All tool design and manufacture atRosell is performed using VISI, whichrepresented a quantum leap from itsprevious software, according to FranzRosell, All our designers are fully

trained, but almost all staff membersare able to work with VISI, he says.About eight or nine other engineerscan use VISI to extract the informationthey need from a model.

The initial tool design process hasthree typical steps. First, the 2D blank

shape is developed from the 3D modelusing VISI Blank, an integrated solu-tion that analyzes material behaviourduring the forming process so as toensure accurate identification of po-tential problem areas prior to design ofthe actual die. After blank develop-ment is complete, the designer usesVISI Progress for designing the bendingand forming stages and undertaking

production of the 3D strip. The soft-wares step-by-step unfolding capa-bility gives the designer completefreedom to experiment at this stage.

When the customer is satisfied withthe process plan, 3D tool design be-gins. Customer approval of the designis based on a presentation of the indi-vidual plate components, whose 3Ddetails, now that VISI is used, Roselland its customer can adjust together inreal time.

Tool manufacture follows. Theforming tools that shape the compo-nent, hardened after premilling with amaterial oversize allowance, are hard-milled to size using VISI Machining, a3D CAM solution that can be used inthe CAD/CAM office or on the shopfloor. A VISI viewer enables the engi-neer to check relationships among theindividual parts of the tool assemblyin the 3D model in order to preventproblems during assembly. Fine-tun-ing of the tool begins with data pro-duced using VISI Blank. Then a proto-type is created for simulation purposesbefore the completed tool is assembledand tried out for the customer.

It is easy to notice the progress wehave made since switching to VISI and3D tool design, says Franz Rosell.

Stamping-Tool Supplier Uses Integrated CAD/CAM Suite to Work More Closely, Effectively with Customers

Vero Software plcCHELTENHAM, GLOS, UK



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Case StudiesCase Studies

Gifu, Japanbased KVK Corp., whichmanufactures faucet hardware forbaths and kitchens, has been seeing itsproduction costs rise. The companytherefore resolved that it would makeup the difference by saving time, andthus money, during product develop-ment. Over the past few years, KVKhad been successful using 3D CAD/CAM to shorten product developmenttime. Now, building on those 3Dbeginnings, the manufacturer hasbrought 3D prototyping in-house,benefiting from the employment of anEden260 3D printing system fromObjet Technologies Ltd.

As its raw material costs increasedsteeply, KVK saw that leveraging its 3Dcapabilities through the installation ofa prototyping system might holddown manufacturing costs. The com-pany expected on-site rapid prototyp-ing capacity to be cheaper and fasterthan dependence on a service bureau.KVK looked for a solution that wouldlet it build models earlier in the designprocess, build transparent hollowmodels for water-flow testing, and usemodel materials that could be platedand painted to closely resemble theactual marketed products.

Following a thorough market sur-vey that included benchmarking ofavailable options, KVK selected Objets

Eden260. It was no more than a fewmonths after installing the 3D print-ing system that the faucet maker wasintegrating models produced on theObjet printer into every aspect of prod-uct development. KVK reports that itsdevelopment periods are shorter andits design process more efficient. Anddevelopment is less stressful overall,owing to KVKs ability to test designsearly and frequently. This reduces therisk that costly changes will have to bemade at advanced development stages.

Checking the products water dis-charge performance is an important

design step. Using a model built withthe Eden260 facilitates this testing.

The subcontracted prototypingperiod was long and costly, explainsYoshiaki Nachi, deputy manager ofproduct development in the KVKdevelopment division. Hence, it wasnot easy to check the amount of waterdischarge and the water discharge stateeach time the shape was changed.However, since installing the Eden sys-tem, he says, KVK performs an accu-rate and fast checking operation, andchanges in the shape can now be effi-ciently examined at a low cost.

KVKs prototyping costs have notdropped noticeably, because the com-pany now creates more prototypes perproduct. But the Eden260 has cut theoverall cost of product development.Our manufacturing unit cost permodel has now decreased considerablycompared to when we subcontractedprototyping, notes Nachi.

KVK now checks each model theday after the 3D data is prepared, car-rying out the water discharge testingimmediately and then moulding againusing corrected data. This has greatlyimproved our work efficiency, ob-serves Nachi. The company can refinethe products shape before orderingthe die, which minimizes expensive,time-consuming die errors.

Adding a 3D Printer Increases Manufacturers Flexibility,Saves Time and Costs Associated with Development

Objet Geometries Ltd.REHOVOT, ISRAEL


Models moulded with the Eden260 have been used both upstream and downstream of product development.

A model of a faucet assembly before the plating process (the yellowish green object at bottom) and after.


Faro develops and markets computer-aided coordinate measuring systemsand measurement software worldwide.The companys portable measurementand imaging systems facilitate thehigh-precision 3D measurement and3D comparison of parts and completesystems in production and qualityassurance areas of manufacturing facil-ities. Faro equipment is employed incomponent and component-assemblyinspection, production planning, andinventory documentation, and in otherapplication areas as well.

Faro is a strong technology providerto the aerospace industry in GreatBritains North West. The companysportable measurement systems are putto use in airplane manufacturing facili-ties, where high accuracy is a vitalstandard and procedures have to meetthe strictest requirements.

Manufax, a precision engineeringcompany based in Stockport nearManchester, measures and aligns com-posites for customers such as Airbususing Faro Laser Tracker systems. Thecompany recently extended the rangeof its measurement equipment byadding a FaroArm Quantum. This arm

is able to measure with an accura-cy of 0.0016 mm.

Says Manufax managing direc-tor Gary Rhodes, The high accu-racy and the great flexibility ofthe Faro products allow portablemeasurement devices to meet theneeds of our customers. We findthe FaroArm and Laser Tracker tobe both very portable and highlyaccurate, which is critical, be-cause in aerospace technologyevery micron counts. Severalother aerospace suppliers, such as

Brookhouse Composites and G. ParkerEngineering, both of which are pro-viders to BAE Systems, also rely onFaro technology for measuring fin-ished parts and verifying jigs.

Aerospace Suppliers in British North West Rely on Portable Measurement Systems to Satisfy High-Precision Requirements



Faro Europe GmbH & Co. KGKORNTAL-MNCHINGEN, GERMANY


http://www.etmm.info/2009/09/036mailto:[email protected]://www.cgtech.co.ukhttp://www.etmm.info/2009/09/037

um. It is available in a wide selectionof positive and negative basic-shapeinserts and in the full M, G, and E tol-erance range for various degrees ofinsert-edge sharpness. The new gradeis also available in CoroCut angledinserts, which have been designed formaximum accessibility in aerospaceapplications.

The GC1115 insert grade joinsGC1105 and GC1125 as PVD-coatedgrades making up a complete seriesengineered to offer lower-cost manu-facturing and reliably undisturbed ma-chining performance.


The GC1115 insert grade, the latesthigh-performance sharp-edge gradefrom Sandvik Coromant, is designedto provide secure, reliable performancein many applications ranging fromgeneral engineering to aerospace. Agood balance of toughness and wearresistance makes this grade ideal forhandling difficult conditions, especial-ly where an important manufacturinggoal is predictable production withfewer unplanned stoppages.

Owing to a special PVD coating thatmaintains sharp edges over a longertime in cut, the insert is reliableenough to machine a complete com-ponent. In addition, its optimizedmicrogeometries produce lower cut-

ting forces, which ensures precision incomponent machining.

GC1115 can be used for finish- tomedium machining in stainless steel,heat-resistant superalloys, and titani-

Versatile PVD-Coated Insert Grades Introduced for ReliableMachining of Heat-Resistant Superalloys and Stainless Steel

Cutting Tools

Version 9.0 of the TECand CCS software pro-grammes for cutting-tool management avail-able from Walter AGfeatures a new look andexpanded functions. Thefree programmes, whichwere developed inde-pendently by the Walterbrands Titex and Proto-typ, respectively, havebeen designed to make iteasier for metal machin-ists all over the world toselect and order the cor-rect drilling, threading,and milling tools. In theprocess, users in production and NCprogramming can obtain importantinformation regarding cutting dataand cost-effectiveness calculations.

The most striking new developmentusers will notice in TEC+CCS 9.0 is thesoftwares design. Up front, the userinterface has been updated. Behindthe scenes are numerous new func-tions that justify this being called acompletely new version. Version 9.0 isavailable on CD to allow installation

Latest Version of Free Tool Selection Software Has New Look, Updated Database, Expanded Functionality

on computers used in production thatlack a network connection.

Common to both components ofthis software offering is the tool data-base, which has been brought right upto date with relevant data and the lat-est prices for all tools being offered byWalter Titex and Walter Prototyp. Thedisplay of discount groups has beenrevised along with the database. Thisfunction makes it possible for the per-hole cost of a tool to be calculated

more accurately thanever before.

Strategic changes inthe TEC programme forselecting drills havemade the tool recom-mendation proceduremore closely resemblethat in CCS for basingthreading-tool sugges-tions on cost per threadand milling-tool sug-gestions on cost permetre. Drill sorting forthe purpose of selectingthe most cost-effectiveoption now is based oncost per hole, and in-

cludes reconditioning costs. Also, pilotdrills are no longer listed in the nor-mal drilling menu; they appear onlywhen a deep-hole drill is selected first.

Key changes in the CCS softwareprogramme include the adoption ofimperial tools and the efficient gen-eration of NC programmes for helixthread-milling from the database.

Walter AGTBINGEN, GERMANYwww.etmm.info/2009/09/039

Sandvik Coromant EuropeZAVENTEM, BELGIUMwww.etmm.info/2009/09/038

Cutting Tools


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removal even at high feedrates; the steep helical spiralangle of 35 at the cuttingedge generates small chips,which are removed swiftlyand safely via the degressivespiral of 12.

Winner-series tools spe-cial surface finish, includ-ing a polished cutting edgeand a self-centring tip,reduces axial pressure. TheirTiAlN coating makes themeven more resistant to highmachining temperatures.Together, the coating andstrong cutting geometryensure long service life-times and, thus, suitabilityfor use in large-scale manu-facturing applications.


The Winner series of spiral-geometry microdrills is par-ticularly designed for deepdrilling in titanium and spe-cial stainless steels. Newly re-leased by Zecha Hartmetall-We r k z e u g f a b r i k a t i o nGmbH, these durable, high-precision microtools featurean innovative geometry, care-fully selected substrate, anddistinctively formulated coat-ing of titanium aluminiumnitride (TiAlN). Thus, theyare especially well suited fordrilling holes at high feedrates and with good chipremoval efficiency.

The Zecha Winner 636microdrill, which is availablein stock diameters rangingfrom 0.5 to 3 mm, is able to drill holes8 to 12 times as deep as its diameter,without internal cooling, in titanium

alloys up to quality class 4 and inmartensitic stainless steels. Its QuickChip spiral geometry facilitates chip

Microdrills for Use on Titanium and Stainless Steels Remove Chips Efficiently and Safely at High Feeds

Cutting Tools

The established Rotaflex

high-performance hole-finishing system for metal-working manufacturers hasnow been developed furtherby Widia Inc. With bothroughing and precision-finishing heads available,the Rotaflex fine-boring sys-tem is well suited for bothroughing and fine-finishingoperations over the diame-ter range of 6 to 520 mm(0.236 to 20.4 in.).

New system upgradesthat reduce vibration makepossible feed rates measur-ing as much as 20% higher in roughmachining applications, improvingmachine tool productivity and en-abling maintenance to be scheduled atlonger intervals. Widia has designedthis system to exhibit a good ratio ofprice to performance.

Versatile, Upgraded Hole-Finishing System Offers Roughing and Precision-Finishing Heads in a Broad Diameter Range

The systems very stable KM-TS

coupling and newly developed RFX

coupling, a major enhancement in theupgraded Rotaflex, are applicable toalmost every machine spindle. Theyprovide for easy assembly and disas-sembly and very stable operation. The

RFX features a bayonet-stylecoupling that ensures cylin-der face contact and trans-mits torque forces better.Two radial screws for clamp-ing enable the coupling tobe preloaded and allow rota-tion in both directions. Stan-dard insert pocket seats sup-port the use of Widia carbidegrades for higher runningspeeds.

New microadjustable car-tridges for the Rotaflex sys-tem have a proprietary radialadjustment mechanism thatpermits radial adjustment

without the axial insert position beingaffected. This mechanism makes pos-sible higher hole-finishing accuracywhile facilitating adjustment.

Zecha Hartmetall-Werkzeugfabrikation GmbHKNIGSBACH-STEIN, GERMANYwww.etmm.info/2009/09/041

Widia Inc.LATROBE, PA, USAwww.etmm.info/2009/09/042

Cutting Tools



http://www.etmm.info/2009/09/043http://www.itf-time.com

nology; precision steel balls vulcanizedinto a rubber ring ensure that the sys-tem positions with better than 0.003-mm repeatability. Extremely insensi-tive to contamination, since only thesteel balls have point contact, CapteXcan be joined and separated easily. Thesystem is equipped with a positive-fitbayonet so that it can also be usedsafely on a rotating spindle.

Hainbuchs zero-point clampingsystem is configured for use on all con-ceivable machines. The interface en-ables all the machines in a productionfacility to be standardized in onestroke, and allows all the clampingdevices in the facility to be swappedfrom machine to machine in seconds.

Currently, CapteX is available forstationary use on dividing attach-ments, turntables, and slow-rotatingspindles (those running no faster than1,800 rpm). A version for fast-rotatingspindles is in development.


The CapteX zero-point clamping sys-tem from Hainbuch GmbH Span-nende Technik is impervious to boththe centrifugal forces involved in turn-ing and the extreme static transverse

forces normally associated with mill-ing. Thanks to an ingenious ring me-chanism with sliding wedges, thismachine interface can be fixed inplace with a very high degree of stabil-ity. Its resistance to deflection is practi-cally indistinguishable from a conven-tional clamping setup that employsmultiple screw joints.

However, not only does the CapteXprovide rigid and

stable clamping; itcan be changedquickly, too. Theuser can loosenand clamp theentire interfaceincluding theclamping de-

vices draw mech-anismwith a sin-

gle screw, which iseasily accessible.

Like most of Hain-buchs clamping de-

vices, CapteX utilizes thepioneering Centrex tech-

Zero-Point Clamping System Provides a Fixed, Precise,Rigid Solution That Can Also Be Changed in Seconds

Machining Accessories

Developed in Japan and marketed byan associate of Kemet InternationalLtd., primarily as an added feature ofits own specialist grinding and lappingmachines, the Eco filtration system isavailable to anyone wishing to havecoolant and cutting oils cleaned downto the 0.01-m level.

An additional benefit of the Eco sys-tem is the lack of filter cartridges andpaper bands. The system also is capa-ble of filtering every type of materialfrom the fluid, including wood, plas-tic, and nonmetallic materials, as wellas the more familiar steels and grind-ing wheel compounds. Better work-piece surface finishes and a lower levelof machine maintenance result fromimplementation of the patented filtra-tion system.

Patented Filtration System for Grinding and Lapping MachineCoolant and Cutting Oils Can Be Built into a Machine Cycle

Two filters, eachcontaining a coilaround a secondcoil that, at the cor-rect flow rate, gen-erates static, attractand hold small par-ticles. When theyare saturated, a sim-ple sliding mecha-nism and change offlow direction move the sludge into acontainer; then the filters move backinto operation. This entire processtakes no more than 20 seconds. Filterdischarge can be either accomplishedmanually or built into a machine cycleas an automatic process.

The Eco filtration system has beenproven in automotive applications

and is moving into the medical tech-nology field. Users are finding thatgrinding wheels require less in-cycledressing and that components are notsusceptible to particle-caused damage.Two-month free trials are available.

Hainbuch GmbH Spannende TechnikMARBACH/NECKAR, GERMANYwww.etmm.info/2009/09/044

Machining Accessories

Kemet International Ltd.MAIDSTONE, KENT, UKwww.etmm.info/2009/09/045



The CNC controls specialist NUM, which has expertise inCNC hardware and software, including such core compo-nents as drives and motors, offers a new, ready-integratedtool head for sophisticated plasma, laser and water-jetcutting machinery applications. The design of the newhead brings numerous technical advantages to cutting ma-chine manufacturers.

Novel mechanical design enables the head to provide theversatility of movement and stiffness essential for imple-menting precision cutting motion, but with the uniqueadded benefit of very low mass. In addition, the designeliminates the cabling runs that would otherwise have toflex with the tool-head movement and could be the causeof system failure.

Because it is so unusually lightweight, the innovativeNUM tool head can be assembled easily on existing CNCplasma- and water-jet-cutting machines, often withoutadditional mechanical adaptation. This technology pro-vides a very simple means of extending the capability ofmachinery from 2D to 3D applications, with precise multi-axis interpolation.

Another NUM innovation is True 3D computer-aidedengineering software, an advanced 3D simulation packagethat combines workpiece simulation with collision moni-toring and other powerful features. A general-purpose ver-sion of NUMs 3D simulator for multiaxis grinding appli-cations, True 3D allows machine builders to offer newgenerations of optimization tools with their machines inorder to help users maximize manufacturing throughputand productivity. It derives its name from the fact that it notonly emulates but simulates real-world CNC commands,and consequently provides an output as close as possible tothe actual machined parts. With this software, machineryusers can virtually prototype and optimize the entire pro-duction process, right down to reducing tool wear.

Cutting Head and CNCSimulator Let Machine ToolBuilders Extend Performance

NUM AGTEUFEN, SWITZERLANDwww.etmm.info/2009/097/046

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D-M-E helps its plastics-moulding cus-tomers become more flexible by offer-ing an extended standard range ofhot runner products. The suppliernow provides a solution for almostany application up to 96 nozzles permould. New Polimax nozzles, for ex-

A pair of entry-level automatic video-based measuring machines extend theSmartScope ZIP range of measuringsystems available from OGP UK Ltd.The new ZIP Lite 250 and 300 bench-top video measuring systems includea high-resolution digital colour cameraand advanced motorized optics, thelatter incorporating OGPs patentedAccuCentric autocalibrating 5:1 zoomlens for keeping images in focus andon-axis throughout the entire range ofmagnification.

Patented LED SmartRing whitelights provide square-on total illumi-nation, pinpointing light from an infi-nite number of directions in order tolocate detail exactly and maximizecontrast on components of almost anyshape. Also, green LED profile andcoaxial surface lights are included forgreater illumination flexibility.

Both machines come with OGPseasy-to-use MeasureMind 3D Multi-Sensor metrology software for measur-

ing parts with simple geometric shapesor complex free-form structures. Nei-ther requires the addition of an exter-nal processor or lens ID facility. Themachines have a granite base and col-umn for stable measurement, an oper-ator-friendly three-button joystick,and high-precision microsteppingmotors to drive x-y motion controlfunctions. A touch probe and lasersensor for measuring parts with hard-to-find features is available as an acces-sory, as are lens attachments for addi-tional magnification options.

Measuring areas for the ZIP Lite 250and 300 are 250 x 150 x 150 mm and300 x 300 x 150 mm, respectively. The250 model can be equipped with a300-mm x-axis as well.

ample, are available in lengths of 50 to500 mm with a shot weight capacityup to 3,000 g. And D-M-E offers a largevariety of tips so that choosing thetype of gate is a simple matter ofchanging the nozzle tip. The newPolifast nozzles for parts up to 50 g

come with a variety of tips, asdoes the Policosmetic series foruse in custom packaging.

D-M-E has improved itsflexibility not only in theopen-nozzle area, but also inits valve gate systems. Withthe Polivalve valve gate sys-tem, the operator can choosefrom a preinstalled system or acomplete hot half and decidewhether an electric or hy-draulic drive is needed, amongother options. The choice ofpreinstalled system or hot halfis available also for the open-type systems; thus the opera-tor only needs to add the cavi-ty plate to start production.

To help deal with todayseconomy, D-M-E offers an eco-

nomical hot runner system. The newEssential-Series is a cost-efficient sys-tem for standard materials in the one-,two-, or four-nozzle format.

Application Variety of Hot Runner Product Range Can Enhance Flexibility of Customers in Plastics Processing

Entry-Level Benchtop Video Measuring Systems Handle Simple Shapes and Complex Structures with Equal Facility

Products & ServicesProducts & Services

D-M-E Europe C.V.B.A.MECHELEN, BELGIUM


OGP UK Ltd.FOSTON, DERBYSHIRE, UK



The road to ever more efficient cutting-tool coatings passesthrough joint industry-academic R&D efforts. The coatingtechnology specialist CemeCon AG has been contributingto these efforts for 20 years, implementing research resultsin its coating systems of the type CC800. It has been con-stantly optimizing the high-power pulsed magnetron sput-tering (HPPMS) technology that produces the ionizationnecessary for ahigh-quality PVDcoating that willprovide the wearprotection that isbeing demandedby tool manufac-turers and endusers today. State-of-the-art HPPMStechnology is be-hind the highionizing capabili-ty of CemeConscurrent CC800/9system for toolcoating.

CemeCon sys-tems offer opti-mized magneticfields, pulse tech-nology, and gascontrol, which, along with the companys patented anodeand booster technology, are responsible for the perform-ance-enhancing characteristics of so-called supernitridecoating materials. The high ionization of the CC800/9 sys-tem allows supernitrides to be produced at comparativelylow bias voltages.

This means that the growing coating is constantlyexposed to an intense low-energy bombardment. Throughthis soft but highly dosed ion bombardment, constant highcompaction of the applied coating is effected without gen-erating avoidable film defects.

Thus, supernitrides exhibit extremely low residual stress,far below that of most conventional coating materials.Thicker coatings, cutting edges better and more uniformlycoated, and optimized adhesion are the advantageousresults.

CemeCon has been pushing HPPMS technology develop-ment in order to further increase ionization. Denser andmore-homogeneous coatings are the research objectives.Harder, tougher, and more adherent than conventionalsputter layers, HPPMS coatings have already produced up tofourfold tool-life improvements in many situations.

High-Pulse TechnologyEnhances Plasma Ionization,Tool Coating Performance

CemeCon AGWRSELEN, GERMANY


[ ]www.etmm.info/2009/09/051



The new RapMan 3D printer, anaffordable alternative for rapid proto-typing and rapid manufacturing (RP/RM) that comes in kit form, has beendeveloped by A1 Technologies Ltd.for educational institutions teachingstudents of engineering and manufac-turing technology computer-aidedtechniques. Building the RapManfrom a kit enables students as young as14 to learn basic engineering princi-ples. Once the printer is assembled, itcan be used to produce 3D parts bymeans of a specially designed extruder

head that lays down a fine bead ofmolten plastic.

Typically, 3D printing takes placeinside a black box. With the RapMan,however, the process is completelyopen to view. The machine is madefrom clear acrylic parts that enable stu-dents to see, and thus better under-stand, the production process.

Though the machine costs just asmall fraction of the price of roughlyequivalent products, its price encom-passes everything needed to assembleand run the equipment, includingsoftware to slice an STL file and con-vert it into the G-code read by theRapMan. The printer is also very cost-effective to operate. Because the con-struction materials cost as little as20/kg, a typical 3D model is extreme-ly inexpensive to produce.

Available extrudable materials,which A1 supplies as filament in 1-kgreels, include ABS, high- and low-density polyethylene, polypropylene,polystyrene, PVC, polycarbonate, andbiodegradable polylactic acid.

Products & ServicesProducts & Services

A1 Technologies Ltd.LONDON, UK


Low-Cost See-Through 3D Printer That Processes a Variety of Materials Is Suitable for Teaching RP/RM Techniques


http://www.etmm.info/2009/09/053http://www.etmm.info/2009/09/052http://www.uniontool.commailto:[email protected]

PH 42 Supra tool steel is a construc-tion material especially well suited forcomplicated plastic-injection mouldcomponents that are subjected to veryhigh mechanical stresses, such as man-ifolds. The manufacturer, DeutscheEdelstahlwerke GmbH, developedthis steel over three years in coopera-tion with an important mould maker.Tests performed by this customershowed that PH 42 exhibits signifi-cantly better performance characteris-tics than materials previously used formanifolds. The mechanical propertiesof PH 42 Supra noticeably exceededthose of 1.2085 and 1.2738, and itsgrindability was superior to that o

emo milano 2009

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