AMT: July / Aug 2010

Advanced Materials Today Jul/Aug 2010 1

2 Advanced Materials Today Jul/Aug 2010

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Advanced Materials Today Jul/Aug 2010 �

July/Aug 2010

ContentsCover Story4 It’s Time for Africa

Corrosion8 The Good, the Bad and the ... Beautiful!

Stockists and Service Centres11 Steel Whenever, Whenever

Welding15 Real World Training

TDM Today(Tool, Die & Mould Making)17 Tooling Around19 Tools for the Trade22 TDM News

Technology25 Future of Casting

Joining28 Nuts About Fasteners

Manufacturing31 Chop, Chop Scissors

Industry News34 Industry News

Endorsing BodiesSAIMechE (SA Institution of Mechanical Engineering)AFSA (Aluminium Federation of SA)CorriSANTIP

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Proprietor and Publisher:PROMECH PUBLISHINGTel: (011) 781-1401Fax: (011) 781-1403E-mail: [email protected] Website: www.promech.co.zaManaging Editor:Susan CustersEditor:Raymond CamplingAdvertising Sales:Di Bluck

DTP: Zinobia Docrat and Sanette Lehanie

DisclaimerNeither PROMECH Publishing nor its endorsing bodies are responsible for the opinions expressed by individuals.

Printed by:Typo Colour PrintingTel: (011) 402-3468

The monthly circulation is 5 840

CopyrightAll rights reserved. No edi-torial matter published in “Advanced Materials Today” may be reproduced in any form or language without written permission of the publishers. While every effort is made to ensure accurate reproduction the editor, authors, publishers and their employees or agents shall not be responsible or in any way liable for any errors, omissions or inaccuracies in the publication whether arising from negligence or otherwise or for any conse-quences arising therefrom. The inclusion or exclusion of any product does not mean that the publisher or editorial board advocates or rejects its use either generally or in any particular field or fields.

Craft Machine ToolsTel: (011) 845 2030Fax: (011) 845 2041

Email: [email protected]

Web: www.craftmachinetools.

co.za

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Visit our in-house exhibition on

3 & 4 November

� Advanced Materials Today Jul/Aug 2010

Danny Thompson, a director of Craft Ma-chine Tools, a division of the Thompson Machine Tools Group, says the time is now for the manufacturing industry to

look for international supply contracts. Negative preconceptions about South Africa have been erased and the world is potentially at our feet.

“The World Cup disproved a lot of negativity sur-rounding the country and also illustrated that we are, in fact, quite capable of producing at the highest level. Now we want to work with our customers to encourage them to look for new business locally and across our borders.

“We feel that this is the best possible time to outfit machine shops in order to take on new business. Current lower volumes mean that more time can be taken to plan improvements and optimise workflow without negatively impacting on output,” Danny says.

Best laid plans“The world-wide recession forced us to look for new avenues of growth and we put a lot of focus into tailoring our product offerings to meet current market conditions.

“We looked at our customer’s future requirements and in some cases we decided to discontinue product ranges. In other instances, we sourced new products to suit the current economic climate and to enable our clients to capitalise on trends locally and abroad.”

An example of this is the Craft range of heavy-duty large spindle precision lathes for oversized work pieces to rotate through the head on the spindle. The lathes are capable of making items ranging from oil rig components to heavy-duty shafts, items that are in high demand across the globe.

Group activitiesThe Thompson Machine Tools Group comprises Thompson Machine Tools, which is the used machine tool division and founding company. Simultaneously, Craft Machine Tools specialises in new machine

Good advice is hard to come by in an age of easy money

It’s Time for AfricaOne of South Africa’s leading machine tool

suppliers is encouraging its customers to

expand their manufacturing reach across

borders and to capitalise on good sentiments

towards the country following the success of

the Fifa World Cup.

COVER STORY


Machines available from Craft Machine Tools:

Haco• Press brakes

• Guillotines

• Plasma cutters

• Rolling

• Punching

• Universal iron workers

Bemato• Saws

• Milling machines

• Surface grinders

• CNC machining centres

Feeler• CNC lathes

• CNC machining centres

Dalian• Lathes 2m – 5m

Craft• Heavy-duty large spindle precision lathes

China / Czech

• Radial arm drills

tools imported from countries such as the United Kingdom, Germany, Belgium, Czechoslovakia, Taiwan, Hong Kong and China.

Interprovince Engineering Supplies is involved in the supply of engineering supplies, parts and accessories for metal working, while Trakmans Auctioneers will sell almost anything that has a market value. As a result, the group can profess to be a one-stop-shop for manufacturers and engineering concerns.

A company with a heartGood advice is hard to come by in an age of easy money, easy imports and a myriad of new-comers to the South African market. But it is worth noting that Thompson Machine Tools Group has been in the same business for the last 40 years.

The company remains a stalwart to the industry it serves. Its simple business philosophy remains to provide very good machines at reasonable prices, good service and backup, as well as honest advice.

At the core of the company are its people and the

The local market has many propositions for would be buyers of machine tools

COVER STORY

group’s directors believe that a company must give something back to the community it serves. In this way the Thompson Machine Tool Group has developed a heart and actively participates in community activities with an emphasis on youth development.



Through its various companies, the group is a keen sponsor and supporter of, particularly, local youth soccer teams and road running. It also takes a keen interest in small and new upstart businesses and gladly lends expertise and planning support to these companies with a long-term view of servicing them through their infancy all the way through to maturity.

The group can profess to be a one-stop-shop for manufacturers

COVER STORY

Directors: Patrick Zackey, Philip, Fred and Danny Thomp-son

“These relationships are built on trust and respect and are the cornerstone of the group’s dealings.”

Time to buildThe local market has many propositions for would be buyers of machine tools and engineer-ing supplies. In order to make the most of money spent, it pays to know your options and to seek advice from people that have experience spanning good times and bad.

“For this reason, we decided to do something different this year and instead of our usual stand at Electra Mining we want you to come join us on 3 and 4 No-vember 2010 for our bigger and better in-house exhibition.

“There is enough space to show lots of new machines, as well as special offers and prizes. Most importantl,y there will be time to discuss clients needs and wants,” concludes Danny.

Craft Machine Tools, Danny Thomp-son, Tel: (011) 845 2030, Fax: (011) 845 2041, Email: [email protected], Web: www.craftmachi-netools.co.za


The stadium has an eye-catching, unique roof-struc-ture and a spectacu-

lar view, overlooking the North End Lake. It consists of six levels on the western

The Good, the Bad and the … Beautiful!

CORROSION

The five tier R2 billion Nelson Mandela Bay Stadium was one of three coastal stadiums built in anticipation of the

2010 FIFA World Cup. This was the first time a world class stadium had been

built in the Eastern Cape. Nelson Man-dela Bay stadium was the last of five new stadiums to start construction.

side and five levels on the southern, eastern and northern sides. The roof is made up of a series of white petals making it look like a flower hence its nickname “The Sunflower”. The stadium boasts 23 private boxes, 150 VIP suites, 60 business suites, a sports and clothing shop, gymnasium, lecture room and function as well as two conference rooms which are able to accommodate 200 people

Ground was broken in January 2007 and the stadium construction was handled by a consortium made up of Grinaker-LTA, Interbeton and Birdair. On 8 July 2008 it was announced that the stadium had been removed from the list of stadiums for the 2009 FIFA Confederations Cup as it was believed that it would not be ready on time. Surprisingly, however, it became the first newly-built 2010 stadium to be completed and handed over.

Coating selectionThe stadium is situated in a C5 marine environ-ment. The painting scope of work was to touch up the shop-applied primer and intermediate coat and apply one full coat of polysiloxane to approximately 2000 tons of steel.

Coating selection was based not only on the re-quirement for resistance to the corrosive marine environment but also to the aesthetic and archi-tectural requirements. The specified coating was an International Paints system, using Interzinc 52 primer, intermediate coat of Interguard 475 and a


CORROSION

final coat of Interfine 878, which is a polysiloxane with a life expectancy of 30 years.

Spills and splashesThe stadium required a very high standard of cosmetic appearance and aesthetics were a key requirement. The coating system offers high performance, high solids finish, an extended lifetime, superior gloss and colour retention and significant improved resistance to yel-lowing and chalking. The tough and hard wearing finish coat exhibits good flexibility and abrasion resistance and it offers protection against spills, splashes of a range of chemicals such as acids, alkalis, solvents and salt solutions.

Coating the steel roof in situ presented several interesting challenges! In order to meet the client’s aesthetic require-ments the coating could not be brush applied as anticipated but needed to be sprayed. Typical South African ingenu-ity came into play as local painting contractor, Bulldog Projects perfected a sustainable technique of spray ap-plication which allowed painting while suspended on ropes in the renowned Windy City conditions.

No incidentsThe total roof area painted was 50 000 square metres requiring 4 740 litres of paint. Overspray unfortunately resulted in the additional painting of approxi-mately 45 000 seats and 238 vehicles – although these were all successfully and timeously restored!

Working on the structure without a safety incident was an achievement in its own right and credit must be given to the site management and the highly skilled access rope crews, who spent 25 000 man hours working at heights in high winds.

It was indeed gratifying to have a small South African company, Bulldog Projects commended by American roofing sub-contractor Birdair, Inc as a professional organisation, experts in their field, who continually met the project technical and delivery constraints associated with this extremely complex roof structure.

Another case where South Africa has left a positive impression – just like the Positive impression left by the new Nelson Mandela Bay Stadium.

Isinyithi Cathodic Protection (Pty) Ltd, Tel: (011) 465-1807, Fax: (011) 467-0458, Email: [email protected]


DO YOUR FORKLIFTSMEET THE

RIGHTCRITERION?

Criterion Equipment is proud to be the sole distributor of TCM forklift trucks in Southern Africa. With over 30 years experience and a highly competent

network of branches, dealers and agencies throughout the region, Criterion will meet all your material handling needs.

HIGHEST RESALE VALUERenown for its durability and simplicity, the comprehensive TCM forklift truck range has proved itself across the globe. Commanding the highest resale value

in the industry bears testimony in itself. Moreover, TCM products with Criterion backing have earned a reputation for being very user and

service friendly, minimising downtime and optimising productivity.

SERVICE FRIENDLYFrom the IC engine range, heavy duty trucks and container

handlers, to the vast array of electric models, Criterion has exactly the right TCM for your specifi c need.

Click on www.criterion.co.za for more information on the TCM range, as

well as the various options of how to acquire your TCM product – or simply give us a call.

If you’re thinking forklift trucks, you’re thinking TCM. And if you’re thinking TCM, you’re thinking Criterion.

Criterion Equipment

1 Wrench Road, Isando, Johannesburg, South Africa

Tel: 011 966 9700Fax: 011 966 9736

E-mail: [email protected]: www.criterion.co.za

Criterion Equipment (Pty) Ltd is a wholly-owned subsidiary of Invicta Holdings Limited

network of branches, dealers and agencies throughout the region,

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The company’s footprint continues to grow and the recent acquisition of competitor, Staalbeer, is proof of their buoyancy in a suppressed market.

Chief executive of the company’s South African Merchants division, Ross Teichmann, attributes the growth of the company to its readiness to deliver what their customers want where and when they need it. This is not always an easy feat when one considers the vast amount of different products available in the market.

Right supply“BSI Steel moves hundreds of tonnes of steel around the sub-continent every day. The success of the business is due largely to the fact that we have effective supply chains that ensure the steel is delivered on time to its destination.

“Our core focus is carbon (mild) steel in all its vari-ous forms. This covers the full flat product range, long products including structural steel, tubing, cold formed sections, roofing & most other related products. To maintain the service levels that are

Steel Wherever, Whenever

Steel stockist, BSI Steel, continues making inroads into the steel supply business in southern Africa with its accurate and timely stocking and distribution business.

Branches• Gauteng: 1 branch and the group’s

main processing and distribution centre.

• Pietermaritzburg: 1 branch

• Zambia: 2 branches (Kitwe & Lusaka)

• The DRC: 2 branches (Lubumbashi & Kolwezi)

• Zimbabwe: 2 branches (Harare & Bulawayo)

• Mozambique: 1 branch in Maputo

• Mauritius: 1 office

BSi has four distinct operations within the group:• Merchants – stock holders who offer “just-in-time” service out of the various branches.

• Bulk sales local – bulk sales into the South African market.

• Bulk sales export – bulk sales into the Southern African countries.

• Processing – primary steel processing as well as a roofing division.

Our core focus is carbon (mild) steel in all its various forms

STOCKISTS AND SERVICE CENTRES

DO YOUR FORKLIFTSMEET THE

RIGHTCRITERION?

Criterion Equipment is proud to be the sole distributor of TCM forklift trucks in Southern Africa. With over 30 years experience and a highly competent

network of branches, dealers and agencies throughout the region, Criterion will meet all your material handling needs.

HIGHEST RESALE VALUERenown for its durability and simplicity, the comprehensive TCM forklift truck range has proved itself across the globe. Commanding the highest resale value

in the industry bears testimony in itself. Moreover, TCM products with Criterion backing have earned a reputation for being very user and

service friendly, minimising downtime and optimising productivity.

SERVICE FRIENDLYFrom the IC engine range, heavy duty trucks and container

handlers, to the vast array of electric models, Criterion has exactly the right TCM for your specifi c need.

Click on www.criterion.co.za for more information on the TCM range, as

well as the various options of how to acquire your TCM product – or simply give us a call.

If you’re thinking forklift trucks, you’re thinking TCM. And if you’re thinking TCM, you’re thinking Criterion.

Criterion Equipment

1 Wrench Road, Isando, Johannesburg, South Africa

Tel: 011 966 9700Fax: 011 966 9736

E-mail: [email protected]: www.criterion.co.za

Criterion Equipment (Pty) Ltd is a wholly-owned subsidiary of Invicta Holdings Limited

network of branches, dealers and agencies throughout the region,

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unlike other stockists, the company has chosen to limit its supply to unworked products and not to get involved in establishing service centres that add further value to the steel.

Great future“BSI Steel is a highly diversified business that provides customers with options in terms of steel supply. While we offer a just in time service to those that need it, we also offer bulk sales to those large production facilities that have a predictable requirement. We have a wide network of branches and traders in Southern Africa and will continue to expand on this as and when the opportunity arises.

“While we do offer “1st stage” processing to our customers, we are always mindful of the fact that to establish a fully fledged service centre, there is the risk of eventually competing with your customer base. This is something that BSi Steel will avoid.

“It has always been our intention to offer fair value and exceptional service to the market and we remain committed to continued improvement in this regard,” adds Ross.

While it does not limit itself, the company does have a range of products that are core to the group

BSI Steel has processing capabilities that operate out of our Gauteng (Kliprivier) facility

Recent developments• On the 1st March 2010 BSi opened a branch in Maputo (Mozam-bique). This is in line with its strategy in other countries in Africa, where it serves the market through stockists as well as bulk sales.

• On 1st May 2010, BSi Steel celebrated its 25th year of servic-ing the steel industry. William Battershill started Discount Steel on 1st May 1985. He rented a small house on the KZN Varsity farm. Initially, his target market was the farming community, where he focused on B Grade tubing. It wasn’t long before William expanded his range to accommodate light industry in the Pietermaritzburg and Durban markets.

• Roofing Division. BSi recently commissioned three roofing lines. The division now offers corrugated iron (8.5 and 10.5mm), IBR profile and widespan profile.

• The company also commissioned a new cut to length line. It installed an internationally acclaimed Schnutz leveler that increases its processing capabilities substantially. The processing range of this machine is 0.8mm to 6mm thickness and 2000mm maximum width.

• June 2010. BSi Steel acquires the privately owned Staalbeer. This acquisition complements the business in many ways and adds to the diverse trading style.

Ross Teichmann


expected from us, we avoid veturing too far from our core offering,” Ross explains.

Although the company does supply some stainless steel products and other specialised steel, this is on a fairly limited basis for the time being. Likewise,

Advanced Materials Today Jul/Aug 2010 1�

BSI Steel is an Altx listed South African based or-ganisation, with strong ties to the southern African markets. Its primary product range is made up of mild (carbon) steel in all its different forms. Its strength lies in its diverse product range, as well as differing trading styles. Not only does it have established branches in southern Africa, but it also trades into other markets where it does not have an established branch network.

It also has established trading relationships with clients in Namibia, Malawi, Botswana, Tanzania and Kenya.

Logistics“ In addition to us running our own fleet of trucks to service our just-in-time customers, we also have years of experience in handling the logistical require-ments needed to service the sub-Saharan markets,” adds Ross.

While it does not limit itself, the company does have a range of products that are core to the group. These include flat products – hot and cold rolled, galva-nized, plate, aluzinc, colour coated. Sections – light, medium & heavy mill (angles, flats, squares, rounds, channels, beams), tubing – hot rolled structural and cold formed sections – lipped channels and angles and open channels.

“BSI Steel has processing capabilities that operate out of our Gauteng (Kliprivier) facility. This facility provides an essential service to the sales divisions in their quest for customer satisfaction through com-petitive pricing, service and quality. It is continually expanding its processing facility in order to be the best in the game,” concludes Ross.

BSI Steel, Ross Teichmann, Tel: (011) 861 7600, Fax: (011) 861 7611, Web: www.bsisteel.co.za


Its strength lies in its diverse product range, as well as differing trading styles

1� Advanced Materials Today Jul/Aug 2010


The “virtual reality” ma-chines overcome many of the problems associated with real-world training,

such as wastage and high cost of materials with the advantages of obtaining immediate feedback of quality of weld or mistakes made.

“Training welders in the real world is a time consuming and costly exercise that requires specialised and knowledgeable trainers to examine welding results, provide feedback to learners and rectify problems.

“Virtual welding provides instant feedback and results. It is particu-larly valuable for training novices or for conveying new techniques,” says Tom Rice of the Austrian Welding Academy.

Upskilling the industryThe academy was set up by Böhler Uddeholm Africa recently to provide skills training for weld-ers from beginner to advanced level. The computerised welding machines form part of the training curricula and are used in the orientation learning phases. Once the trainee has mastered the welding exercises on the virtual training station they hone their skills using real materials and the appropriate welding equipment.

Böhler Uddeholm’s worldwide partner, the Austrian welding equipment supplier, Fronius, supplied the machines for the academy. It is a world-leader in the supply of welding equipment for industry and developed the virtual reality machines in response to calls for more cost-effective and less wasteful training practices.

In addition the developers saw an opportunity to provide instant and useful feedback to trainers with accurate results available at the click of a button.

According to Tom the “virtual reality” training sta-tion is particularly appropriate for the local market where it can, if need be, be transported to different locations to give on-site training.

“It is quick and effective and is useful when training

Real World TrainingWelder training has entered the space-age with the acquisition of virtual welding machines for the newly

established Austrian Welding Academy in Isando.

people how to weld specialised ex-pensive materials. It saves a fortune and contributes to more affordable training fees,” he says.

South Africa’s Austrian Welding Academy follows similar centres set up around the world to improve the skills of welders. The academies make use of highly skilled and ex-perienced welders and technologists who impart world-class techniques to learners.

The academy also makes use of the latest equipment in order to put learners in real-world situa-tions using machinery that is most likely to be encountered in the workplace.

Tom Rice, Austrian Welding Academy, Tel: (011) 571 2390, Email: [email protected]

Virtual welding provides instant feedback and results

WELDING



As a sub-sector to the manufacturing sector, it is well hidden from the public eye and worldwide, this sector, as a standalone sector represents

only a fraction of the turnover of the manu-facturing sectors, making it less important in terms of development support.

Few however are familiar with the effect tooling can have on the cost of producing a product. Tooling can represent as much as 15% of the initial cost invested to bringing a new product to market.

Competitive manufacturingBetween 30 and 50% of a product’s Life Cycle Cost (LCC) can be attributable to tool-ing performance. Competitive manufacturing is thus heavily reliant on a strong tooling sector support.

TASA recently attended the ISTMA (Inter-national Specialised Tooling and Machining Association) World Conference in Windsor, Canada, held in June 2010. TASA is affiliated to ISTMA via the European chapter – ISTMA Europe, where it is in the company of all the top European tool-making countries such as Germany, Portugal, Spain, Italy and others.

At the world conference, the three main groupings of the worldwide tooling fraternity, ie, ISTMA-Americas, ISTMA-Europe and ISTMA-Asia, get together to share trends, technology developments and strategy. Some interesting observations came from the conference.

StandingsIn 2009, the worldwide tooling consumption amounted to 65 billion Euros. The European contribution to this turnover stands at 14 billion Euros for the same period. The peak turnover of South African tooling consumption (largely depended on automotive industry model launches) is estimated at R6 billion (4% of EU and 1% of global turnover).

The European tooling industry’s focus going

forward will be on focus (specialisa-tion), lean manu-facturing, innova-tion, technology convergence, sup-ply chain develop-ment, financial performance and added value sup-ply.

Transfer to a knowledge based sectorThe EU will be investing billions of Euros into strengthening its manufacturing capac-ity through the Manufuture programme. ISTMA Europe has succeeded in positioning the tooling industry to participate in this investment through the European Tooling Platform to run under Manufuture.

This structure will serve as the governance structure, through which the roadmap for investment into the tooling sector will be developed.

South Africa, through the National Tooling Initiative Programme has taken a bold step in following suit, to develop and strengthen its tooling sector. TASA has, similar to the EU, created the INTSIMBI structure to act as the governance structure through which the NTI roadmap for the industry is being developed and executed.

Through its NTI programme, TASA is at the forefront of using the Manufuture model to position the tooling sector to improve its service to the local manufacturing industry.National Tooling Initiative, Dirk van Dyk, Tel: (012) 643 9360, Email: [email protected], Web: www.ntipweb.co.za

Tooling AroundThe activities of the Tool-making Association of SA (TASA) have been stead-ily escalating over the past 4 years through the establishment of the National Tooling Initiative Programme (NTI) aimed at the rehabilitation and growth of

this critical manufacturing industry support sector.

Tooling consumption amounted to 65 billion Euros

Dirk van Dyk

Official magazine of the NTIP

Until now our tool, die and mould makers (TDM) had a rough time trying to stay up-to-date with developments and happenings in their industry.

Not any more, as Advanced Materials Today takes up the reins on behalf of the National Tooling Initiative Programme (NTIP) to act as its official mouthpiece and to keep the industry informed.

TDM Today is a new section in our magazine that is dedicated solely to TDM. It will update readers on the latest NTIP initiatives, training and skills development, as well as bringing up-to-date local and international news to the desktops of decision makers within the industry.

There will be a focus on best practices and each issue will profile a local TDM related com-pany that upholds world-class manufacturing practices. Even more features will be brought into the section as it expands in months to come.

The announce of the magazine as the official magazine of the NTIP comes as a result of its focus on manufacturing within the metal working and other advanced materials industries and because of its broad reach to an appropriate readership.

From this issue, all members and prospective members of the NTIP will receive a complimen-tary Advanced Materials Today magazine in their post boxes on a bi-monthly basis.

The partnership is attracting widespread compliments and considerable interest has already been shown from industrial advertisers wishing to reach this important segment of the market. We look forward to being of service to the industry.



In South Africa it is no different and here we have companies like Conver-Tek that manufactures world-class tools, dies and moulds to rigorous demands of plastic manufacturers in selected

precise industries.

According to Bevan Davis, managing director of Conver-Tek, the quality of the design, cooling, steels used and manufacture of the actual moulds to be used, has an enormous bearing on the quality, cost, output, and life of the product and mould.

“That is why it is critical to make use of only the best designs, tool steels, cutting tools and toolroom machinery in their manufacture,” says Bevan.

Tools For The Trade

Exploding populations and global competitive plastic related markets

around the world rely on smart manufacturing to meet high volume

demand for quality items.

Bevan checks a mould before spark erosion taks place

Only the highest quality steel is used

TDM COMPANY PROFILE

Microspray irrigation

Specialised needsHe explains that modern tool and die making is specialised and in many instances complex with many interrelated requirements for specialised plastic engineered products.

“For example, a tool may be required for quality high speed injection moulding of engineering polymers that must last through the entire life-cycle of a product (sometimes +10 years), while maximising speed, quality, critical sizing, no runner wastage and minimising costs, machine downtime, repairs to tools and production scrap.

“In order to achieve this one needs to understand the product requirements, plastic materials needed, production, manufacturing process and engineer tools in such a way that they deliver beyond the expectations of the client. We have tools that have delivered ± 100,000,000 units that still produce to the original tight spec and quality. The long term cost of the tooling into the product is a fraction of a cent versus the ongoing hidden added production costs of non performing “cheap” tools.

Best-of-breedConver-tek upholds the motto “what you put in, is what you get out, and there is no such phenomena as a cheap quality tool” and Bevan is a firm believer in this principal. The company makes use of only the highest quality tool steel from its long-time supplier, Böhler Uddeholm.

“Depending on production requirements and expected tool life we use some tough high spec steels to build our tools. These steels are difficult to machine in the precise detail with standard cutting tools. Here we make use of CNC Chamille spark erosion technology with delicate electrodes for precision detail. This of course increases the


We have tools that have delivered ± 100,000,000 units

Bevan shows the newly developed anti-tamper water meters built and designed in-house by Convertek

costs of the tools”.

“We invested heavily in recognised machine tools that are up to the precision toolmaking task and make use of the highest quality cutting tools and spark eroding equipment to build our tools.

“There is a good reason why we use the machines we do. They have been found to deliver the best performance for this type of work internationally and are up to the rigours of working the kind of materials that we do,” Bevan says.

The company’s machine shop makes use of Haas and Deckel CNC milling machines, Victor CNC lathes and CNC Chamille spark erosion equipment. Most of the cutting tools, on the other hand, are provided by Sandvik.

Concept to completionGone are the days of crafting tools, dies and moulds over an extended period of time. Modern TDM is in itself becoming a highly technical production process nowadays. Customer demand calls for ergonomic design, rapid product development from concept, to prototype and end-product to compete with Chinese and Eastern opposition toolmaking companies.

Every aspect of tool, die and mould making requires expertise and it all begins with a fit for use precise design. This is achieved with the assistance of 3D modelling and CAD / CAM software. All parameters need to be taken into consideration and, when the final drawings are presented, will be taken to rapid prototype level. The exact dimensions and functions of the product can be provided using rapid prototyping.

“We have recently grown a detailed scaled model for a new racing car. It has been fully tested in the wind tunnel at Wits to finalise the design. Tools are now being cut for this racing car to be raced at Le Mans next year. The aerodynamic design was fully tested using rapid prototyping technology,” Bevan adds.

From there it goes into the manufacturing process using the captured approved CAD design data and it is machined to specification at the machine shop. After vigorous quality checks the tool, or mould will be delivered after it has been jointly commissioned by Conver-Tek’s staff and the customer to ensure it performs to the designed spec.

Aftersales“We will supply all the production parameters to the client to ensure that the tool is properly utilized to ensure it performs optimally,” Bevan says.

Conver-Tek’s efforts have not gone unnoticed. It was recently recognised as an outstanding local firm by the University of Aachen in conjunction with the University of Stellenbosch, who undertook benchmarking studies of South African tool, die and mouldmakers against their European compatriots on behalf of the National Tooling Initiative (NTI) recently. “We like the rest of Europe will have to compete against the Chinese and need to adjust our performance to compete for the same slice of cake. Our quality and performance is our selling edge.”

TDM COMPANY PROFILE


More than meets the eyeThere is more to Conver-Tek than manufacturing and supplying tools, die and moulds. The company is, in fact, its own best client, as its other core business is plastic injection moulding of products for the water and engineering plastics sectors. The company has worked specifically in the armaments, medical, water, motor, electronics, pump and pool industries.

Although the divisions were started simultaneously and complement each other, they maintain a high degree of independence. Experience gained in the injection moulding production lines often transpires to improvement and optimisation of services to customers on the tool, die and injection moulding side of things.

Innovation stationConver-Tek is seen by many as an innovation house. Many of the products produced on the plastic and tooling side have stood the test of time and some have even changed our lives.

“We were one of the inventors of the original micro irrigation system and produced both the tooling for their manufacture and the end products ourselves. Although it has been licensed, copied and produced elsewhere in the world it still makes use of our original concepts and materials.

“We further developed the first plastic water meters for Meinecke in Germany that withstand 80 Bar burst pressure. This was considered as impossible by the engineers at the time.

“The company also originally developed and pro-duced the tooling and production for the legendary Kreepy Krauly pool cleaner for over 20 years that revolutionised the way pools are cleaned around the world,” says Bevan proudly.

What’s nextAnd the innovation doesn’t stop there. Conver-Tek has produced many other “world first” plastic de-velopment innovations, most recently the company was awarded the contract to design and produce tamper-proof all polymer water meters in housings for metropolitan municipalities in South Africa. The meter boxes and fittings are patented innovations of the company and world-wide interest has already been expressed in them.

A plastic car muffler system and a plastic solar geyser with P.V. power and combined water heating are in the pipeline and are being shown to interested concerns globally. A few new technologies in the challenging water industry to resolve ongoing prob-lems are in an advanced stage of development.

“In order to compete in a global competitive market-

Modern TDM is in itself becoming a highly technical production process nowadays

place dominated by countries with huge manufactur-ing infrastructures we have had to keep innovating and producing better quality products locally than can be found anywhere else in the world in order to stay ahead of the pack,” concludes Bevan.

Bevan is currently Chairman of TASA Gauteng and a director of the NTI. The main purpose of these functions is to uplift and develop the toolmaking industry which has been written about in the intro-duction to this TDM section of the magazine.

Conver-Tek, Bevan Davies, Tel: (011) 827 2460, Fax: (011) 827 2498, Email: [email protected], Web: www.convertek.co.za

Kreepy krauly

Tools at the disposal of the tool and die maker

TDM COMPANY PROFILE


TDM NEWS

According to a benchmarking study under-taken for the National Tooling Initiative (NTI) by Aachen University and the Uni-versity of Stellenbosch this situation can

cause a price squeeze. In many instances the all too powerful customer gets to dictate pricing with the threat of taking business elsewhere.

The situation is clearly not a healthy one and com-pany owners and managers should put in place

urgent plans to broaden their customer bases, even if that means looking abroad for new additional business.

The success of the Fifa World Cup may serve as just the introduction South African businesses need.

FindingsKey findings of the benchmark are that SA has by far a smaller customer structure, we have no real ‘movement’ in customer structures, there is no pooling of skills among toolmakers and no joined projects of toolmakers for customers. Rather, there is

mistrust and fighting for customers.

One of the key sug-gestions made by Aachen University scientists, as a re-sult of the findings, was that the country should develop clus-tering activities with pooled resources and skills to serve key sectors.

Official mouthpieceKey to the success of such clusters would be the establishment of communication platforms to reduce mistrust, and hence the agreement by the NTI to appoint “Advanced Materials Today” as the official mouthpiece of the initiative.

Aachen University: www.rwth-aachen.deUniversity of Stel-lenbosch: www.sun.ac.za

Grow Your Customer Base

From comparisons of South Africa’s tool, die and mould (TDM) making market vs European and South American countries, it is clear that our industry is too dependent on too few customers.

The situation is clearly not a healthy one

The accompanying graphs illustrate our position against the European and South American companies

www.hitech.co.za

CNC MACHINES

EXCLUSIVE AGENTS FOR

16 Nguni Drive, Longmeadow West, ModderfonteinPO Box 931, Bedfordview, 2008, South Africa

Tel: 011 608-0088 • Fax: 011 608-0148E-mail: [email protected]

E


www.hitech.co.za

CNC MACHINES

EXCLUSIVE AGENTS FOR

16 Nguni Drive, Longmeadow West, ModderfonteinPO Box 931, Bedfordview, 2008, South Africa

Tel: 011 608-0088 • Fax: 011 608-0148E-mail: [email protected]

E


sible for revitalising the TDM sector in Gauteng in its broadest sense. This role includes assisting tooling companies to be globally competitive in terms of quality, cost and delivery, a process that will require the conducting of bench-marking exercises with successful countries such as China and Germany.

“The GTI is a support function to the NTIP and its activities. Therefore my role as GTI CEO is to assist the TDM sector to achieve its maximum potential in the Gauteng area,” says Henk.

He will assist SMME’s and BEE companies to effectively compete in the tooling industry. He will also be tasked with creating the support mechanisms to enable the toolmaking

industry to recapitalise and use the appropriate technologies to be competitive.

Henk is no stranger to the tooling industry. Be-fore taking the reigns as CEO of GTI, he was CEO of the Western Cape tooling ini-tiative. He holds a Masters degree in Industrial and Mechanical En-gineering from the University of Stellenbosch and has 20 years ex-perience in the manufactur ing industry in the fields of design, procurement and manufacturing.

Dirk van Dyk, NTIP CEO, says with a fully functioning tooling initiative in the Gauteng region, members of the Tooling Association of South Africa (TASA) can feel confident that they have an association that is constructively protecting and promoting their interests. “With his deep understanding of the tooling industry and what we are trying to achieve, Henk is the ideal candidate to drive this initiative,” he says.

National Tooling Initiative, Dirk van Dyk, Tel: (012) 643 9360, Email: [email protected]

See it in 3DAdvance Design So-lutions was recently appointed as premier reseller for IronCAD, a leading provider of 3D design produc-tivity solutions for industrial applica-tions.

Advance Design So-lutions is a division of Puremission Engi-neering that has of-fered design services to various industries throughout South Africa. While work-ing with their clients, Advance Design So-lutions observed a need from engineers for a 3D design so-lution that offered freedom to design and modify products during analysis and validations stages of the development cycle. The IronCAD design solutions offered a perfect solution for these customers with its innovative design ap-proach and short learning curve.

“Within our design services operation, we have ob-served a need for designers to have a solution that is easy to learn and use that could take the three dimensional concept in the designer’s mind and bring them to reality for advance interrogation.

“Being new to IronCAD ourselves, within a day of use, we were able to be up and running in IronCAD productively, meeting the demanding needs of our customers. It was a natural progression to offer this solution to allow our customers the ability to be equally innovative in their design concepts and to give them the ability to produce production-ready products” says Sam Du Plessis, general manager of Advance Design Solutions.

Advance Design Solutions, Tel: (011) 326 2040, [email protected], Web: www.ironcad.co.za

New Gauteng leaderIn its drive to revitalise the tool, die and mould making (TDM) sector in Gauteng, a move aimed at bringing the manufacturing sector to competitive levels, the National Tooling Initiative Programme (NTIP) has appointed Henk Snyman as CEO of the Gauteng Tooling Initiative (GTI).

As the newly elected GTI CEO, Henk will be respon-

Advance Design Solutions observed a need from engineers for a 3D design solution

Henk Snyman

TDM NEWS


One of the latest innovations comes from optical mea-suring specialists, GOM, in Germany with the

introduction of the Atos 3D Digitiser. Using advanced camera technology in casting applications, the Atos allows full field measuring and fast validation of the object’s complete and complex surface rather than collecting a few points with a probe and leaving large unknown areas.

Local supplierAurelio Grech-Cumbo, CEO of RGC Engineering, the sole-distributor in South Africa, says the technology is based on the principle of triangulation and projects different patterns onto

Future of CastingCasting and forging measuring can be labori-ous and time consuming in the field unless new technologies are embraced and used. Optical measuring systems are at the fore-

front of new technologies in the industry and can save time and effort, while returning

accurate information.

the object which are recorded by two cameras. The computer automatically calculates the 3D coordinates for each camera pixel of the scanned surfaces with very high precision and resolution.

Each individual measurement takes approximately 1-2 seconds and is automatically transformed to a common object coordinate system using previously

Measurement of a Pattern Plate with the GOM ATOS System

ATOS Inspection Software: Typical measuring report

TECHNOLOGY


applied reference points. During measurement, the software checks online for system calibration, sen-sor movement or any ambient changes that might affect the measurement.

Data on the moveThe Atos 3D optical digitizer is mobile and can simply be transported to an object, so that heavy casts, tools and models can be easily inspected right away on-site in foundries, tool- and die- shops. Due to its design, the sensor head is built to perform in harsh and adverse production environments.

As a non contact optical measuring device, Atos is also ideal to check sensitive sand cores before the casting process.

The measuring volume can be adapted to specific measuring tasks and object sizes within a few minutes by interchangeable lens sets. Due to this flexibility, the Atos system is able to measure ob-jects of various sizes, from filigree injection-molding components to a complete aircraft. Turntables, robots or multiple axis motion units are available for automated measurement of multiple parts.

Software A software suite called Atos Inspection Software is available with the unit and provides a number of functions essential for the casting industry. In ad-dition to full field 3D shape and dimension analysis against CAD, the software allows calculation of material thickness in order to check material allow-ance for further processing. It is possible to control size and position of basic primitives and also virtual calipers. Inspection sections with tolerance bands are available as well as classical 2D dimension-ing tools. The Atos reference point system allows

moreover checking of parting surfaces for offset, fitting and proper closing of mould halves.

For documentation and further processing the Atos Inspection Software includes enhanced reporting and documenta-tion functions and interfaces in order to generate standard or customised 3D measuring reports or traditional tables with CMM points. Results and deviations can be exported to various formats such as Excel, HTML, Word, etc. For recurring measuring tasks the software evaluation can be automated using macros and scripting language. GOM also provides a free Atos 3D Viewer and such measuring results can be eas-ily shared with customers or colleagues from other departments.

Non-contact measuring of sand cores with Atos

Touch probe for smaller measuring volume

Atos System with GOM touch probe

The computer automatically calculates the 3D coordinates for each camera pixel of the scanned surfaces

TECHNOLOGY


Touching and probing In the past, evaluation of optically hidden surfaces such as water jackets, cooling holes, deep pockets and deep cylinders, had to be measured on classical CMMs, a process which is very time-consuming due to necessary fixing and alignment of the parts.

The GOM touch probe as an add-on to the Atos 3D Digitizer helps to overcome this obstacle. The handheld touch probe enables the user to switch between 3D full-field measurement and online tactile probing of specific single points. A time-consuming modification or rebuild of the sensor setup is not necessary.

The GOM touch probe is a calibrated set of point markers which are optically tracked by the Atos 3D Digitizing system measuring the online 3D coordinate of the calibrated probe tip.

A live inspection of points and primitives is avail-able. Tactile probing of geometries such as planes, spheres, cylinders and cones as well as circular, slotted and rectangular holes and borderline seg-ments is also possible. The touch probe allows fast point based probing against CAD to determine deviations to reference data also in difficult to ac-cess areas.

LightweightThe touch probe allows effortless measurement over long periods and for larger measuring projects. A constant rigid mounting of the part such as on CMM´s is not necessary. Due to the dynamic ref-erencing either part or sensor can be freely moved to find comfortable positions. The Atos software allows various alignment strategies at any time, while the mechanical and cable-free probe can be operated via a remote control.

An audio-feedback signalises probed points and elements to guarantee a safe workflow and dif-ferent touch probe sizes are available for small to large objects.

The modular concept of the GOM touch probe al-lows an adaption for many different applications via fast interchange of probe heads and extenders. In addition the user can create customised touch probes for specific tasks.

RGC Engineering, Aurelio Grech-Cumbo, Tel: (011) 887 0800, Fax: (011) 887 7833, Email: [email protected]

The modular concept of the GOM Touch Probe allows an adaption for many different applications

TECHNOLOGY

Log onto www.promech.co.za to read back issues of

“Advanced Materials Today”


I t seems that no matter how well designed an item is or how strong the materials used are, if it needs jointing, the chances are that a potential

weak point will ex-ist unless the right solution is found. The job of the fas-teners division at Bearing Man Group (BMG) is to seek out technologies that are appropriate for different industries and applications and to bring them to our shores.

As a result BMG has agencies from the world’s leading manufacturers of fasteners. These include Nord-Lock bolt securing systems, Huck range of fasteners as well as locally developed lockbolts and Thome +

Schwind spe-ciality fasten-ers for critical or extreme ap-plications.

Runs like clockworkAt the main warehouse in City Deep, Jo-hannesburg, the opera-tion runs like a retail fast moving goods store with a massive range o f fas ten -ers stocked and shipped around the c l o c k t o destinations where they are needed. Keeping track of the hun-dreds of differ-ent items, in different sizes and materials

Nuts About FastenersA dedicated team of fastener enthusiasts are ensuring that our manufacturing industry has the latest and best fasteners avail-

able to them, sourced from all corners of the globe.

is a major feat and supplying the correct quantities and products at the right time is a challenge that has been perfected over the years.

Challenging conventionIt is the more specialised jobs that really get the blood of the BMG team pumping. It provides them with the challenges that keep the job stimulat-

ing. As newer, better and stronger materials are developed, fastener technology

needs to be adapted or exist-ing technologies tested and

specified to match the new materials.

Fasteners that require optimal pe r fo rmance i n e x t r eme temperatures, abrasive en-

vironments or that are subject to corrosion from exposure to chem-

ical processes require specialist knowledge.

According to Darryl Campbell, BMG Fastener general manager, no other fasteners are better for such applications as the range available from Thome + Schwind.

These are manufactured in standard, stainless steels and high nickel alloys for extreme and critical applications. This is the pinnacle of fastener evolu-tion and each component is machined to precise specifications and can be manufactured to meet demanding requirements.

Although the use of these fasteners in everyday applications would be overkill, it is in applications such as shipbuilding, petrochemical, process and nuclear technology that these fasteners have found a niche. Although usually too expensive for mass-produced goods the Thome + Schwind fasteners are tailor made for tightly engineered goods and structures.

Ever tightIn a similar way the use of Nord-Lock securing systems has found a niche in the South African market. The Nord-Lock’s proven wedge-locking method uses tension rather than friction to secure a bolted joint. This system has proven itself effec-tive in semi-permanent applications or where joints Darryl Campbell, BMG Fastners general manager

NordLock

If it needs jointing, the chances are that a potential weak point will exist

JOINING


Lock bolts

in the interest of our customers and only local products that can match international standards are stocked,” says Darryl.

He adds that it is the company’s focus that has earned it a reputation for quality and reliability of supply and has resulted in engineers specifying its products in a number of high profile contracts through the years. One of the more recent contracts is the Gautrain Rapid Rail Link project.

“We feel that we earned bragging rights on this, as it is a high-profile project that requires strict quality and reliable supply. We supplied all the integral requirements for the project with our Huck Fit systems,” says Darryl.

In an instance like this where human lives are at stake and consistent quality is required it is refreshing to know that BMG’s fastener specialists have carefully studied the requirements and sup-plied their client with a solution that is up to the demands that will be placed on it.

2010 recession discretion Supplying the 100 branches around the country is a smooth operation that runs like clockwork. But, 2009 was a tough year for most and BMG fasteners felt the effect of the slow-down in the manufacturing industry. Darryl’s outlook for the year ahead is bullish post the Soccer World Cup.

“We are ready for the year ahead and feel cus-tomers will be far more prepared for the boom than they were for the recession. We anticipate that most decision making in the country will

start-up again now that the World Cup month is over and business should

improve dramatically.

“The other big move this year will be away from Cadmium Plating because it is considered to be carcinogenic. Also, we will move away from Hexavelent to Trivalent

Chrome in electroplating of fasteners to ensure we reduce workers to exposure to possible side effects,” concludes Darryl.

BMG, Darryl Campbell, Tel: (031) 576 6262, Fax: (031) 576 6525, Email: [email protected], Web:

www.bmgworld.net

Customers will be far more prepared for the boom than they were for the recession

JOINING

need to be tight under any conditions and the user prefers having the option of opening the joint in future. Unlike welded joints the Nord-Lock can be released and reused.

The Nord-Lock system is available in a variety of different materials and sizes for any application where a tight, lasting joint is required. Like the Thome + Schwind systems the Nord-Lock system is pricier than conventional locking systems, but users can rest assured the joint will not loosen under tough conditions.

Structural integrity A product that has been a mainstay of BMG’s line-up is the Lock Bolt. This product is useful in applications that require high strength permanent fasteners. These are commonly used in construction projects or for the joining of heavy gauge steel. It is a permanent solution that will not work loose even during extreme vibration and thanks to the company’s specially developed semi-automated tools provides a fast and effective means of joining.

Lock bolts have been used in landmark applica-tions around the world where structural steel has been joined on site in a similar way for decades. Its simple yet effective design has ensured that it remains the most popular permanent bolt in use around the world today.

Due to demand from the local market, BMG itself has developed an effective lockbolt and tooling solution that is available at a considerably lower price to suit local needs. In applications where cost considerations are important the locally manufactured lockbolts are proving to be popular and demand is high.

Global best“We have our roots firmly in South African soil, but rather than only supporting local suppliers, have made a decision to stock the best offerings from around the world that conform to strict qual-ity codes and standards. We made this decision

Advanced Materials Today Jul/Aug 2010 �1

D rop or damage their scissors in any way and you are likely to feel the cold blades in places other than through your hair.

What few people outside of the trade know is that good cutting scissors add flair and accuracy and when you are at the top of you game with little to differentiate yourself from the competition, it is vital that your cutting tools are up to the job.

Made in JapanGood hairdressing scissors are made in a number of factories around the world, but few inspire as much history and custom as those from Japan. They can cost anything between a thousand Rand up to R25 000 per pair and embody the highest levels of blade craftsmanship known to man.

A crafted pair from the Land of the Rising Sun could probably slice an apple into quarters in mid air with a couple of wooshes of a skilled arm.

The reason the Japanese scissors are highly regarded is that the blades are made in the same way as the legendary Samurai sword, which possesses arguably the best blade produced by man.

Samurai wayBlade making was once the noblest of crafts and blacksmiths would spend days, weeks even months crafting swords. It was intensely spiritual and on delivery a bond was forged between the blade and the owner as a matter of deep belief.

Beyond the mystics was the fact that if the sword failed in battle and didn’t deliver decisive cuts, the owner would perish. Thankfully, the same fate does not meet a bad hairdresser with a blunt pair of scissors.

But, any good hairdresser will tell you that a blunt or misaligned scis-

sors smashes its way through the hair strand and leaves a splintered end that will deteriorate with time and lead to the dreaded “split end” that turn perfect coifs into bad and unsightly hairdos. Like

Chop, Chop ScissorsThe world’s best hairdressers regard their scissors as an extension of themselves without which they are doomed to be lesser mortals with the ability of your average side-of-the-road barber.

MANUFACTURING

They can cost anything between a thousand Rand up to R25 000 per pair

�2 Advanced Materials Today Jul/Aug 2010

the mystical sword, the scissors blade should cut cleanly through the strand leaving no jagged bits or rips.

Steel temperingJust like the Samurai swordsmiths, scissors makers craft their blades by alternating hard brittle steel with soft malleable steel. This is heated up and beaten flat, many times over until the craftsman is happy that the right temper is achieved. Once forming is completed, the leading edge of the blade is heat treated, tempered and honed to a razor sharp edge.

Good hairdressing scissors are made in a number of factories around the world

MANUFACTURING

Cutting testThe process usually reveals itself through a noticeable grain, much like a wood grain, on

the blade. However, this is not standalone proof of the quality of the steel nor skill of the craftsman. For this purpose suppliers back up claims with scientific data and proof. They also offer lengthy guarantees and after sales service in case some-thing goes wrong.

In ancient times it was harder to satisfy the enqui-ries of the fearsome Samurai who had to be shown actual cutting results. These included cutting tests performed on bamboo trunks and other objects.

The results were then inscribed under the handle. Results measured the cutting effect of a single stroke and the number of bamboo trunks cut down.

But top warriors and their leaders needed more. For this reason the best swords were often tested on prisoners and the results also inscribed under the handle. One stroke may have accounted for three necks or two torsos or a number of limbs. Anyone who owns an ancient and authentic Samurai sword can therefore verify the effectiveness of their sword on human flesh.

Advanced Materials Today Jul/Aug 2010 ��

Salon qualityTop salons know that the Samurai way is upheld by the likes of companies such as Hikari, who has a distributor in South Africa, as well as Matsuzaki, distributed through Final Touch, a sister company of the well-known Carlton Hair studio and these salons are prepared to pay top-dollar for these scissors.

To this day, some of the best known scissors still originate from Japan, although the cold precision blades produced in Germany and other countries compete technically, they do not hold the same weight of history.

When next you have your hair cut remember that the blades of many of the top scissor brands are not sommer like the ones you buy at the local hardware — they are legitimate tools of the trade.

Carlton Hair International, Nadia, Tel: (011) 646 2420, Web: www.carltonhair.com, . Hikari, Paul Missenden, Tel: (011) 326 2643, Web: www.hikari.co.za

MANUFACTURING

A hairdressing scissor’s price is determined by the the amount of man-hours spent making it.

Quality scissors can take up to 90 days to manufacture

The cutting edge is fine and can last month before they need to be resharpened

Scissors need regular services for rebalancing, sharpening and alignment

Scissors have a cutting edge and cutting surface on each side of the blade

The first requirement for Japanese scissors makers is to have a “sharp eye and steady hand”

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�� Advanced Materials Today Jul/Aug 2010

Industry News

Supercraft into orbitBritish aerospace company, Supercraft has enhanced its airframe manufacturing ability with the addition of three multi-axis machining centres from Yamazaki Mazak UK.

Founded in 1982 as an aerospace fabrication company, Supercraft has developed over the years into a full-service manufacturer for machining and fabricating high precision aerospace components, adding treatments such as welding and painting, before building these parts into recognisable airframe assemblies.

40 years of screwingLocal fastener manufac-turer, Tel-Screw Products, recently celebrated its 40th birthday and 10 000 th line item held on its shelves.

Through the years, the com-pany has become known for its ability and willingness to manufacture or source any product in any quantity for its clients and coined the phrase “ we will make any quantity, except half of anything.”

The business started in Germanton on the outskirts of Johannesburg 40 years ago and at the time spe-cial fasteners were mostly imported. “Our original staff consisted of a total workforce of four people, and since the move to Boksburg in 1984 has grown to 140 people, led by a team of fully qualified artisans,” says Ron-nie Teleng, managing director of Tel-Screw.

“Many of our products are marketed overseas and across our borders through the bolt and nut merchants that we supply. We also sell directly to clients in the mining, building and motor industries.

“Our strong feature has always been the specified fastener that no-one else carries or will manufacture and we are prepared to make any quantity required in a short delivery time.

“For special breakdowns, we are able to offer a 24-hour turn-around time, depending on the component,” adds Ronnie.

Tel-Screw is also equipped to do all types of bending and forming and is capable of undertaking cold heading, hot forging, thread rolling, screw cutting, hot bending, cold bending auto machining and NC machining. It has full tool room facilities for milling, welding and guillotining.

Tel-Screw Products, Ronnie Teleng, Tel: (011) 898 3200, Email: [email protected], Web: www.telscrew.co.za

Giant recycled soccer ballThe Aluminium Federation of SA, in partnership with Hula-min, KMG and other stakeholders launched a Guinness World record recycling project at Brightwater Commons in Randburg.

The project took three months to complete and included the collection of tonnes of used aluminium foil for recycling. Thirty schools took part in the collection of foil, which was deposited into a 2.5 m diameter aluminium soccer ball.

KMG undertook the mammoth task of supplying the alu-

Ronnie Teleng of Tel-ScrewProducts

The installation of two Mazak Variaxis multi-surface, simultaneous five-axis machining centres has improved productivity and reduced work in progress at Supercraft

The 100 employee company has grown its turnover over the past two to three years by around 30 percent. Key to this growth has been the move to more modern, and versatile, machine tools, especially the multi-axis machines from Yamazaki Mazak.

In addition, it has invested heavily in some of the most up-to-date manufacturing technology. Key to its growth has been the move to more modern, and versatile, machine tools, especially the multi-axis machines from Yamazaki Mazak.

“We bought our first Mazak about four years ago,” says Paul Barber, Supercraft’s sales director.

He adds that the potential to take time out of jobs, both through reduced set-up and also higher machine performance was a necessity.

“We manufacture some very complex parts,” says Nigel Prior, Supercraft’s manufacturing engineer. “With our previous ma-chine capacity these would take up to six set-ups to complete. With the Variaxis we achieve this in two, and with the twin pallet arrangement we can run first and second operations back-to-back. This improved our service of supplying fast track deliveries to our aerospace customers.”

Yamazaki Mazak UK, Web: www.mazak.eu. Hi-Tech Machine Tools, Peter Killian, Tel: (011) 608 0088, Fax: (011) 608 0148, Email: [email protected], Web: www.hitech.co.za


minium and precise laying out, laser cutting facets from flat 1.5mm aluminium sheet and bending connections to 36 degrees so that the pieces connected together like Lego for final welding.

The common soccer ball made from a combination of hexa-gons and pentagons is a truncated isosahedron.

KMG Steel service centres are one of South Africa’s largest suppliers of steel, stainless steel and aluminium and has branches nationwide.

KMG, Melody Barber, Tel: (011) 929 5000, Fax: (011) 929 5062, Web: www.kmg.co.za

Industry News

New nutA new 2-start FED-E-B double-threaded flanged single nut that enables machine tool manufacturers to considerably improve the load capacity of ball screw assemblies while maintaining identical dimensions has been introduced into the market.

The new nut achieves static and dynamic capacities of up

to 292 000N and 104 600N respectively, with screw di-ameters of 40 to 63mm. An additional circulation of balls doubles the ball count and thus increases the load capacity as compared to the standard version. This high performance nut, in conjunction with multithread precision screws with pitches of 20, 25 and 40mm, reaches travel speeds of up to 150m/min. The rotation-symmetric design allows both the screw and the nut to be driven. Bosch Rexroth provides the ready-to-install ball screw assemblies cut to size with machined ends.

The service life of double-threaded nuts with standard seals is up to eight-times longer than that of the single-threaded nut. Machine manufacturers can thus scale axis rigidity and performance for identical mechanical construction simply by exchanging the nuts.

Tectra Automation, Greg Calder, Tel:(011) 971 9400, Fax: (011) 971 9440, Email: [email protected] Work in progress at KMG’s Isando Works

The newly introduced 2-start FED-E-B double-threaded flanged single nut

Cut and drilledLocal distributor of capital equipment, First Cut, has equipped Delmas-based steel fabrication and construction company B&T Steel with a Kaltenbach cutting and drilling line, a


Industry News

Compact CNC controllerTectra Automation, the sole distributor of Bosch Rexroth pneumatic products in southern Africa, has introduced the company’s new harmonised IndraMotion MTX control plat-form to the South African market.

This innovative controller presents all hardware and software

Under pressureThe Pressure Vessel Manufacturers Association (PVMA) has changed its name to the Pressure Equipment Manufactur-

ers Association (PEMA) in response to changing market conditions.

Newly elected PEMA chair-man, Peter Viljoen, says that this is not just a name change but a fundamental re-launch. “It is the revamp-ing of the philosophy of the organisation to make it more relevant to its members and the industry as a whole.

“The PVMA has always been affiliated to both SEIFSA and SASSDA but when SASSDA made a policy decision to shed many of its affiliated organisations, including the PVMA, we used the oppor-tunity to have a good look at what we were doing.

“The name change was the first and most obvious ac-tion as the organisation had to align itself with the new Pressure Equipment Regula-

A high-performance 32-bit processor in the central control cabinet assembly of the system provides for short CNC and PLC cycle times

capital equipment installation and investment which was crucial to increasing B&T Steel’s production.

B&T Steel has been in operation for over 15 years, offering innovative steel solutions, through the manufacturing and erection of high-quality steel structures.

“The Kaltenbach cutting and drilling line supplied to B&T Steel by First Cut now facilitates a fully automated steel production process for the company,” says Andrew Poole, director of First Cut.

“The installation of the Kaltenbach capital equipment assists B&T Steel in processing up to 700 tonnes of steel a month,” adds Robert Fourie, product manager at First Cut.

B&T Steel’s technical director Norman van Vuuren adds that the choice to purchase the Kaltenbach drilling and cutting line has effectively moved B&T Steel’s business into a new dimension in which it is strategically well-positioned to develop a presence in numerous industries.

“B&T Steel has set very high targets for future growth, and therefore invested in new equipment to improve our capacity and customer service going forward,” says Norman.

First Cut, Andrew Poole, Tel: (011) 614 1112, Email: [email protected]

functions for turning and milling machines in a central control cabinet assembly that is fully compatible with the MTX CNC family from Bosch Rexroth with intelligent IndraDrive servo drives, the new IndraMotion MTX micro achieves accuracies down to the nanometre.

Specifications correspond to the typical requirements of compact machine tools. The IndraMotion MTX micro is ideal for automating up to four feed drives for turning or milling machines as a CNC controller with integrated PLC.

A high-performance 32-bit processor in the central control cabinet assembly of the system provides for short CNC and PLC cycle times and enables production accuracies down to nanometres, while ensuring high productivity. The I/O interface with modular expansion capability integrates 24V DC auxiliary sensors and actuators into the automation setup despite the lack of additional coupling relays.

A user panel offers a variety of standard functions that also make it possible to commission and optimise without a programming unit. The IndraMotion MTX micro is currently one of the most compact system solutions for turning and milling machines on the market and has already proven it-self in several recently developed machine tools and is now available locally through Tectra Automation.

Tectra Automation, Georg Venter, Tel: (011) 971 9400, Fax: (011) 971 9440, Email: [email protected]


Peter Viljoen

Industry Newsto be replaced due to problems caused by operating in the harsh environment, while the fourth system, an existing Prosafe solution, was still performing well.

“This is one of the largest systems of its kind that has been installed in southern Africa, from the number of keys used to the actual size of the installation,” says Roy.

“Improved safety and durability were the two main require-ments of the system.

“The system itself eliminates the need for a lot of keys that can be misplaced or misused. The keys are manufactured from 316L grade stainless steel, are specially coded, and can only be manufactured by Rockwell Automation to help ensure the safety integrity of each system. The system can be configured as mechanical or electro-mechanical, depending on the customer’s requirements. In the case of the smelter, a combination of both methods was used which allows for the monitoring of individual keys and integration into the existing control system.

Rockwell Automation, Adrian van Wyk, Tel: (011) 654 9700, Email: [email protected]

Prosafe trapped key interlocking switches

Gaining momentumAfrimold 2010, a trade exhibition for mould-making, tool-ing, design and application development, is gearing up for a successful debut event at the Sandton Convention Centre, Johannesburg from 16 – 18 Aug 2010. Show times are 16 and 17 August 10h00 to 19h00 and 18 August 10h00 to 18h00.

Afrimold, aims to create a platform to highlight mould-making and tooling and to enhance product development throughout the African continent as well as advancing business, tech-nology and design.

Prestigious exhibitors who have already secured their places at the inaugural event include 3D Solids, Retecon and Bohler Uddeholm Africa.

Margie Oosterlaak, Marketing Manager at 3D Solids says the company is very excited to be participating in this first event in Africa. “We are part of the Stratsys Group which traditionally participates in both euromold and amerimold. This show will give us the chance to demonstrate our 3D printers for prototyping to our direct target market on the African continent.”

“Our product is such that it needs to be seen for customers and prospects to appreciate the true value of our system and afrimold provides us with the ideal platform for exposure to our specialised target market. We have had

interest from Namibia and look forward to enhancing our interaction with them at the exhibition,” she concludes.

A high level conference program is planned to run concur-rently with the afrimold exhibition which will address tooling technologies from design through manufacture and conver-

tions (PER), which now involves all pressure equipment, including accessories, and not just pressure vessels.

“There are other fun-damental changes. For example, we have ex-panded membership to incorporate the gamut of industries in the value chain including users of pressurised equipment,” says Peter. “Also, we are dedicat-ing ourselves to help uplift the entire pres-sure equipment industry

through education and training initiatives directed mainly at skills development.”

He adds that a strong and cohesive industry association is critical in the promotion of the industry to both local and foreign companies wishing to do business with its members. “I am pleased to say that PEMA will quickly be in a position to do just that.”

PEMA, Tel: Peter Viljoen, Cell: 082563.8207, Email: [email protected]

Trapped key system installedRockwell Automation has designed and delivered a trapped key interlocking system for a chrome smelter in Steelpoort in the Mpumalanga Province.

The Allen-Bradley Guardmaster Prosafe system is being em-ployed across the smelter’s four furnaces to improve safety


Industry News

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Plastics innovations at K 2010Few industries have been hit as heavily by the 2009 economic crisis as the construction sector. Sales of pipes, profiles and boards have fallen dramatically and plastics processers and machine manufacturers have experienced a significant drop in business.

By the time of K 2010, the world’s leading trade fair for the plastics industry taking place in Düsseldorf from 27 October to 3 November, manufacturers of pipes, profiles, boards and insulating materials are hoping for a revival of business.

Organisers say the current market situation is difficult to assess although it looks as if the crisis bottomed out in mid-2009 and the market then stabilised at a low level. If the US market is taken as an indicator, a study published by the Freedonia Group market research institute (Cleveland, Ohio, USA) at the beginning of 2010 gives cause for hope.

Plastics companies from around the world will gather at the show from 27 October to 3 November at K 2010 in Düssel-dorf. The world’s leading trade fair for the plastics industry will be presenting a complete overview of the production of plastic pipes, profiles, boards and insulating materials for use in the construction industry.

www.k-online.de

sion and include all the manufacturing disciplines such as plastics, metal forming and foundry (low pressure, high pressure and sand casting.)

In addition, specific industries will be targeted including automotive, consumer, medical, building and defense.

Afrimold South Africa , Ron MacLarty, Cell: (072) 353 6699, E-mail: [email protected], www.afrimold.com

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AMT: July / Aug 2010