April 27, 2018
In CNC systems, the design of a mechanical part and its manufacturing program is highly automated. The part’s mechanical dimensions are defined using computer-aided design (CAD) software, and then translated into manufacturing directives by computer-aided manufacturing (CAM) software. The resulting directives are transformed by post-processor software into the specific commands necessary for the chosen machine to produce the component. What that means, in simple terms, is that the days of “one man, one machine” are now a fast-fading memory. One programmer at a computer console can program, implement, and supervise machine work that would be the equivalent of several operators on lathes, grinders, routers, mills, and shapers in earlier times. Computer-controlled, automated machining methods can achieve reaches, holds, and other actions that human operators and conventional machines typically don’t do efficiently. Generally, lathes and machining centres have two axes, but more sophisticated models have more, allowing for more advanced jobs to be…
April 4, 2018
The Facility for Intelligent Fabrication (FIF) combines the knowledge and resources of the UoW, TAFE NSW and the Welding Technology Institute of Australia (WTIA). FIF was formed in recognition of the changing business climate, as the Illawarra transitions from large-scale heavy manufacturing, and the need for local manufacturers to innovate and adapt to remain competitive. The facility draws on decades of research-based welding and automation expertise and welding training at both UOW and TAFE NSW, enabling local firms with their own history of fabrication expertise to access specialised knowledge and skills in automation. FIF will develop and implement solutions to industry challenges and provide demonstrations of technology and proof-of-concept, including prototype development. It will also support the adoption of new technology with technical education, training and certification support. Gareth Ward MP, Parliamentary Secretary for Education and the Illawarra and South Coast, launched the facility on behalf of John Barilaro, Deputy Premier, Minister for Regional New South Wales, Minister for Skills, and Minister…
March 30, 2018
Demand for the parts is expanding as lifespans lengthen and aging results in arthritis and osteoporosis. Worldwide trends towards higher body weight and obesity put additional strain on skeletal joints. Changing lifestyles, from a lack physical activity for some to increased sports participation for others, further fuel demand for renewed body parts. Growth of emerging economies is giving greater numbers of people the resources to afford orthopedic devices. The Global Market Insights consulting group predicts that the global orthopaedic devices market will grow to €50bn by 2024. Competition prompts tooling development Orthopaedic devices include hip and knee replacement components, artificial elbow and ankle joints, trauma repair instruments, spinal bone plates and various repair pins, rods and fasteners. Joint reconstruction makes up over 40% of the market, with the majority of that in hip and knee…
March 24, 2018
Industry 4.0 is the latest phase in digitisation for the manufacturing sector. With increased productivity through intelligent, networked production systems, an Industry 4.0 marketplace means that machines offer their services and exchange information with products in real-time. Using internet or cloud-based platforms for businesses to connect to their machinery enables manufacturers to digitally connect to their own production line, machinery and supply chain. Access to the production control system via tablet or smartphone allows mobile productions planning. Cloud technology provides workers with an insight into the status of productions orders and the machines along with ease when adjusting information such as job orders or production quantities. Industry 4.0 has been driven by four disruptors: a rise in data volumes; increased computational power and connectivity; the emergence of analytics and business intelligence capabilities (for example, new forms of human-machine interaction such as touch interfaces and augmented-reality systems); and improvements in transferring digital…
March 23, 2018
“Many customers get fixated with the capital cost of an air compressor, and whilst those that want to save energy costs will look a little deeper and review service costs, very few understand the long-term total operating cost of compressed air,” said Southern Cross CEO, Mark Ferguson. “The largest cost related to producing compressed air is in energy, and this typically represents the highest energy usage in the plant. With continuously rising energy costs, it’s an area in which businesses can readily address to achieve substantial potential savings. Two-stage compressors really are low-hanging fruit.” A single-stage compressor typically used in industry is limited by the overall compression ratio across a single airend. This compression ratio in most industrial applications is around 9:1 according to Ferguson. High compression ratios, particularly as pressures increase, results in significant internal slippage which leads to loss of capacity and a reduction in efficiency. A high compression ratio also means higher bearing loads as the elevated internal pressures and…
March 23, 2018
The laser cutting and fabrication specialists service a diverse range of industries, including automotive, transport, aerospace and shop fitting, among others. With a strong focus on company culture, Laser 3D place high importance on attracting and retaining great staff, with an aim to build upon their knowledge and training where possible. Laser 3D’s CEO Bruce Thomas says that there are three main factors that contribute to the company’s success: technology, customer relationships, and dependable suppliers. Ten years ago, Laser 3D used four different machines from four different suppliers. The company now uses one supplier, Headland, and Trumpf machinery only. Consequently its processes are fully streamlined where possible as all staff members can operate all the machinery in the factory. Technology is critical to automating processes and ensuring quick turnaround times for customers. “We use technology wherever and whenever we can in order to streamline processes,” says Thomas. “We make sure that we fully understand each and every customer’s individual needs. We place high value in our customer relationships…
March 16, 2018
How does a manufacturer, once considered too small to be regarded as a competitor by larger businesses, become the only major cutting tool manufacturer in Australia, competing globally with the world’s best? The pursuit of excellence has paid off for Sutton Tools, a multi-award winning Australian manufacturing icon that now exports 50% of its Australian manufactured products globally and is the preferred brand for the IPH Group, France’s largest distributor of industrial tools. The company also supplies Rolls Royce in Romania, Triumph Motorcycles in Thailand, Moog Aerospace in the Philippines, and Foxconn in China. Sutton Tools is typical of successful Australian companies that understand the challenges faced when market demand or conditions change, or when opportunities are presented and decisive action is needed. The business is a textbook case for study by any manufacturing business that wants to stay ahead of the competition, while developing a…
March 9, 2018
In his best-selling 2000 book, Malcolm Gladwell defined ‘The Tipping Point’ as “the moment of critical mass, the threshold, the boiling point”. By that definition, direct metal printing (DMP) is standing on the precipice, as it moves rapidly from prototyping to production for mission-critical, risk-averse applications in defence and aerospace, where nothing is left to chance. An example of this mainstream acceptance is a long-term partnership between 3D Systems and Thales Alenia Space to leverage DMP for aerospace components. Based in Toulouse, France, Thales Alenia Space is one of the leading aerospace suppliers in the world, with revenues topping €2bn in 2014. The company has 7,500 employees in eight countries, specialising in space telecommunications, navigation, Earth observation, exploration and orbital infrastructures. The collaboration between Thales Alenia Space and 3D Systems can be seen in the production of antenna brackets (190mm x 230mm x 290mm) for a geostationary telecommunications satellite. DMP is now qualified and fully available for Thales Alenia Space’s titanium aerospace applications. Today, for certain products like the satellites, 80%…
March 9, 2018
The new Lincoln Spirit 400 machine – now operating in the company’s 400sqm plate-processing facility – was specified to deliver industry-best standards of cut quality on standard and specialty steels, including stainless steels and heavy-duty chromium carbide protective plates up to 60mm thick. According to TW Woods’ Managing Director Tom Woods, high-quality, wear and impact-resistant materials are now in high demand as coal and mineral processing plants place new emphasis on long-life products that avoid delays and breakdowns as mines step up production. The same quality, traceability and accountability standards are being required by private and state organisations involved in the energy, marine, oil & gas and defence sectors, where safety and durability are paramount. The investment in state-of-the-art plasma cutting technology has also been complemented by the installation of a new Truflow spray booth and bake oven to deliver best-quality protective finishes for customers in industries including defence, energy, manufacturing, mining, minerals-processing, materials-handling, metals, process engineering, and water and…
March 2, 2018
Among other things, the new system from acp (advanced clean production GmbH) increases productivity by around a third when machining workpieces made from polyether ether ketone (PEEK) and aluminium. A further advantage is that components and machines stay much cleaner. In recent years, the use of CO2 as a coolant for machining processes has become much more popular as an alternative to conventional cooling lubricant concepts. One of the reasons for this is the higher rate of material removal, which increases productivity and also reduces tool wear and the associated downtimes. The so-called cryogenic cooling method with carbon dioxide therefore decreases production costs. With its quattroClean snow jet technology, acp offers a cooling system that has proved its worth in serial productions. It can also be integrated into CNC machines and machining centres at a later stage. The quattroClean system works with liquid carbon dioxide, which is generated as a by-product from chemical processes as well as from the generation of energy…
March 2, 2018
As a world leader in laser cladding technology, RUAG Australia was successful in 2016 in winning a highly competitive Capability Technology Demonstrator (CTD) grant from the Commonwealth Government to develop a new laser repair technology using Direct Energy Deposition where powdered metal is applied under controlled conditions. With a track record of research and development in additive repair technologies RUAG’s research and innovation team have already successfully developed an alternative technology for the rapid repair of corroded, worn and damaged components using a cold spray technique, known as Supersonic Particle Deposition. The process is currently being used to restore structural integrity of corroded panels on aircraft. The recent CTD grant focuses on laser deposition of hard steels used in aircraft structures, such as SS4340 and 300M, to develop a rapid repair technology for the recovery of corroded or worn structural parts. Corrosion is recognised as a significant contributor to the lifecycle…
February 23, 2018
Four new deals worth a total of more than $80m are expected to generate nearly 50 new skilled jobs. Tamar Hydro in Exeter was selected in November to build hydro turbines for Indonesia, while Taylor Bros in Hobart will build two high-powered Antarctic landing barges for Australia’s new icebreaker RSV Nuyina. Meanwhile Liferaft Systems Australia (LSA) has signed a contract to build inflatable marine evacuation systems for a new class of warship being built in Britain, and Penguin Composites is working on its first major Defence-related contract and putting on 15 new employees. Tamar Hydro will create 20 new positions after signing the contract to build turbines for an extensive mini-hydro network in Indonesia; the deal is expected to bring in about $45m over three years. General Manager, David Hillier, said it was a significant coup for the Exeter-based business, which is now looking for a larger factory in the Westbury or Bell Bay areas. “This contract will bring us into the modern age with new machinery,” he said. “A…
February 23, 2018
Star Cutter Company specialises in carbide and preform manufacturing, cutting tools and CNC machines for tool/cutter grinding and hob sharpening. Founded in Detroit in 1927, the company today operates six manufacturing facilities at strategic locations throughout Michigan. Since 1998, Star Cutter has partnered with NUM in development of application-specific CNC hardware and software. During the course of this collaboration, the two companies have advanced cutting tool machine technology significantly – Star Cutter currently manufactures seven highly specialised lines of machine tools, six of which are based on NUM’s CNC systems. Star Cutter originally used Fanuc controllers for its machines. However, with a goal to bring its customers even more capability and ease in realising complex tool forms, as well as to gain more flexibility and speed in integration of third-party motors and simplify the development of control…
