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Tungaloy Ceramic Insert Grade Conquers Turning Of Cylinder Liners

Tungaloy Ceramic Insert Grade Conquers Turning of Cylinder Liners

Tungaloy Corp. has launched the TZ120 grade ceramic inserts designed for efficient machining of cast iron.

A zirconia-toughened aluminum oxide grade with superior thermal properties, TZ120 enables extended tool life and process security at high cutting speeds, making the grade ideal for high-speed, dry machining of centrifugally cast cylinder liners. The new grade will allow Tungaloy’s extensive line-up of ceramic insert grades to provide a variety of cast iron turning solutions at high speeds.

Its key properties include tough ceramic grade with chemical and thermal stability, providing excellent resistance to strong acids at elevated temperatures. The uniform distribution of the zirconia grains in the alumina matrix imparts superior fracture and notch wear resistance, preventing premature insert failure during demanding operations

Ideal for machining of centrifugally cast iron cylinder liners, the inserts are designed for dry machining only as the use of cutting fluids is detrimental to insert life.

 

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Walter Launches Double-sided Indexable Inserts

Walter Launches Double-sided Indexable Inserts

Walter Tools is introducing a new Walter Launches Double-sided Indexable Inserts for turning machining operations under the designation MU5. The insert can be used universally both for steel forged parts in automotive series production, such as drivetrain or gearbox components, and for components made from stainless materials.

In forged parts, the Walter MU5 geometry minimises crater wear, and thereby enables reliable, fully automated series production. For users with changing materials and small quantities, the Walter MU5 is appealing due to its universal use for steel and stainless materials. The combination of improved chip breaking with a longer tool life will also be equally beneficial for both target groups. These characteristics of the MU5 inserts are due to the positive macro-geometry.

An open chip breaker groove (long tool life and soft cutting characteristics), a V-shaped chip breaker (improved chip breaking) and a curved cutting edge (high surface finish quality). For copy turning, the MU5 geometry does not just improve chip breaking for longitudinal turning and facing, but also for inclines or radii that would otherwise be critical.

During the numerous field tests, the MU5 has also already proven that it significantly lowers tool costs, particularly when combined with the wear-resistant Tiger·tec Silver grades. The machining parameters of the insert are f: 0.15–0.6 mm; ap: 0.5–4 mm, which applies to 60 percent of all applications. In order to offer customers the best possible solution for their applications, the new MU5 insert is available in all common basic shapes.

 

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Tungaloy Ceramic Insert Grade Conquers Turning of Cylinder Liners

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Walter To Close Frankfurt Facility

Walter To Close Frankfurt Facility

Walter AG, one of the world‘s leading providers of precision tools for metal machining, plans to phase out production at its manufacturing and reconditioning site in Frankfurt. The company is thus seeking to consolidate its production footprint in Germany in order to remain efficient in a changing market. The products manufactured in Frankfurt are to be relocated until spring 2021 to other plants within the group.

“This has not been an easy thing to consider given the impact on our staff,” stressed Richard Harris, president of Walter. “We see declining market activity and need to take actions to safeguard our competitive position and profitability. It will be no longer economically viable to maintain the current scale of operations in Germany.”

At the same time, Walter continues to push forward its successful international strategy. “The major growth opportunities for our target industries over the next years are in the Asia-Pacific region and the U.S.”, said Harris. “With our expanding international presence and our successful strategy as a process and development partner for our customers, we are very well positioned in those markets.”

Over the last few years, Walter’s already globalised business has again seen a considerable shift of gravity towards the international markets. “With sales becoming generally more and more localised, we must address the growing mismatch between production capacities and sales generated in our domestic market,” said Harris.

At its manufacturing site in Frankfurt, Walter employs around 200 employees, almost all of whom would be affected by the intended closure. “We are conscious of the potential impact on the staff involved and strive to provide support and alleviate individual hardship as far as possible,” Harris said. “This will be an important element of our negotiations with the works council.”

 

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Tungaloy Expands Exchangeable-Head Drill Series

Tungaloy Expands Exchangeable-Head Drill Series

Tungaloy’s DrillMeister exchangeable-head drill line now includes new TID type drills in cylindrical shanks that accommodate drill head diameters ranging from 10.0 mm to 19.9 mm (from .398″ to .783″).

Tungaloy DrillMeister features a unique self-locking interface that interlocks between the drill head and shank body, enabling a simple and quick tool exchange. Operators can replace the drill head without having to remove the drill body from the adapter or re-measure tool offset vales, thus saving time. The drill head can be easily assembled while remaining on the machine. The drill body incorporates strong helical flutes with polished surfaces for reliable chip evacuation. This feature is especially important in deep hole drilling applications where smooth chip evacuation is vital.

The new Tungaloy TID drills are offered with a cylindrical shank. A precision-ground cylindrical shank with no flats provides a close runout accuracy and high torque transmission when clamped with a full surface contact in a high-precision collet chuck, milling chuck, or hydro-chuck holder.

In addition, all the new drills have longer shank lengths (LS) than the existing TID drill lines. Longer shanks enable more flexible adjustment of a drill overhang length when being clamped in the holder.

Hole making operations often require drills with a flute length that is way longer than the hole depth to be machined, just to avoid a fixture or structural interference. The new Tungaloy TID drill can provide an extended drill overhang by shifting out the shank clamping position in the holder, while retaining a minimum flute length necessary for smooth chip evacuation and tool stability.

Enhanced with the new drill line, Tungaloy DrillMeister provides customers with high productivity, reduced of tool inventory and elimination of regrinding costs.

 

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Asia Set For A Rebound In 2020

Asia Set for a Rebound in 2020

The Asian economy is set for a rebound in 2020 as some of 2019’s export headwinds ease, policymakers pro-growth policies reinvigorate domestic economies, Southeast Asia continues to emerge as a global powerhouse, and consumption remains a bright spot, according to Deloitte’s latest Voice of Asia report.

However, the report argues, three main downside risks must be contained for this predicted rebound to emerge. That is, economies should avoid excessive stimulus that could cause a boom-bust cycle, US policy needs to remain stable, and financial risks, particularly from quantitative easing, need to continue to be reined in.

In Southeast Asia, pro-growth policies have been encouraged by rate cuts in the US and Europe, and economies including Indonesia, the Philippines, Malaysia and Singapore are expected to increase spending on public projects as a proportion of GDP.

“There are also positive signs on the trade integration front,” says Deloitte Asia Pacific Clients & Industries Leader Vivian Jiang. “The Comprehensive and Progressive Trans-Pacific Partnership gives its 11 members, including four ASEAN economies, enhanced market access, and the Regional Comprehensive Economic Partnership will reduce export-import paperwork and has introduced a limited degree of service sector liberalisation.”

Addressing specific sectors, the report suggests the automotive and aviation sectors will be bright spots after a period in the doldrums, with electronics another highlight.

“The decline in the automotive sector since 2018 was caused by factors including new emission standards in several markets, and other restrictions on production. This decline is likely to reverse this year, with a further boost from continued luxury sales volume growth” says Vivian. “Problems in the aviation sector are likely to ease as well, and there are signs of a resurgence in semiconductor billings, which should boost the electronics sector to help drive regional exports.”

On consumption, the report suggests, Asia can look forward to increased demand driven by labor market stability, increasing remittances, and easing monetary conditions.

“China’s consumer story remains intact even as household leverage continues to increase,” says Deloitte China Chief Economist Sitao Xu. “High debt is bound to limit people’s ability to consume, and banks’ non-performing loans could rise if home prices decline, but there tends to be more willingness among Chinese parents to help out their families if debt does become an issue.”

The Voice of Asia report is also positive on prospects for the infrastructure sector, which is increasingly emphasised by governments across the region. In Indonesia, the Philippines, Malaysia and Singapore, public works spending is rising as a proportion of GDP.


Market-by-Market Outlook

Australia

Australia’s economic slowdown has been caused by home-grown factors including worsening drought conditions and house price declines. Although tax and interest rates have been cut, there may not be a meaningful pickup in the Australian economy until 2021.

China

The Chinese Mainland is regaining its balance despite a long-term, secular growth downtrend, and Hong Kong, despite well-publicised difficulties over the past several months, remains a world leading financial center, with its currency peg to the US dollar holding firm, and could benefit from government stimulus.

India

India’s economy has been suffering from the effects of the Non-Bank Financial Companies (NBFC) crisis after problems in its formal banking sector. Corporations are still highly leveraged. It should bottom out in 2019 but remain subdued despite government stimulus and amid considerable downside risks.

Indonesia

Indonesia looks set to maintain steady growth of about 5 percent in 2020, with a young workforce, increasing urbanisation and monetary policy support for demand. The economy is becoming more stable but has yet to fully take advantage of the diversion of production out of China.

Japan

Exports have contracted and business confidence is subdued, and natural disasters have further depressed economic activity, but GDP growth has been quite resilient. Economic growth is expected to sustain at about 0.5 percent over the next two years.

Malaysia

Strong domestic demand led by household spending underpin Malaysia’s economic resilience, and its exports have outperformed. Its competitive currency, growth in manufacturing activity and a resumption in infrastructure projects are expected to support continued economic growth.

New Zealand

The economy slowed in early 2019, largely due to global headwinds. It is expected to return to trend levels of about 2.5 percent growth in the next couple of years, supported by factors including a tight job market, still-strong population growth and decent export prices and volumes.

The Philippines

The Philippines economy bottomed out in mid-2019, and is set to be boosted by a revival in the electronics sector, strengthening exports thanks to an expected pick up in the Chinese economy, continued strength in remittances and policy support that should drive consumption.

Singapore

Singapore is also expected to enter a recovery in 2020, supported by improving global growth and stronger electronics and precision engineering demand. There are also green shoots in finance, insurance, essential services and the “new economy”. The outlook for investment growth is also positive.

South Korea

We are upbeat about prospects for the South Korean economy in 2020, with an expect increase in demand for its manufactured goods. Government measures including a record budget of KRW513.5 trillion (US$4.36 billion) for the year should protect against downside risks.

Taiwan

Taiwan’s economy was resilient in 2019 despite being caught in the crossfire of the US-China trade war and the step-down in the global electronics cycle. We expect the economy to be outperform in 2020 on rising private investment, government policy to attract high-end manufacturing and other factors.

Thailand

After a slow start, Thailand’s economy is expected to pick up in 2H20, with export growth likely to have bottomed out, increasing tourist arrivals, rising farm incomes, positive fiscal policy and a recovery in private investment.

Vietnam

Vietnam is expected to remain one of Southeast Asia’s outperformers in 2020. It is one of the main beneficiaries of the relocation of production from China, which is prompting a surge in foreign investment. Its main challenges are manpower constraints, supply chain frictions and an infrastructure gap.

 

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Amada Miyachi Europe Releases New Welding Power Supplies

Amada Miyachi Europe Releases New Welding Power Supplies

Amada Miyachi Europe has launched the CD-V Series of Capacitive Discharge Power Supplies and TL-V Series of weld heads. Featuring a fully controllable dual pulse output and a full-colour 3.5 in user interface, the CD-V Series give consistent welding output for repeatable process results.

Typical applications for the power supply series include battery tab welding, interconnects, honeycomb tacking, fine wire to pad processes, and jewellery repair, among others.

Amada’s CD-V series includes built-in peak current indication for immediate weld fire confirmation, pulse shaping with adjustable upslope to reduce expulsion during welds, an ultra-fast rise time for conductive material welding, and the ability to go rapid fire between pulses for quick welding of adjacent locations.

In addition, the CD-V series makes handling a variety of weld schedules easy, as it is able to store up to 8 schedules at one time, giving the operator the ability to easily change between weld schedules. Other ease-of-use features include a weld counter, programmable squeeze time, and a push button rotary encoder for intuitive operation.

The CD-V series is built in the USA and works with the following AMYA weld heads: Models TL-V80F-E2-0A, TL-V88F-E2-0A (manual cable driven); and Models TL-V80A-E2-0A, TL-V88A-E2-0A (standard air solenoid driven).

The weld heads are designed to complement the new power supplies. There are four variants with air actuated and manual actuated motion. The heads are designed for robust usage and come standard with a robust stand and electrodes.

 

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Top 10 Metal Cutting Articles For 2019

Top 10 Metal Cutting Articles for 2019

As we move into 2020, we take a look back at the most popular metal cutting articles for 2019. For your enjoyment, here is the list of the top 10 most read metal cutting articles over the past year.

  1. Increasing Automation, Connectivity And Energy Efficiency In Metal Cutting
  2. The Perfect Combination for Structural Parts—Faster, Better, Lower Cutting Forces
  3. Adapting Cutting Tools To Changing Trends
  4. Efficient Machine Tooling
  5. Getting Ahead in the Medical Market
  6. Market Outlook 2019: An Insight Into This Year’s Industry Megatrends
  7. EDM: Past, Present and Future
  8. A Look at Walter’s Two-in-One Machining Concept
  9. Choosing the Best Machining Centre for Your Application
  10. New Demands, New Solutions

 

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Bystronic Partners With Kurago For Smart Production Management Innovation

Bystronic Partners with Kurago for Smart Production Management Innovation

To develop pioneering process solutions that will drive forward the vision of a smart factory environment, Bystronic is now working with software specialist Kurago within the framework of an innovation partnership. In this venture, Bystronic will be able to rely on Kurago as a strong partner with extensive know-how in the field of consulting and software development for smart production management.

The demand for automation and digital process solutions is increasing across the complete field of sheet metal processing. This trend is having a major impact on our customers’ business models and strategies. The sheet metal processing world will face a fundamental change in the near future and software will play a key role in this transformation. Digital solutions will support users with the planning, interlinking, monitoring, and optimization of all their production processes. All this will boost the sheet metal processing industry to new levels of productivity and transparency.

By joining forces, Bystronic and Kurago will be able to fast-track solutions to make a powerful vision come true very soon.

The first important step of this partnership will be the development of a brand new enterprise operational environment for the sheet metal processing sector, where all the processes relating to the day-to-day business of customers will take place, enabling them to achieve operational excellence and gain a competitive edge. Cloud technology will enable customers to expand Bystronic solution as their company grows, thus reducing the total cost of ownership (TCO). In addition, this solution will allow tech companies of all sizes to develop and offer new products and applications designed specifically for the sheet metal processing sector.

Together with Bystronic, Spain-based Kurago will conceive, create, promote, and implement software that will optimize the manufacturing of metal parts. As a centre of excellence for software, Kurago will develop manufacturing systems that will make the smart factory vision a reality and guide and structure sheet metal processing throughout the entire value chain—with all types of machines from any manufacturer.

“We are convinced that this partnership will allow Bystronic and Kurago to pool their expertise and energy in order to achieve a sustainable impact on the future trends and demands in the sheet metal processing industry. Our shared goal is to offer our customers pioneering solutions that drive them forward on the path towards a digitally extended manufacturing environment,” said Alex Waser, CEO of the Bystronic Group.

Jesús Martínez, CEO of Kurago, said, “We are grateful and delighted to be able to seize this opportunity to make the digital factory come true together with Bystronic, an innovation leader in the sheet metal processing sector. The enterprise operational environment we will develop will constitute an open space where many market players, who currently still view each other as competitors, will start cooperating. This environment will be a fully digital ecosystem, which is the only way we can make this revolution a reality. Cloud computing enhances the capabilities of all players and levels the playing field, opening up the same opportunities to everyone, while also preserving the differences and competitive advantages that make each of them the best choice for their own customers. This will benefit all Bystronic customers around the globe.”

 

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Siemens Addresses Overheating Challenges In Additive Manufacturing

Siemens Addresses Overheating Challenges in Additive Manufacturing

Siemens Digital Industries Software has released the Additive Manufacturing (AM) Path Optimizer, a beta technology integrated in NX software to help customers solve overheating challenges and help reduce scrap and increase production yield to achieve the industrialization of AM, or the use of AM at the industrial scale.

Siemens has developed this next generation advanced simulation technology to help maximize the production yield and quality of powder bed fusion manufactured parts. This latest extension of Siemens’ end-to-end additive manufacturing solution feeds the digital thread, informing each step of the industrialized additive manufacturing process.

Building on the Simcenter Additive Manufacturing Process Simulation solution announced in November 2018, AM Path Optimizer complements Siemens’ strategy for the digital twin of the manufacturing process and addresses errors originated from suboptimal scan strategies and process parameters. These can lead to systematic failures due to overheating, which can cause scrap and inconsistencies in component quality. The company has had success demonstrating this beta technology with TRUMPF as a partner.

“With the AM Path Optimizer, Siemens and TRUMPF can push industrialization of additive technologies further forward,” said Jeroen Risse, AM Expert at TRUMPF. “In our demonstrations, we saw an improvement of geometrical accuracy, elimination of re-coater errors caused by overheating, as well as a more homogenous surface quality. Also, the scrap rate is expected to be reduced significantly.”

The technology uses an innovative approach combining physics-based simulation with machine learning to analyse a full job file in few minutes before execution on the machine. This technology is expected to help achieve “first time right” prints and drastically reduce trial and error. It can also help reduce printing costs and enable the printing of components that are nearly impossible to achieve today.

“AM Path Optimizer is the latest innovation in Siemens’ end-to-end additive manufacturing solutions, and one that we feel will have a great impact on the use of additive manufacturing for powder bed fusion manufactured parts,” said Zvi Feuer, Senior Vice President, Manufacturing Engineering Software of Siemens Digital Industries Software. “The combination of NX for AM and our Simcenter AM technology within the Xcelerator portfolio provides our customers with key capabilities to assist manufacturers in designing and printing useful parts at scale, which is unmatched in the market.”

 

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MSC Generative Design Solution Cuts Additive Manufacturing Design Processes By Up To 80%

MSC Generative Design Solution Cuts Additive Manufacturing Design Processes by Up to 80%

MSC Software Corporation (MSC), a part of Hexagon’s Manufacturing Intelligence division, is one of the leading providers of computer-aided engineering (CAE) simulation software and services. The company has released the MSC Apex Generative Design, a new design optimisation solution that improves quality through unparalleled automation of design processes with embedded manufacturing knowledge.

MSC Apex Generative Design aims to improve productivity by up to 80 percent compared to classic topology optimisation. The software produces a part design that is ready for additive manufacturing (DfAM) within a few hours—a fraction of time usually required—making reliable additive manufacturing more cost efficient and accessible.

In MSC Apex Generative Design, the designer only needs to specify the boundary conditions and design objective. Multiple lightweight design candidates that explore the possibilities of the design space will be produced that provide optimal stress distribution and minimize weight. This enhances the creative process, so designers have more time to optimise the product’s concept and integrate additional features that add value. The software’s intelligent smoothing technology ensures that every candidate has a perfect finish that is ready for print.

“New design freedoms in additive manufacturing require a new generation of software solutions that take full advantage of the new DfAM possibilities. We make the generative design process smarter by producing design candidates that both satisfy the engineering criteria and look as the designer intended when 3D printed,” said Dr. Thomas Reiher, Director of Generative Design at MSC Software.

Conventional topology optimisation workflows require manual work and multiple tools to achieve production-ready results, which can lead to information loss as data is converted. MSC Apex integrates all relevant steps within one CAE environment to improve productivity with a single user experience from design to additive manufacturing preparation.

The design process is workflow-oriented, providing easy and fast model setup from existing geometries or mesh in common CAD, STL, or MSC Nastran BDF formats. Designers can find optimized design candidates and perform design validation within the same CAE environment, simplifying the work process and reducing design iterations dramatically. The result is a fully integrated, automated optimization process in which compatibility for previous and subsequent operations plays a vital role. This unique capability implies the conversion from the CAE mesh to CAD with no manual reconstruction of geometry, considerably simplifying the work process for designers.

The MSC Apex Generative Design for Additive Manufacturing solution combines print-ready geometries with robust metal (Simufact) and polymer (Digimat) build process simulation from Hexagon’s additive manufacturing portfolio. Designers only generate part designs that can be successfully manufactured using their chosen material and print process to eliminate costly prototyping.

 

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