April/May 2018 Volume 23 No. 2 - Machine Tool Market

Featuring XPR300: Cutting capabilities on Stainless Steel Cutting capabilities on Aluminium 5-axis cutting demonstrations Wireless diagnosis

Rhino machine launch: Newly developed CNC Clear Cut software Drastic increases in production Laser pointer plate alignment Ohmic and float head sensing

Open day21-22 June 2018

W W W. C N C C L E A R C U T. C O . Z A

April/May 2018 Volume 23 No. 2

1

APRIL/MAY 2018 VOLUME 23 • NO. 2

INSIDE

Proprietors & Publishers

MTM Publications (Pty) LtdReg. No: 2005/030589/07

AddressPO Box 2434, Northcliff, 2115, South AfricaTel: (011) 476-3211/3 Tel: (011) 476-3240

Fax: (011) 476-3216

Website: www.machinetoolmarket.co.za

E-mail: [email protected]

Publishing EditorGerd Müller

Production DirectorMonica Müller

Production ManagerSue Ashley

AdvertisingJason Rohrs

Accounts, SubscriptionsMonica De Koker

Agents – Europe:komm-ma Kommunikation und Marketing

Uschi Hengst e.k.Adolf-Ohm-Weg 25

D 79539 Lörrach, GermanyTel: 00 49 7621 420 918Fax: 00 49 7621 420 919

e-mail: [email protected]

Subscription RatesSouth Africa:

R430-00 (one year), V.A.T. included.

Southern African States:Airmail: R1140-00 (one year)

Overseas:Airmail: R2040-00 on application

Advertisements / EditorialsThe publisher reserves the right to refuse and/or omit any advertisement and gives no guarantees that advertisements or editorial contributions will

be inserted on the date ordered.

Whilst every care is taken to ensure that information in Machinery & Accessories Market SA is accurate

and up to date the publishers cannot accept responsibility for mistakes or omissions.

CopyrightAll rights reserved to MTM Publications (Pty) Ltd. No part of this publication may be reproduced, or

transmitted in any form or by any means, electronic or mechanical, including photocopying, recording, storage in a retrieval system, or otherwise, without

the written permission of the publisher.

Machinery & Accessories Market – APRIL/MAY 2018

6 AUTOMATION

18 NEWS – INTERNATIONAL 18 SMART TECHNOLOGIES ARE DRIVING TOMORROW’S PRODUCTION – EMO HANNOVER 2019 19 ECONOMIC CONFIDENCE AHEAD OF IMTS 2018 19 WHY CARSHARING PLAYS A DECISIVE ROLE 20 A321LR WITH RECORD-BREAKING FLIGHT

22 NEWS – LOCAL 22 THE NEW BMW X3 NOW ROLLING OFF THE LINE 23 DENEL SHOWCASES PRODUCTS FOR GROWING ASIAN-PACIFIC MARKETS 24 COEGA WELCOMES THE SIGNING OF IPP CONTRACTS 24 COEGA – APPOINTMENT OF SPECIAL INVESTMENT ENVOY 26 DEVELOPING NEW MANUFACTURERS

32 RESEARCH 32 AUTOMATED LIGHTWEIGHT CONSTRUCTION REDUCES WEIGHT AND COSTS

28 CUTTING TOOL TALK

30 PRODUCTS

Tel: (012) 541-0552 • Fax: 086 684 6813Email: [email protected]

www.cncclearcut.co.za

12 Fairwood Road, Rosslyn East 0200

CNC CLEAR CUT

CNC CLEAR CNC CLEAR

Open Day21-22 June

2018

12, Fairwood Road, Rosslyn, Pretoria

Simple, inexpensive, compact• Variety of materials • Enhanced productivity in thin sheets • Low investment and operating costs • Simple to operate • Simple design and short installation time

FIBER LASERS

AD-R PRESS BRAKESFast, stronger, accurate with new design

PLASMA CUTTERSSHEARS IRON WORKER PUNCH/LASERPLATE ROLLING MACHINE SECTION ROLLERS BANDSAW

Local: 08600 DURMA (38762)International: +27 11 865 4090

[email protected] | Byron 083 231 1955www.durma.co.za

THE WINNING FORCE

Other machines available:

• CNC punching machines

• Variable rake swing beam and mechanical shears

• CNC plasma cutting systems

• L angle processing centers

• Plate roll benders

• Profile benders

• Iron workers

• Bandsaws

• Corner notchers

• Laser and Plasma Consumables • Press Brake Tooling • Eccentric Presses • Press Feeding Equipment and Compressors

Local: 08600 DURMA (38762) | International: +27 11 865 4090 | [email protected] | Byron 083 231 1955 | Sean 073 167 5913

Bending Area

Reference Pins - Centering Device

LUD - Loading/Unloading Device(Push support is closed)

LUD - Loading/Unloading Device(Push support is open)

ATS - Automatic Tools Set-Up

Perfectly equipped for sensitive bendingEnergy efficient solutions

PANEL BENDERBending Center

THE WINNINGFORCE


[email protected] 083 231 1955 | Sean 073 167 5913

Simple, inexpensive, compact• Variety of materials • Enhanced productivity in thin sheets • Low investment and operating costs • Simple to operate • Simple design and short installation time

FIBER LASERS

AD-R PRESS BRAKESFast, stronger, accurate with new design

PLASMA CUTTERSSHEARS IRON WORKER PUNCH/LASERPLATE ROLLING MACHINE SECTION ROLLERS BANDSAW



THE WINNING FORCE

Other machines available:

• CNC punching machines

• Variable rake swing beam and mechanical shears

• CNC plasma cutting systems

• L angle processing centers

• Plate roll benders

• Profile benders

• Iron workers

• Bandsaws

• Corner notchers

• Laser and Plasma Consumables • Press Brake Tooling • Eccentric Presses • Press Feeding Equipment and Compressors

Local: 08600 DURMA (38762) | International: +27 11 865 4090 | [email protected] | Byron 083 231 1955 | Sean 073 167 5913

Bending Area

Reference Pins - Centering Device

LUD - Loading/Unloading Device(Push support is closed)

LUD - Loading/Unloading Device(Push support is open)

ATS - Automatic Tools Set-Up

Perfectly equipped for sensitive bendingEnergy efficient solutions

PANEL BENDERBending Center

THE WINNINGFORCE



CENTRE LATHEC6236/1000 C6340/1000

CD6266C/2000 GH6266C/3000 CW61100Q/4000 CW61100Q/6000

PLATE ROLLS ESR 4.5 *1300

• 4.5mm rolling thickness• 1300mm rolling length• Cone rolling attachment

Q35Y-12 40 ton hydraulic

QA32-8B 36 ton mechanical

TURRET MILLING MACHINEX6323V

3hp variable speedTable: 1370 x 254mm

3 axis digital read out & power feedMachine vice, clamping kit & collet set

LOCKFORMERLC12DR

Pittsburgh lock former0.5 - 1.2mm

SEMI AUTOMATIC SURFACE GRINDERMY-250

Magnetic chuck : 540 x 250mmTable Travel: 560 x 260mm

SURFACE GRINDERMJ7115

Table: 152 x 304mm

RADIAL ARM DRILLSZQ3032x10 ZQ3040x14

ZQ3050X16

UNIVERSAL IRON WORKERS

CNC PLASMA CUTTER HCZ SERIES3000 * 1600 & 6000 * 2200

New CNC Plasma Cutter HCZ 3000 * 1600New CNC Plasma Cutter HCZ 6000 * 2200Includes• HP-160 Amp plasma source (25mm cutting capacity)• Dual heads plasma/flame• Heavy duty water table• Fast cam software

SEMI AUTOMATIC BANDSAWS180 - 400 CUTTING DIAMETER• Hydraulic Clamping• Coolant Pump and work lamp

HYDRAULIC GUILLOTINES QC12YSERIES 4 - 16mm• Estun E20 2 axis NC controller• Electronic backstops with ball screws• Built in oil chiller on oil tank

HYDRAULIC PRESS BRAKES WC67YSERIES: 63 - 400 TON• Estun E20 2 axis NC controller• Electronic backstops with ball screws• Built in oil chiller on oil tankUNIVERSAL IRON WORKERS

IW-90 SERIES: 36 - 90 TON• Built in laser for easy & quick punching• Built in hydraulic clamps for shearing• Oil chiller on oil tank• Dual foot pedals

PYRAMID PLATE ROLLS W11SERIES: 6-20mm

www.mtool.co.za

NOW OPEN!! MTOOL Durban 248 Bluff Road, Bluff Durban 4025Email - [email protected] | [email protected]

Contact: Carlo - 082 881-8514 | Enore - 083 544-2231 | Rynhardt - 082 909-6555

CENTRE LATHEC6236/1000 C6340/1000

CD6266C/2000 GH6266C/3000 CW61100Q/4000 CW61100Q/6000

PLATE ROLLS ESR 4.5 *1300

• 4.5mm rolling thickness• 1300mm rolling length• Cone rolling attachment

Q35Y-12 40 ton hydraulic

QA32-8B 36 ton mechanical

TURRET MILLING MACHINEX6323V

3hp variable speedTable: 1370 x 254mm

3 axis digital read out & power feedMachine vice, clamping kit & collet set

LOCKFORMERLC12DR

Pittsburgh lock former0.5 - 1.2mm

SEMI AUTOMATIC SURFACE GRINDERMY-250

Magnetic chuck : 540 x 250mmTable Travel: 560 x 260mm

SURFACE GRINDERMJ7115

Table: 152 x 304mm

RADIAL ARM DRILLSZQ3032x10 ZQ3040x14

ZQ3050X16

UNIVERSAL IRON WORKERS

CNC PLASMA CUTTER HCZ SERIES3000 * 1600 & 6000 * 2200

New CNC Plasma Cutter HCZ 3000 * 1600New CNC Plasma Cutter HCZ 6000 * 2200Includes• HP-160 Amp plasma source (25mm cutting capacity)• Dual heads plasma/flame• Heavy duty water table• Fast cam software

SEMI AUTOMATIC BANDSAWS180 - 400 CUTTING DIAMETER• Hydraulic Clamping• Coolant Pump and work lamp

HYDRAULIC GUILLOTINES QC12YSERIES 4 - 16mm• Estun E20 2 axis NC controller• Electronic backstops with ball screws• Built in oil chiller on oil tank

HYDRAULIC PRESS BRAKES WC67YSERIES: 63 - 400 TON• Estun E20 2 axis NC controller• Electronic backstops with ball screws• Built in oil chiller on oil tankUNIVERSAL IRON WORKERS

IW-90 SERIES: 36 - 90 TON• Built in laser for easy & quick punching• Built in hydraulic clamps for shearing• Oil chiller on oil tank• Dual foot pedals

PYRAMID PLATE ROLLS W11SERIES: 6-20mm

www.mtool.co.za

NOW OPEN!! MTOOL Durban 248 Bluff Road, Bluff Durban 4025Email - [email protected] | [email protected]

Contact: Carlo - 082 881-8514 | Enore - 083 544-2231 | Rynhardt - 082 909-6555


Automation

PANEL BENDING – FULLY AUTOMATIC PROCESSING WITH TOP PART FLEXIBILITYThe TruBend Center 7030 offers the highest degree of part flexibility and fastest offline programming on the market fitted with highly accurate ACB angle measurement technology.

Panel bending with maximum part flexibility is faster with the TruBend Center 7030, TRUMPF’s fully auto

matic bending cell. The machine turns the parts automatically, freeing up the operator and increasing the productivity of the bending process. The usual benefits of TRUMPF panel bending are retained

– short side lengths, small profiles and parts with formed sections, recesses, diverse radii or multiple negative bends

– the machine reliably bends them all with precision. The laserbased ACB angle measurement system enables operators to work with greater precision and in conjunction with TRUMPF TecZone Fold (the fastest offline programming tool on the market), more efficiently than ever.

Fully automatic machine with top part flexibility

Using the new rotary part manipulator, the TruBend Center 7030 can bend parts fully automatically. The manipulator secures the sheet and rotates it as needed into the required position. Here, axis speeds of 3,000 millimeters per second make it possible to achieve significantly increased productivity compared to the semi-automatic TruBend Center 5030 panel bender.

When it comes to positioning smaller parts, the patented 2-axis part manipulator also comes into play. The synchronized interaction of rotary and 2-axis part manipulator allows what is for fully automatic panel bending an unusually large degree of freedom to shape components. With its TruBend Center 7030, TRUMPF is offering a fully automatic panel bending machine with an additional vertical axis for the 2-axis part manipulator. This makes for unprecedented flexibility, since the gripper modules can fasten onto parts in a variety of positions, making it possible, for example, to secure narrow profiles on their edge or grip them with clamps and bend them. Without this additional feature, many parts would be impossible to manufacture. The vertical axis also ensures that the operator can easily remove parts with downward edges.

The TruBend Center 7030 is designed to allow for a wide range of shapes and formats, including sheets of aluminium up to 4 millimeters thick, mild steel up to 3 millimeters thick, or stainless steel up to 2.2 millimeters thick. The machine handles extremely short side lengths, boxes up to 220 millimeters deep, small profiles, narrow or negative bends and diverse radii. A single tool can be used to achieve these different bending radii very quickly and that increases both creativity and productivity by allowing product designers to incorporate more curves in trim panels or create exceptional

geometries. Because the machine operates with extremely high precision (the accuracy of repetition is precise to within hundredths of a millimeter) and uses bending tools that are mechanically stable, it can process with a minimum of tool marks which is a great advantage in the case of stainless steel and painted sheet metal.

First angle measurement system for automatic panel bending

Precise angles are essential for bending. The main threats to achieving this precision come from variations in material characteristics such as strength, spring-back and fluctuations in material thickness. To ensure precise angle measurement, the TruBend Center 7030 is fitted with TRUMPF’s tried and tested Automatically Controlled Bending (ACB) solution. This makes it the first fully automatic panel bending machine to have an angle measurement system, which means quality parts from the outset. The two ACB laser modules for negative and positive bends are placed with the additional bending tools, and they automatically move into position for the measurement process. The laser then projects a line onto the sheet and a camera detects the position of the line and calculates the part angle in real time.

Another special feature of the TruBend Center 7030 is the extremely powerful TRUMPF programming software TecZone Fold. This is the fastest programming tool on the market, and it has won over users of the TruBend Center 5030. TecZone Fold automatically creates bending programs in a few seconds – as well as 3D-simulations complete with collision monitoring, which makes efficient workshop programming possible for the first time for panel bending. This operator-friendly software is included in the base model, and it runs on the control unit as well as on the office PC (as an offline version). That makes the TruBend Center 7030 extremely economical even for manufacturing small batches or single parts.

For more information, please contact Retecon – Tel: 011 976-8600.

Panel bending with maximum part flexibility has now got even faster with the TruBend

Center 7030, the fully automatic panel bending cell.

Using the new rotary part manipulator (highlighted in blue), the TruBend Center

7030 can bend parts fully automatically – the manipulator secures the sheet and rotates it

as needed into the required position.

The TruBend Center 7030 is the only fully automatic panel bending machine with an additional vertical axis for the 2-axis part

manipulator. This makes for unprecedented flexibility, since the gripper modules (highlighted in blue) can fasten onto components in a variety of positions.

PRODUCTIVITY | RELIABILITY | QUALITYContact Franz Studer

Tel: 011 976 8600 • Fax: 011 394 2471

[email protected] • www.retecon.co.za

RETECON (PTY) LTDYour Partner in Metal Working

Cape Town: 021 555 2270/1 • Port Elizabeth: 041 453 2720 • Durban: 031 701 8149

NEW: Robo2Go - Automation can be that easy!

+ Available for all DMG MORI universal turning machines with CELOS®

+ Free access for maximum operator acceptance

+ No robot knowledge required, control system completely via CELOS®

+ Can be used flexibly on multiple machines

+ Simple positioning of the automation equipment by pallet truck

+ Three options: Loading capacity 10 kg, 20 kg or 35 kg

PRODUCTIVITY | RELIABILITY | QUALITYContact Franz Studer

Tel: 011 976 8600 • Fax: 011 394 2471RETECON (PTY) LTDYour Partner in Metal Working

CELOS® App

Controlled by CELOS® – no robot knowledge required!


Automation

For more information, please contact First Cut – Tel: 011 614-1112.

XACT SMART RANGE OF PRESS BRAKES

While many fabricators in business today require an easytouse bending solution that is affordable

and which will complement their existing cutting and welding facilities, Bystronic has released the 100/3100, 160/3100 and 225/4100 models of their Xact Smart press brake range in South Africa.

In terms of bending force, the 100/3100 model will exert 100 tons/1600 kN, the 160/3100 160 tons/1600 kN, and the 225/4100 model 225 tons/2250 kN. The 100/3100 and the 160/3100 offer bending lengths of 3100mm while the 225/4100 model has a 4100mm bending length. The standard stroke for all three machines is 200mm and each has an open height of 480mm.

Options of extending the daylight and stroke by 100mm to an open height of 580mm are also available on all three models.

Other features of these press brakes are an intuitive user interface, LED work-space lighting, Energy Saver, Fast Bend increased speed as well as options of two, four or five-axis back gauge, hydraulic tool clamping and most importantly a laser safety system.

In terms of the user interface, with the use of Bystronic’s BySoft 7 CAD/CAM software, it is possible to design parts, create cutting plans and bending programmes. When manufacturing, it is possible to monitor the production process. In spite of the power of Bystronic’s BySoft software, it is user-friendly and easy to operate. Moreover, this software package will integrate Xact Smart press brakes with other smart machines in a factory operating environment.

Bystronic press brake operators are invited to use the Bystronic Bend Solver application for the calculation of all bending parameters.

The Bend Solver illustrates the complex calculations using easily understandable visualizations. Depending on the material and its thickness, it provides the information about the required bending force, box height, upper tool height, the lower tool opening, the radius and the minimum flange length. In addition, should a manufacturing facility have a number of Bystronic press brakes of varying capacities, it is possible to establish which bending machine will be most suitable for the job in hand.

For operators, interface with an Xact Smart press brake is through an intuitive touch-screen. When bending steel parts, consistent accuracy is absolutely vital. Bystronic’s Xact Smart press brakes offer the highest levels of repetitive accuracy of any press brake on the market.

Bystronic also offers a comprehensive range of tools that will cover nearly every conceivable bending application. These tools will fit a range of clamping systems, while the hydraulic

clamping of tools allows for rapid changes leading to greater productivity. Bystronic tools offer outstanding quality and a long service life thanks to manufacture using high-strength tempered 42CrMo4 steel, with deep inductive hardening to between 58 and 62 HRC.

In a busy production environment, it is still possible to keep track of tools as the most important information is engraved on the surface of the tool. However, should a custom tool be needed for a special application, Bystronic and First Cut will be happy to have such a tool designed and manufactured and delivered quickly and reliably.

Users of Xact Smart press brakes will benefit from decades of expert product design and knowledge in the processing of sheet steel. With advanced fiber lasers for ever-faster fabrication, complementary Xact Smart press brakes provide all the speed and versatility required for bending solutions within the high-speed automated Industry 4.0 environment which characterises manufacturing today.

Bystronic’s new Xact Smart available locally from First Cut.

Machinery & Accessories Market – APRIL/MAY 2018 9MTM®

• TEL: (011) 918-5138 • FAX: (011) 918-5139 • •161 DORMEHL ROAD, ANDERBOLT, BOKSBURG NORTH • PO BOX 2698 BENONI 1500 •

Monday-Thursday 08:00-17:00 • Friday 08:00-14:00 | Saturday by appointment Friday 08:00-14:00 | Saturday by appointment

Harp Machine Toolswww.harp.co.za

e-mail: [email protected] FACILITIES AVAILABLE - ONLY 24 HOURS FOR APPROVAL

Harp Quality never lets you down

HARP SMTCL HORIZONTAL BORING MILL

HARP SMTCL RADIAL DRILL

TPX6113/2 (130mm) / TPX6111B/3 (110mm)

Models: Z3080 / Z3063 / Z3050 x 1 / Z3032 x 10/1.

IN STOCK NOW!!!


Automation

AUTOMATION SOLUTIONS FOR AMADA PRESS BRAKES

A piece of integral technology able to advance productivity is AMADA’s innovative ATC (automatic tool changer). The HG-ATC is the company’s flagship press brake and is unique in the marketplace. ATC technology facilitates the automatic locating and precise loading of punch and die profiles using an independent four-axis tool manipulator, delivering dramatic time gains. In fact, using a clever algorithm to guarantee the best set-up time means the HG-ATC can load even the most complex tool layout within just 3 minutes.

HG-ATC press brakes can also be equipped with AMADA SF75 sheet followers. These handy devices, which fit to the front of the machine, make it easier to handle large, heavy parts, which perhaps would have previously required two operators. As a result, labour costs can be immediately halved.

Of course, most people associate auto mation with robotics, and here AMADA’s latest offering is the HG-ARs. This robotized bending cell, which is equipped with the new AC-300 automatic pallet changer and ATC, perfectly illustrates all the productivity and flexibility gains that can be achieved using the latest automation technology. Material load/

unload and bending functions are performed by a seven-axis articulated robot, which is capable of a complete range of motions.

A seven-axis robot also features in AMADA’s HG-Rm press brake system for bending large-scale parts featuring complex rib and panel shapes. Here, special grippers dedicated to rib parts are used to process complex shapes in short cycle times. The automatic re-gripping device, which does not require any manual set-up, is equipped with two motorized arms and automatic scissor supports.

From a software perspective, AMADA can offer its advanced VPSS 3i suite for the provision of streamlined workflow from initial 3D CAD model to finished product, taking in processes such as cutting, punching, bending and welding. The key to the success of the VPSS 3i system is the constant data link between the separate software modules (such as Blank CAM, Bend CAM and Weld CAM), the machines and the central database. This database stores all parts, machines, tools, materials and technology-related information in a consistent way, distributing the data quickly and reliably. All of AMADA’s automation solutions incorporate the latest digital technologies in line with smart factory concepts.

For more information, please contact AMADA – Tel: 011 453-5459.

While many assume press brakes to be mature technology, AMADA continues to push the boundaries

of what can be achieved with this core metalforming process. As a result of recent developments, the company can offer a number of important automation advancements that are designed to deskill and reduce costs for fabrication shops everywhere.

For your Used Machine Tool requirements

Established 1988

Tel: (011) 476-3211 / 476-3213

®

Gauteng: Tel: (011) 453-5459 Fax: (011) 453-5442 Cell: 082 465 5924 (Rick) e-mail: [email protected] Town: Tel: (021) 706-0502 Fax: (021) 706-0503 Durban: Tel: (031) 700-5070 Fax: (031) 700-5077

The Amada Product Portfolio includes:CNC TURRET PUNCH PRESSES,

CNC LASER CUTTERS, CNC PRESSBRAKES, NC HYDRAULIC/MECHANICAL SHEARS, SOFTWARE,

BANDSAWS, BANDSAW BLADES, SALES & SERVICE.

NEXT GENERATION SERVO ELECTRIC PUNCH MACHINE

EM Z 3612 MII• Set-up time reduction• Process integration

LOW ENERGY CONSUMPTION, HIGH-SPEED PRODUCTIVITY

HG 1003 ATC• Introduce rush jobs seamlessly

• Triple or quadruple the amount of set-ups performed each day

SERVO/HYDRAULIC PRESS BRAKE WITH AUTOMATIC TOOL CHANGER

LCG 3015 AJ• Lower operating costs• Expanded capabilities• Lower maintenance• Proven performance• System integration• Energy efficient• Elimination of harmful emissions

Fiber Laser Cutting System

MTM®


Automation

For more information, please contact Durmazlar – Tel: 011 865-4090.

DURMA PANEL BENDER BENDING CENTRE

Fast manufacturing and high precision repeatability are amongst the most important criteria in today’s sheet

metal processing industry. For this reason, automation and robotic systems are increasingly in demand. Similarly, bending machines also require change in application technology. Complex bends that cannot be performed by using automated and robotic subsystems and conventional bending machines, can be performed with high precision repeatability by using the Durma CNC fully automatic servo Panel Bender machine. The Panel Bender machine should not be confused with conventional bending machines. The Durma Panel Bender is a fully automatic sheet bending machine equipped with different systems in every direction.

While featuring 28 fully automatic operation axes, all axes are servo controlled in addition to 40 pneumatically controlled motion- and

positioning axes. Thanks to the smart con sumption system, the machine calculates the optimum amount of

energy required, thus providing energy saving.

The Panel Bender machine is built on a stress relieved carrier body, which features

a bending device, holding devices and movement – plus positioning equipment. In front of the machine, there are a referencing- and manipulator device which manage positioning of the part to be bent.

As a working principle, the blanking sheet material manipulator is clamped between the upper and lower clamps. The manipulator device, has the ability to rotate and move toward, lean the sheet against the referencing pins in the reference device and the appro-priate position. After this point the panel bender machine, having reference informa tion, is fixed on the sheet bending area by means of the holding device and the appropriate bending is performed by movement of the bending device.

While the machine is able to handle sheet materials in thicknesses between 0,5mm - 3,2mm, it can also bend aluminium material up to 4mm thickness and stainless steel material up to 2,2mm.

The Panel Bender machine meets the require-ments of manufacturing sectors such as elevator, steel door, panel, kiosk and control panel, cabin and case, industrial cooling systems, industrial ventilation systems, industrial kitchen, domestic appliance and lighting systems manufacturing.

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Automation

For more information, please contact Reef Engineering & Manufacturing – Tel: 011 864-1730.

AUTOMATION IN THE STEEL MACHINE TOOL INDUSTRY

The 4th Industrial Revolution (Industry 4.0) is driven by the rapid growth in processing, communication networks

and data storage capabilities. Industry 4.0 focusses on the intelligent, horizontal and vertical networking of people, machines, objects and ICT systems for the dynamic management of complex systems.

But what are the benefits of these systems and what is driving the 4.0 revolution?

There is a need for flexibility and flexible ma-chines. The ability to quickly change production to react to customer demands. Multi-purpose machines, must be able to produce a range of product types on a single machine, with short changeover and set-up times.

While there is the need for transparency, all machines and company systems must be able to communicate through one network and protocol. The complete production process must be visible, in order to optimize monitoring and improving maintenance processes.

There is a need for flexible machines that can produce small batches, customized on a make to order basis and a need for maximum machine availability, early detection of faults and reduction of unexpected machine events, culminating in systems for simple fault finding and self-correction with maintenance carried out on an as required scenario based on actual machine state feedback. Spare parts are ordered and stocked according to real time information.

Resources need to be used efficiently with minimization of waste. The interface between human and machine is simple, comfortable for flexible machine control, using the latest technologies such as IPads and cell phones.

How do such requirements affect the machine builder and automation blueprint? Machines

providing ease of use, flexibility and optimal efficiency will, in themselves, require more design input and use of the latest technologies.

All designs are now being produced in 3D CAD using digital software platforms. This has greatly improved accuracy as well reduc-tion in design time. Such designs can now simulate and animate the machine function while it is possible to check the interaction between machine functions. At this level the animation is controlled by the design platform. From CAD designs as well as machine design requirements, it is possible to design the auto-mation platform including motors, gearboxes, control logic, sensors and function. Taking both the CAD design and the automation platform, the motion, control, visualization, network and other software are developed.

The next major step with I 4.0 is combining the CAD and automation platform so that the machine animation is controlled by a simulated automation control system. The end result of combining these two platforms is called a digital twin.

The concept of a digital twin in future automation systems includes machines that are developed and designed in modules. Such modules are combined in digital format to simulate a production line. Complete simulation prior to manufacture allows for

testing, improvements, checking human interface and many other benefits prior to manufacture. As actual manufacturing times and costs can then be reduced, it is also possible to train line operators on digital platforms.

Machines will have a large quantity of sensors providing direct feedback to the local network via OPC UA. This is now a universal standard protocol for such communication. For example, motors will directly transmit temperature, pressure transducers transmit pressure to name a few. All devices will transmit information.

Another change in Automation includes the digital twin operating in parallel to the actual machine. The machine has its own control system. The digital twin is given the same commands. The digital twin is also receiving all the data from sensors and installed devices and compares this data to expected data. The digital twin can then determine if corrections need to be made to the control settings of the actual machine control. Machines will then self-correct and optimise. The control system, sensors and digital twin can send data to local edge devices or the cloud. (See diagram)

Authors: Graham Ellett – Reef Engineering. Scip Vernede – SA Power Services

Tel: (011) 864-1730 • Fax: (011) 864-1405

• Servo Roll Feeders • Straighteners• Feeders • Schnutz Precision Levellers

REEF Press Feeding

REEF Presses

CoilProcessing Lines

• e-mail: [email protected]®

With decades of experience you can rely on

Engineering & Manufacturing Co. (Pty) Ltdwww.reefeng.com

With decades of experience you can rely on

COMPLETE SOLUTIONS FOR THE METAL FORMING INDUSTRY

Established 1942 Engineering & Manufacturing Co. (Pty) LtdEstablished 1942 (Pty) Ltdwww.reefeng.comwww.reefeng.com

Engineering & Manufacturing Co. (Pty) Ltdwww.reefeng.comwww.reefeng.com

COMPLETE PRESS REBUILDING, PRESS MAINTENANCE,

SPARES, SPECIAL PURPOSE MACHINES

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NewsInternationalSMART TECHNOLOGIES ARE DRIVING TOMORROW’S PRODUCTION EMO Hannover 2019 positions new business models

based on intelligent networking

EMO Hannover 2019, the world’s premier trade fair for the metalworking industry, will be held from 16 to 21

September 2019 under the motto of Smart technologies driving tomorrow’s production. It will thus be concentrating on the current paradigm shift in industrial production operations, which are no longer focusing (only) on better, faster, more accurate, but on the development and implementation of new functions within the framework of Industry 4.0. Digitalization and intelligent networking in conjunction with numerous new developments, from Big Data, data analytics and artificial intelligence, all the way through to the platform economy, create the foundations for new business models, so that customers and vendors can reach a new level of productivity.

“The last EMO Hannover had already shown that Industry 4.0 has arrived in the machine tool industry,” says Carl Martin Welcker, General Commissioner of EMO Hannover 2019. “As the world’s leading innovation platform, we are progressing this trend by focusing on the next development step in production operations: the technical options opened up by digitalization and networking, which are being increasingly reflected in new business models,” he adds. “This doesn’t mean that in future we shall no longer be working on optimizing machines and processes in the traditional way. I am, however, confident that quantum leaps forward in terms of productivity, quality and reliability will be triggered primarily by the new technologies. So in 2019 we will

be seeing an abundance of solutions that implement new services for the machine tool industry’s customers.”

Rendering data intelligently usable

For new business models on a broad front, first of all the immense quantities of data generated by digitalization and networking of machines and processes have to be reduced to a usable level. Because only if you can extract the relevant data (Smart Data) from the super abundance of Big Data can you derive an entrepreneurial benefit from Industry 4.0. Last year, scientists at the German Academic Society for Production Engineering (WGP) in their position paper on Industry 4.0 had already published an action guide and shown how Big Data can be rendered manageable using the data mining method, for example. Besides this guide, the professors at the WGP contribute their state-of-the-art expertise to other bilateral arrangements between the industrial sector and the academic community. Not least, they utilise the EMO Hannover in order to showcase for a global public the projects they are conducting together with industrial partners.

Utilizing artificial intelligence

In recent years, artificial intelligence (AI) has achieved some amazing breakthroughs. One of its capabilities, machine learning, enables machines and processes to optimise themselves with the aid of Smart Data. They detect patterns in data flows and derive the appropriately responsive actions. The system learns from every situation.

Artificial intelligence has already arrived in our everyday reality. To ensure that the mechanical engineering sector also benefits from this, the VDMA has published a study entitled Machine Learning 2030, which is intended as a kind of roadmap. The recom-mendations for companies, politicians and researchers are currently being firmed up and implemented in a VDMA working group. It’s now only a question of time before this futuristic scenario, too, arrives in the factories. The automotive industry, for example, is already making massive use of artificial

intelligence and entering into appropriate alliances. This is adequately exemplified by the cooperative arrangement between Mercedes-Benz and the graphics-chip manufacturer Nvidia. Together, they are aiming to put an AI-based vehicle on the road in the next few years. For machine tool manufacturers, too, artificial intelligence offers an abundance of potential.

Utilizing new economic structures

There is fresh evidence almost daily that the use of Industry 4.0 is helping to develop new economic structures. More and more platforms are being created, on which manufacturers and service providers can support their customers from a single source using a product-themed approach. So machine tool manufacturers, too, will be well advised to seize the opportunity and take this trend on board. Because the trend towards a platform economy is unmistakeable, as current studies show.

There are already some examples here, like Virtual Fort Knox, a Cloud-IT platform for production companies created by the Fraunhofer Institute for Manufacturing Engineering and Automation (IPA) in Stuttgart.

“It functions as an IT backbone for Industry 4.0 solutions and networks production companies with software vendors and machinery manufacturers. But IT companies, control system and machinery manufacturers will also be offering their solutions.

“We are seeing how new technologies are influencing and even driving forward developments in the machine tool industry,” says General Commissioner Welcker. “By September 2019, numerous specific solutions will be available on the market. I can say this with confidence, since many EMO exhibitors will be using this international shop window, in order to showcase their corporate capabilities and enhance their profiles.” Industry 4.0, he adds, creates new customer needs, to which machinery manufacturers must respond in order to remain competitive.

Author: Gerda Kneifel, VDW Press and Public Relations

Carl Martin Welcker, General Commissioner of EMO Hannover 2019.

Machinery & Accessories Market – APRIL/MAY 2018 19

NewsInternationalECONOMIC CONFIDENCE CONTINUES TO BUILD AHEAD OF IMTS 2018Manufacturing sector anticipated to grow 8 to 9 percent in 2018.

Numerous major economic indicators signal that the U.S. manufacturing industry, the second largest market

in the world with a value of nearly $9 trillion, will enjoy its strongest growth in more than a decade leading up to IMTS 2018, held Sept. 1015, 2018 at McCormick Place in Chicago. Overall manufacturing growth for 2018 is expected to increase by 8 to 9 percent compared to 2017, according to Patrick McGibbon, Vice President of Strategic Analytics, AMT – The Association For Manufacturing Technology, which produces IMTS.

“Economic indicators suggest a longer term, continued expansion. In the short term, we anticipate immediate acceleration in capital investment among IMTS 2018 visitor and exhibitor companies,” says McGibbon.

“Changes to the U.S. tax law should further

encourage purchasing during and after the show. Reduced tax rates will increase available capital. R&D tax credits expand innovation and fully expense capital expenditures which encourages purchasing.”

“The U.S. manufacturing sector is expressing economic confidence at levels not seen since the dot com boom. If there was ever a year to experience the energy, optimism and

innovations offered at IMTS, this is it,” says Peter R. Eelman, Vice President – Exhibitions & Business Development at AMT, who has participated in every IMTS since 1980.

Orders for manufacturing technology in January 2018 were up 44 percent compared to January 2017, according to the latest U.S. Manufacturing Technology Orders (USMTO) report from AMT. It was the second-largest January in the 22 years recorded by AMT’s USMTO program.

The February 2018 Manufacturing ISM® ReportOnBusiness® notesthatthePMI® (Purchasing Managers Index) registered 60.8 percent, an increase of 1.7 percentage points from the January reading of 59.1 percent and the 18th consecutive month of expansion. A reading above 50 percent indicates the manufacturing economy is generally expanding.

Other positive indicators include U.S. cutting tool shipments, a metric produced by the U.S. Cutting Tool Institute (USCTI) and AMT. With a year-to-date total of $2.195 billion, cutting tool shipments for 2017 was up 8.3 percent over 2016. The Michigan Consumer Confidence Index rose to 120 in March, the highest level in over 14 years.

Industry capacity utilization stands at 78 percent and is headed toward 80 percent, which economists consider a key metric that signals full utilization. At this point, supply chain and labor constraints can hinder further expansion. Some of the strongest U.S. segments include automotive (82.9 percent capacity utilization), aerospace (77.6 percent) and energy and power generation (79.8 percent) segments.

WHY CARSHARING PLAYS A DECISIVE ROLE IN THE BREAKTHROUGH OF ELECTRIC MOBILITYcar2go publishes White Paper

Electric carsharing gives new impetus for the breakthrough of electric vehicles. car2go, the

global market leader in the freefloating carsharing sector, recently published a White Paper showcasing the five main reasons why ecarsharing plays a central role in the development of electric mobility.

Cont. on page 20


NewsInternationalTHE A321LR “GOES LONG” WITH RECORD-BREAKING FLIGHT

The A321LR variant of Airbus’ A321 jetliner underscored its impressive range with a recordbreaking flight

from Mahé in the Seychelles islands to Toulouse, France – covering a total distance of 4,750 nautical miles in 11 hours.

This milestone was reached in late March as part of the A321LR’s 100-hour flight test and certification programme. To make flight conditions as realistic as possible while evaluating cabin systems, the A321LR carried 162 human heat-replicating dummy passengers in addition to its 16-member test crew.

According to flight test engineer Jim Fawcett, the A321LR’s flight characteristics and fuel consumption were as expected throughout the lengthy trip. He added, “the A321LR has completed 15 test flights. It is an excellent aircraft that keeps its promises in terms of flight behaviour, passenger comfort and fuel consumption.”

The A321LR has the longest range of any single-aisle jetliner, with an increased maximum take-off weight of 97 tonnes (compared to 93.5 tonnes for the A321), plus the addition of a third auxiliary centre fuel tank. The jetliner is ideally suited to transatlantic routes, allowing airlines to tap into new long-haul markets that were not previously accessible with current single-aisle aircraft.

The A321LR – which is on track for a 2018 service entry – also features a new door configuration that enables up to 240 passengers to be accommodated in the widest single-aisle fuselage in the sky.

The record-breaking flight followed A321LR hot weather testing performed at Sharjah International Airport in the United Arab Emirates, which was selected by Airbus due to the optimal weather conditions and this location’s excellent facilities.

“Fully electric carsharing is an optimal test environment for electric cars. The technology is subjected to maximum strain and proves its suitability for everyday use under real conditions,” said car2go CEO Olivier Reppert at the Future Mobility Summit in Berlin. The valuable knowledge gained on a day-to-day basis is of benefit not only to vehicle manufacturers, but also for the overall system of electric mobility including electricity providers, network operators, battery manufacturers, research institutions, cities and of course, the users.

“We are convinced that the future of carsharing is electric – which is why we are promoting its systematic development. Fully electric carsharing fleets further strengthen the already positive effects of carsharing, for example the improved air quality in metropolitan areas. Additionally, we help cities solve the chicken-and-egg problem incurred with the charging infrastructure. Hence, we make a significant contribution towards the further promotion of electric mobility as a whole,” explains Reppert.

car2go already operates purely electric carsharing fleets in three locations (Stuttgart, Amsterdam and Madrid) with a total of 1,400 vehicles which are used by 365,000 customers. Thus, car2go is one of the world’s largest providers in the electric carsharing sector. An additional 400 electric cars will be introduced by the end of 2019 in Hamburg.

“Electric mobility and carsharing both follow the same strategic goal: to make cities a cleaner and better place to live. But there is more to it,” states the car2go White Paper.

“We understand purely electric driving to be an interaction of a variety of components – from the battery to the electricity network, to the charging infrastructure and then the undeniably positive customer experience.” It is about promoting the overall system of electric mobility.

Cont. from page 19

Air Seychelles, which operates Airbus aircraft on its international services, hosted a senior delegation from the company during the A321LR’s visit.

This variant of Airbus’ A321, which will enter service in 2018, has the longest range of any single-aisle jetliner.

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NewsLocalTHE NEW BMW X3 NOW ROLLING OFF THE LINE AT ROSSLYN PLANTA new chapter in South Africa’s automotive story began recently as BMW Group South Africa started production of the new BMW X3 at its Rosslyn plant. With customer vehicles now rolling off the line, BMW Group once again demonstrates its commitment to its operations in South Africa.

In 2015, BMW Group announced a R6bn investment into South Africa in order to prepare BMW Group Plant Rosslyn

for the BMW X3 production. This event is the culmination of three years of hard work and planning resulting in production starting on time in Rosslyn.

The BMW Group assigns production to its facilities around the world on the basis of various factors. Demand for BMW’s X-derivative models has grown to more than 30% of worldwide sales since the launch of the first BMW X5 in 1999. BMW Group Plant Rosslyn was assigned production of the new BMW X3 on the basis that demand exceeds the capacity of the Group’s plant in Spartanburg, South Carolina. This change has secured the future of Plant Rosslyn as well as the livelihoods of thousands of people at facilities and in the supply chain.

BWM Group Plant Rosslyn was the first plant built by the BMW Group outside of Germany. The plant built the BMW 3 Series for 35 years, manufacturing a total of 1,191,604 units during the period and increasing production with every model. With a planned maximum capacity of 71 000 units of the BMW X3, which was later increased (with an additional R160m investment) to 76 000, BMW Group Plant Rosslyn has the opportunity to flexibly match volumes to demand and to build more cars than ever before.

Tim Abbott, CEO of BMW Group South Africa and Sub-Saharan Africa, says the successful ramp-up of production of the BMW X3 at Rosslyn is a vote of confidence in the country and in BMW Group South Africa’s associates.

“The allocation of production of such a crucial model to our plant is about as big a vote of confidence as it gets,” Abbott says. “The demand for the BMW X3 globally is powerful and ramping up on time and to the right standards is vital to the model’s success.”


NewsLocalDENEL SHOWCASES PRODUCTS FOR GROWING ASIAN-PACIFIC MARKETS

The Denel Group recently showed its range of products and various capabilities at an international

defence exhibition attended by highlevel decisionmakers from the region and other parts of the world in Malaysia.

“South East Asia is an important market for Denel with significant potential for business growth,” says the Group CEO, Zwelakhe Ntshepe. “We already have well-established relationships with a number of countries and regional defence manufacturers and are pursuing major opportunities that will soon open up.”

The Defence Services Asia Exhibition – DSA 2018 – held in Kuala Lumpur recently was attended by defence decision-makers, heads

of armed forces and industry leaders from more than 55 countries.

Many of the countries in the Asian-Pacific are re-equipping their defence forces in response to changes in the regional security environment. Denel has identified opportunities for business growth in countries such as Thailand, Indonesia, Vietnam, Brunei, Myanmar, the Philippines,

Bangladesh and Singapore.

“Our capabilities in landward defence, artillery and armoured vehicles are well-known in the region because of our long and strong relationship with the Malaysian defence industry. We will also focus on our proven capabilities in missile technology, especially the Umkhonto surface-to-air missile system which can be deployed in both the landward and maritime environments,” says Ntshepe.

Denel has been active in Malaysia for 16 years. Its primary contract is for the supply of 177 modular turrets to be fitted onto 8X8 armoured vehicles for the Malaysian army. The R4-billion contract is the largest export contract in Denel’s history.

Denel Land Systems manufactures the turrets in partnership with the Malaysian Company, DRB-HICOM Defence Techno-logies (Deftech). The contract forms part of Malaysia’s economic enhancement programme which will contribute to the establishment of production, assembly and testing facilities in the country. While Denel is manufacturing the bulk of the system’s components such as the guns and sights, the assembly and testing of the turrets will be done in Malaysia.

In addition to the turrets, Denel has also supplied G5 155mm artillery and ammunition, 81mm long range mortars and NTW20 anti-materiel rifles to the Malaysian army and SS77 machine guns to the country’s navy.

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NewsLocalCOEGA WELCOMES THE SIGNING OF IPP CONTRACTSThe Coega Development Corporation (CDC) welcomes government’s commitment to clean energy, which forms part of the broadened South African energy mix.

The announcement by the Department of Energy follows the signing of the Renewable Energy Independent

Power Producer Procurement Programme (REIPPPP) contracts from Bid Windows 3.5 and 4, worth fifty six billion rands (R56 bn) by Minister Jeff Radebe recently.

Cumulatively, the twenty-seven (27) projects are expected to add 2 300 MW of electricity to the national grid over the next five years. “With various localization and socio-economic impact potential linked to them,” highlights Sandisiwe Ncemane, CDC Project Development Manager – Energy Projects.

The CDC as a state-owned entity adopted an energy approach that is aligned to the prevailing vision for an integrated energy transition (including of electricity, liquid fuels and natural gas) for SA’s economy in terms of energy security, diversity and socio-economic development. The organization has an integrated approach consisting of five (5) focus areas, namely, power generation,

manufacturing, enablers, centre of excellence and operations & maintenance.

Currently at the Coega Special Economic Zone (SEZ) and linked to the renewable energy component manufacturing, is a wind tower manufacturing facility that has supplied wind towers to the various wind REIPPP projects within the region.

To complement the logistics movement of the wind blades, the CDC has invested over R9 million in a lay down area for normal and abnormal cargo. The 12 hectares of land in Zone 1 of the Coega SEZ located on the boundary between the Port of Ngqura and the Coega SEZ has played an integral role in the regional connection of wind power.

Cementing the Coega SEZs status as a hub for mega energy projects, is the Dedisa Peaking Power Plant – R3.5 billion investment with a capacity of 342MW. Further evidence of Coega’s traction as one of the leading investment hubs, the SEZ is allocated 1000MW

The Coega Development Corporation (CDC) welcomes the appointment of the investment envoy introduced by

the President of the Republic of South Africa, Cyril Ramaphosa, in a bid to generate at least $100 billion in new investment over the next five years.

The president’s investment envoy consists of the former Finance Minister Trevor Manuel, former Finance Deputy Minister Mcebisi Jonas, the executive chairperson of Afropulse Group, Phumzile Langeni and the chairman of Liberty Group and former CEO of Standard Bank – Jacques Marie. The envoy will report directly to the president and their work coordinated by the newly appointed economic adviser‚ economist Trudi Makhaya.

“The Coega SEZ as a Foreign Direct Investment destination is looking forward to working closely with the team to ensure that we attract

investment to both regional and national economy,” says Dr Ayanda Vilakazi, CDC Unit Head, Marketing, Brand and Communications.

As indicated, the aforementioned group will be travelling to major financial centres in Asia, Middle East, Europe and the Americas to meet with potential investors as well Nairobi, Lagos as well as from Dakar to Cairo. According to Ramaphosa, the investment envoy is part of a broader push by government to advance economic integration in Southern African region and across the world.

“The CDC is enthusiastic about the new venture the investment envoy is taking and strongly encourages economic integration locally and beyond the borders of South Africa especially with emphasis placed on more effective use of industrial incentives and local procurement requirements the CDC has to offer investors,” concludes Dr Vilakazi.

Hub for clean energy – wind turbine located in the Coega SEZ was amongst the first in

the Eastern Cape even supplying electricity to the NMB stadium during the soccer 2010

world cup.

in the Independent Power Producer (IPP) Gas to Power Programme. As such, the organization is driving an Environmental Impact Assessment for the Gas to Power Plant.

Appreciating the diverse nature of the energy mix, the CDC is working closely with various entities with a focus on advancing readiness for nuclear localization. “This is to ensure that the CDC continues to build momentum related to the national energy transition in order remain relevant to the developmental trajectory of South Africa,” concludes Sandisiwe.

COEGA – APPOINTMENT OF SPECIAL INVESTMENT ENVOY

Dr Ayanda Vilakazi, CDC Unit Head, Marketing, Brand and Communications.

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NewsLocalDEVELOPING NEW MANUFACTURERS

Advancement in machine learning and industrial innovations vital to boosting South Africa’s manufacturing sector

Following the 2008 financial crisis, which caused many industrial sectors around the globe to dwindle, South Africa’s manufacturing industry experienced a similar downturn and almost a decade later, its recovery remains a work in progress.

To revive the ailing South African economy, ambitious growth targets have been implemented along with government-led initiatives, such as The Manufacturing Circle’s Map to a million jobs in a decade plan which aim to boost the manufacturing sector. The programme focuses on creating between 800 000 and 1.1 million jobs (with five to eight times as many secondary jobs in the process) and increasing manufacturing’s input of South Africa’s economy by 30%. It’s therefore imperative to understand how recent manufacturing dynamics have changed to introduce policies that are successful in developing new manufacturers.

Professor Joseph Stiglitz, a Noble Prize-winning US economist and professor at Columbia University, recently remarked at the Redi 3X3 Summit: A Strategy for Inclusive Growth and Economic Transformation in South Africa hosted in Cape Town by the Economic Research Southern Africa and the Bureau for Economic Research, that while many countries aspire to drive their economic strategies according to those modelled by the East Asian economies of China, Japan and South Korea, such a scope of achievement cannot be replicated easily unless countries integrate today’s innovations whilst systematically improving the output of their public education sector to achieve this goal.

Next generation technologies such as big data, IoT, machine learning and robotics, also present potential growth opportunities for a nation’s manufacturing sector. Insight into the complex information related to processes, standards, procedures, productivity, sche dules and machine performance allows improvements in quality and respective unit output levels.

Notably, not all manufacturing units across an economy share similar patterns however, certain uniform operational data can be collected across a vast number of facilities to identify and trace patterns relating to productivity, cost and compliance with quality standards. This solitary view of all operational data simplifies the challenges associated with managing complex data and supports the automation of manufacturing operations through the development of prescribed standards.

Herein lies the opportunity for experienced data scientists to make a positive contribution to the manufacturing sector by extracting and processing credible and valuable information.

The above-mentioned benefits of machine learning have been observed and recorded in real-world manufacturing scenarios, specifically at one of the largest foundries in the Southern Hemisphere. Here, integration of innovative practices yielded a 0% external scrap rate, thereby contributing towards a R10 million cost saving for the manufacturer every month and eliminating the cost of defects and errors. These savings were reinvested to further increase productivity, thereby enabling the company to tender for projects against some of the world’s most progressive manufacturers.

To rebuild its manufacturing industry, South Africa currently faces two major challenges: Firstly, there’s the task of acquiring machine learning capabilities that are on par with nations having established benchmark manufacturing sectors; and secondly, the upskilling of a high-performance workforce capable of tackling the complexities associated with the development of innovative capacity.

The formulation and employment of a specialized approach favouring

Informing the Machine Tool Market in southern Africa

Published online at

www.machinetoolmarket.co.za

skill enhancement over mass job creation is a fundamental step in driving the progress of manufacturing in South Africa. This mechanization of manufacturing support requires significant investment in STEM fields – science, technology, engineering and maths – readily priming workers for the skills necessary to incorporate and execute these exponential technologies.

A new age manufacturing strategy that dually serves the nation’s economic interests as well as works in alignment with the growth of other sectors, should demonstrate how leveraging technology, education and skills appropriately can yield benefits in the long term. To achieve this goal, strong cooperation is required on part of government entities, academic institutions, manufacturing associations, investors and the private sector, all of which share the common objective to develop new and advanced manufacturers across Sub-Saharan Africa.

The Manufacturing Indaba 2018 is hosted with the joint support and strategic partnership of the Department of Trade and Industry (the dti) and the Manufacturing Circle, the industry’s voice. This year’s event will underline the development of new manufacturers by empowering prevalent, innovative technologies with the objective of enhancing the South African manufacturing sector to a level that is relatively competitive with other nations. This discussion will enlighten anyone vested in the manufacturing sector to keep abreast of the rapidly-changing technological realm confronting the industrial sector.


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• Range from 4mm to 20mm.• Range from 4mm to 20mm.• Range from 4mm to 20mm.

• Horizontal metal Band Saw - Capacity: 250mm with

miter cutting.


A NEW LOOK FOR GEAR MILLING?Technology and its products are often causative – a technology might be applied to develop more effective and intelligent products, which in turn can play an important role in advancing that technology.

This interrelationship may be observed in metalworking. Over the last few years, leadingedge technology has

resulted in multitasking machine tools and machining centers with impressive working possibilities. At the same time, this progress in machine tool engineering is significantly changing metal cutting technology.

The advanced multifunctional machine tools increasingly widen the range of machining operations that can be performed. Technological processes developed for these machines are oriented to maximize machining operation for one-setup manufacturing, creating a new source for more accurate and productive manufacturing. Milling gears and splines is one of the operations suitable for performing on the new machines.

Traditionally, gear (and spline) making is a complicated process that involves milling, chamfering, grinding and other operations. With batch manufacturing, the majority is made on specific machines: gear hobbing, gear shaving, gear grinding and so on. Developments in technology have changed the limits of hardness for cutting and considerably increased operational accuracy. This in turn has reduced abrasive machining in gear making while decreasing rough cutting. The modern multifunctional machines, which meet the requirements of one-setup manufacturing, have proved to be perfect for various gear making operations.

These new machines require appropriate tooling, and cutting tools manufacturers should prepare their response accordingly, which is why producers of general-purpose rotating cutting tools are reconsidering the role of gear-milling cutters in their program for standard product lines.

ISCAR, a leader in the cutting tool industry, is embodying this trend with a three-point

T-SLOT, a family of modular milling cutters SD-SP…, was originally developed for milling relatively narrow slots and grooves. A cutter comprises a shank and an interchangeable solid carbide head, mounted on the shank with the use of a specially designed SP-connection. The connection ensures a very durable assembly that withstands considerable cutting forces during slot milling, even in cases when a tool works with high overhang. The heads of the same diameter vary in their width. The cutting geometry of the heads is intended for efficient slot milling of different engineering materials. The design features of the heads do not limit their field of application by milling slot and grooves. The subsequent development stage introduced T-GEAR – a family that uses a SP-connection but is intended for form milling gear teeth.

A MULTI-MASTER end milling tool comprises a shank carrying inter changeable solid carbide cutting head with treaded rear area for quick-change connection with the shank. MULTI-MASTER benefits include minimum setup time and more than 15,000 possible configurations of tools assembled from the standard shanks and heads. If necessary, the assembly can be completed by extensions. The shanks have been developed in a variety of materials: steel for general-duty applications, tungsten carbide having higher rigidity, and heavy metal featuring increased vibration resistance, which considerably expands assembly options.

program for form gear-making tools – milling cutters carrying indexable inserts, milling cutters with replaceable cutting heads based on the T-SLOT concept and milling cutters with replaceable MULTI-MASTER cutting heads

MODUGEAR, the family of indexable gear-milling cutters (Pic. 1), reflects a conventional design approach, comprising disk-type tools with tangentially clamped LNET inserts. The

Pic. 1

Cutting Tool Talk


Cutting Tool Talk

QCP-2M – AN UPGRADED VERSION OF ICP-2M SUMOCHAM DRILLING HEADS

ISCAR is upgrading the SUMOCHAM ICP2M drilling heads by introducing a revolutionary drilling head geometry

that features enhanced centering capabilities, improved surface finish and overall quality of the machined hole.

The new QCP-2M drilling heads are available in 8.0 to 25.9mm diameters, in 0.1mm increments. These new drilling heads ensure a hole tolerance of IT8 and can be mounted on any SUMOCHAM standard drill body with the appropriate pocket size.

The QCP geometry should be regarded as an improved version of the previous generation SUMOCHAM double margin inserts (ICP-2M). The new geometry design features superior self-centering capabilities when compared to the current ICP-2M inserts, by gaining better hole straightness, roundness and surface finish.

The tool is made from IC908 TiAlN PVD nano layer coated grade, ensuring high wear resistance, stable and predictable wear progression and high surface quality. The MQL cooling feature increases efficiency.

For more information, please contact ISCAR South Africa – Tel: 011 997-2700.

tangential clamping principle provides an extremely rigid and durable cutter structure that results in stable and precise enough machining tooth or spline profiles. Its principal application is producing involute gears of relatively low accuracy and rough gear-milling operations that feature a 1-1.75mm gear module range.

The cutters with replaceable heads have two significant advantages compared with gear milling tools carrying indexable inserts. They offer better precision and allow the design of gear-milling cutters that are small in diameter but feature quite a large number of teeth. The replaceable heads are mounted in bodies (shanks), which are standard-line products suitable not only for the gear-milling heads but also for other types of head (for milling slots and grooves, for example). This enables customers to increase operating efficiency of the versatile shanks and to reduce tool stock, providing added value.

The replaceable solid carbide heads of the T-GEAR SD D32-M…-SP15 family are mounted in standard T-SLOT SD-SP15 cylindrical shanks and transform the latter into 32mm diameter gear milling cutters (Pic. 2). The precise profile of the cutters’ teeth and the accurate and reliable SP-connection between the shank and the head define its range of use: milling involute gears featuring a 1-2mm module.

Both types of milling cutters, those with indexable inserts and those with replaceable heads, meet the requirements of standard DIN 3972, basic profile II.

There are two types of MULTI-MASTER spline and gear making solid carbide heads. The first type is represented by the MM SS heads that were specially designed for milling involute spline shafts, specified by DIN 5480 and ANSI B92.1 standards. These heads are intended for 1, 1.25, 1.5 …, 3mm module (DIN 5480) and 8, 10, 12 …, 24 diametral pitch (ANSI B92.1).

The heads of the second type, MM SG, are used in milling spur gears in accordance with DIN 3972 (module 1-1.75mm) and ANSI B6.1 (diametral pitch 15-24) standards.

The main application field for MULTI-MASTER heads is the efficient production of small to medium batches of spline and spur gears in various industrial branches.

The world of gears is very rich and multiform, embracing a wide variety of external and internal gears: spur, helical, bevel, hypoid and more. Manufacturing these gears encompasses an entire, dynamic industrial sector with its own methods, equipment and tooling. The introduction of multitasking machines in gear milling as a serious alternative to a dedicated machine represents a new challenge to this sector and producers of commonly-used cutting tools should be ready for this significant change. ISCAR meets this challenge while maintaining the requisite high standards demanded by end users.

Pic. 2


Products and the unit stops when the programme is finished. For increased production a flying shear is incorporated. These units can handle 30 ton coils and widths of material up to 2020mm.

Our vibratory bowl feeders are used to orientate parts and feed them to down line assembly machinery by means of a vibrator pack and an aluminium spiral track bowl ranging in diameter from 150mm to 710mm and various track sizes. Typical feed rates are 40 to 200 parts/minute.

We have manufactured special purpose machinery for the production of roll-on deodorants, making bricks and even roof tiles. Most car manufacturers have A.P. Design equipment in their plants. We help to keep the railways running and help to make industrial diamonds.

A.P. DESIGN – A PROUD SOUTH AFRICAN MANUFACTURER

Advertorial

Established 45 years ago, manufacturer of cut to length lines, machine tools and special purpose machinery A.P.

Design has always taken advantage of new technology, including intelligent servo drives. While even today small machines are fitted with PLC’s, we now upload links via the internet to PLCs & HMIs.

Together with latest technology available, comes the need for smart interfaced advanced field devices. These range from a sub miniature infra red sensor to vision recognitions systems. With the vast amount of options available we can build machines that are much more cost effective and user friendly.

At our company all design work is done on Autodesk Inventor 2019 work stations. These software packages allow A.P. Design engineers to system check the functionality of machines prior to being built, which includes FEA (Finite Element Analysis).

All components used in the building of machines including electronic and system interfaces are manufactured in-house.

While A.P. Design provides press shop turnkey solutions and automation of presses and guillotines, the company also manufactures vibratory bowl feeders for small parts, servo drive roll feeders and eccentric presses. Our servo roll feeders come in any length required. While the units are controlled by a closed loop servo drive, models are available from 200mm to 1250mm wide. We have strip feeders available up to 400mm wide and 400mm feed length x 4mm thick. Smallest available 38mm wide and 50mm

feed length x 1mm thick with feed accuracy ± 0,15 per 0,5m.

Our range of products also includes two-in-one decoiler straighteners used to straighten material from coil for subsequent use in a strip feeder or electronic roll feeder; this material will then be fed to a press or guillotine. Coils over 2000kg and more than 1100mm in diameter and 200 to 1250mm width can be fed.

A wide range of custom made hydraulic presses are available from 30 to 1000 tons. These are either simple machines with a cylinder and platens or maybe more complex with die cushion.

We manufacture decoilers in a number of varieties, widths and tonnage with small units from 500kg and a width of 100mm to 30 tons and 2500mm wide. These units can be non-motorized (Haul-off) or fully motorized with electronic controls.

Our cut to length lines (CTLL) will comprise of a decoiler, feeding the coil into a leveler. The leveler will straighten the steel and an encoder will measure the steel to the correct length for cutting. Most CTLL have guillotines fitted which will do the cutting. Some CTLL have slitters fitted (blanking line) which will cut the material into strips and then recoil the steel onto spools or into coils. Most CTLL are run by a PLC and HMI screen which are programmed to do batch cutting and setting parameters. The operator will programme the length and number of pieces required,

For more information, please contact A.P. Design

– Tel: 011 010-0495.

45 Years'Service to the

Industry

VISIT OUR WEBSITE http://www.apdesign.co.zae-mail [email protected]

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Research

AUTOMATED LIGHTWEIGHT CONSTRUCTION REDUCES WEIGHT AND COSTS

Like veins in the human body, copper cables run through the fuselage of aircrafts. They transmit electrical signals for temperature-measuring sensors, LEDs in ceilings or electronic connections in seats. During their installation, individual cables are combined into harnesses.

“The process of producing and installing cable harnesses is currently 100 percent manual. This is very time-consuming and expensive,” says Dr. Ralf Zichner. He is head of the Printed Functionalities department at the Fraunhofer Institute for Electronic Nano Systems ENAS in Chemnitz, Germany and works together with his research team on manufacturing processes that automatically print electrical conductors directly onto aircraft components. The advantages: There is no waste during production, the print templates can be adapted quickly and flexibly, the classic laying of the cable harnesses is eliminated and the aircraft manufacturers save space and weight.

“We use electrically conductive silver ink, which we apply by screen or inkjet printing in layers of only a few microns directly onto lightweight aerospace materials, such as high temperature resistant plastics,” explains Zichner. In addition to the use of printing technologies for the production of printed conductors, the Chemnitz scientists also integrate microcontrollers, diodes, capacitors, resistors and other electronic components into aerospace modules. Ink and printing processes have to be optimally matched to the materials on which the printing is to occur. The Fraunhofer ENAS has extensive expertise regarding these processes, especially in terms of aerospace requirements. The technology is about to be launched. It is currently being optimized in the Fraunhofer Go Beyond 4.0 Lighthouse Project.

An example of aviation-grade plastics are high-temperature resistant thermoplastics. They are an important component of lightweight, stable fiber reinforced plastics (FRP), which are indispensable in the construction of aircraft. Thermoplastics can be reshaped or formed in a specific temperature range; they also cool down quickly after processing and can be processed at a fast pace. In addition, they are impressive due to their good flame resistance and the possibility of functional integration. “In aviation, though, there has previously been a lack of concepts for the cost-effective production of functionally integrated thermoplastic structures,” notes Tobias Joppich of the Polymer Engineering/ Thermoplastics Processing Department at the Fraunhofer Institute for Chemical Technology ICT in Pfinztal, Germany.

Together with partners in the LuFo V-1 program, the research institute has taken an important step towards exploiting the potential of thermoplastics in the construction of aircrafts. Together, they have developed a new component and production concept with modular stiffening elements that is specially adapted to cargo holds. The light-weight construction experts produce these from fiber-reinforced high-temperature thermoplastics in a hybrid molding process, a combination of forming and injection molding processes. The lightweight components are flame retardant, stable, can be automated in large quantities and are easy to assemble. “This allows manufacturers to quickly stiffen interior walls of cargo holds according to a flexible design,“ says Joppich. The stable grid structure is then attached by laser transmission welding to the inner wall of the cargo hold. The new concept can also be applied to other aircraft components, including the body shell, clips or internal components, such as seat structures. Hybrid material combinations can also be realized by the Fraunhofer ICT.

The aircraft of the future flies electrically and autonomously, is featherlight and can be

conveniently produced in a fully automated manner. While the electri fication and permanent autopilot are still in their infancy, lightweight construction is already indispensable today. Digital manufacturing processes are about to be applied. Fraunhofer presented new automated production technologies for lightweight construction materials at the ILA, the largest innovation trade fair in the aerospace industry.

The Fraunhofer ENAS manufactures printed circuit boards in screen printing on a

flexible plastic film. The tracks transmit electrical impulses – for example, to make

LEDs glow. © Fraunhofer ENAS

Hybrid stiffening panel for use in the freight hold of aircrafts. © Fraunhofer ICT

Lifting and Transport Equipment

THE PERFECT SOLUTION

Tel: (011) 678-0092WAK TRADING (PTY) LTDGround Floor Fairland House, 193 Smit Street, Fairland 2195E-mail: [email protected]

Simple and safe operation, standard range for loads up to 100 metric tons, special designs for specific lifting and transport problems made to order, sturdy castors for any application, adjustable and steerable

castor - trolleys for transport in workshop facilities, revolving transport trolleys.

QUALITY‘MADE IN

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Documents

April/May 2018 Volume 23 No. 2 - Machine Tool Market