From ovens to boilers and from mixing machines to grinders, producing industrial food processing equipment requires a high volume of welding operations. As in any industry, increasing productivity is a chief concern but food and beverage equipment manufacturers must also prioritise hygiene to ensure welds are food grade.

To remain competitive, manufacturers must seek solutions that increase production speeds and minimise the risk of contamination. Handheld laser welding, using laser devices like LightWELD®, has emerged as the ideal solution for many in the food industry as an easy-to-use technology that enables faster, more consistent welds and enables new equipment design possibilities.

Handheld Laser Welding Keeps Things Clean

Industrial food and beverage equipment relies on more than just welds to join part features – manufacturers also make use of fasteners such as nuts, bolts, washers, and rivets. Unlike in other industries, the use of fasteners, as well as threaded holes, must be considered in relation to food contact areas.

Incorrect use of fasteners creates difficult-to-clean geometry that form microcosms for bacterial growth. This risk imposes limitations on how equipment is designed, not to mention increased fabrication costs.

The number of fasteners required in a piece of equipment can only be reduced somewhat by traditional welding methods like Metal Inert Gas (MIG) and Tungsten Inert Gas (TIG), which introduce significant heat input that can damage or distort sensitive features. Laser welding, by comparison, generates considerably less heat during the welding process and is used extensively across industries for thinner metal parts.

This reduction in heat input compared to MIG and TIG opens more fabrication options to designers to help minimise fastener use and reduce material costs. Handheld laser welding also produces very high-quality welds with excellent and hygienic finishes.

The laser welding process is resistant to defects like microcracking, a concern when welding thinner joints using traditional methods, minimising the risk of bacterial growth. Handheld laser welding devices can also be used to spot weld with no part contact required, eliminating common resistance spot welding concerns like bacteria-friendly indentations and asymmetrical welds caused by issues like tip pressure and alignment.

Read more here at page 30

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Email your letter to the Editorial Team at Christellee@epl.com.sg

The post Handheld Laser Welding & Cleaning Technology Addresses Food Industry Challenges appeared first on Asia Pacific Metalworking Equipment News | Manufacturing | Automation | Quality Control.

Fast and straight to the right service employee

To give plant users even faster and more effective support in such cases, Ecoclean also offers a range of digital services. These include the new service app for IOS and Android that is designed for smartphones as well as for the web interfaces of desktops and tablets. The application software, which is currently available in seven different languages, automatically forwards service requests directly to the service staff at the responsible Ecoclean branch.

The app has various menu options for contacting the service team, such as ‘Report malfunction’, ‘Spare parts inquiry’ and ‘Technical support’. This pre-selection helps to ensure that the request is routed to the appropriate member of the relevant service team. If a company has more than one Ecoclean cleaning system in operation, the machine in question can be selected from the ‘My Machines’ menu. This way, service employee know exactly which system is concerned as soon as they are contacted, and have the necessary documentation at hand.

Easy to use and reliable: real-time connection via chat and video

During the service request, a two-way real-time connection with chat, photo and video functions simplifies communication between the machine operator and the Ecoclean service team. For example, the photo of a defective component can be sent live, enabling it to be quickly identified by the service employee and an order or quote initiated. The information and instructions required to remedy a problem or for system maintenance can be transmitted directly to customer’s staff by smartphone. The video chat function allows helpdesk employees to follow the work being carried out in real time and intervene immediately if something goes ‘wrong’. With the telephone or chat function, queries can be answered straightaway or more detailed instructions given.

This helps make sure that malfunctions or maintenance tasks are not only rectified or performed more quickly by the plant user’s staff but also more reliably. Consequently, the digitised service support minimises unscheduled machine downtimes and associated production losses. This also reduces the number of necessary trips by support staff as well as CO₂ emissions.

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Released at SEMICON Japan 2019, the forecast shows equipment sales registering a 5.5 percent increase to $60.8 billion in 2020 and continued expansion into 2021, with record revenues of $66.8 billion as leading device manufactures invest in sub-10nm equipment, especially for foundry and logic.

The SEMI year-end forecast shows sales of wafer fab equipment – consisting of wafer processing, fab facility and mask/reticle equipment – falling 9 percent in 2019 to $49.9 billion. The assembly and packaging equipment segment is on track to decline 26.1 percent to $2.9 billion in 2019, while semiconductor test equipment is forecast to drop 14.0 percent to $4.8 billion this year.

Taiwan will dethrone Korea as the largest equipment market and lead the world with 53.3 percent growth this year, followed by North America with a 33.6 percent uptick. China will maintain the second spot for the second consecutive year, and Korea will fall to third after throttling back capital expenditures. All regions tracked except Taiwan and North America will contract this year.

SEMI expects the 2020 equipment market recovery to be fuelled by advanced logic and foundry, new projects in China, and, to a lesser extent, memory. In Europe, equipment sales will surge 45.9 percent to $3.3 billion. Taiwan is forecast to remain the top equipment market next year on the strength of $15.4 billion in sales, with China second at $14.9 billion and Korea third at $10.3 billion. More upside is likely if the macroeconomy improves and trade tensions subside in 2020.

In 2021, all sectors tracked are expected to grow and the memory spending recovery will hit full stride. China is expected to ascend to the top position with equipment sales of more than $16 billion, followed by Korea, and Taiwan.

The Year-End Total Equipment Forecast is based on SEMI’s industry-recognised World Fab Forecast database and input from equipment manufacturers. Total equipment includes wafer processing, fab facilities, mask/reticle, total test, and assembly and packaging equipment.

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The post Global Semiconductor Equipment Sales Forecast—2020 Rebound, 2021 Record High appeared first on Asia Pacific Metalworking Equipment News | Manufacturing | Automation | Quality Control.

By Stephanie Riegel-Stolzer, member of the board of management, Kasto Maschinenbau.

Owing to aluminium’s special characteristics, the rules for sawing it differ from those for other materials such as steel. Cutting speeds must be higher and cutting forces lower. To ensure clean, exact cuts, it is especially important to have an optimum cutting geometry along with good lubrication and cooling.

Chips can readily cause problems owing to the high speeds and must be removed in an effective manner. Users who saw aluminium on a regular basis are therefore advised to purchase a machine that is specially designed for this purpose.

The Kasto portfolio includes a wide selection of machines in all sizes, from semi-automatic floor-standing circular saws for workshops to gantry-type band sawing machines for aluminium mills. Kasto, based in Achern-Gamshurst, Germany, is a company that provides solutions for sawing tubes, profiles and solid materials as well as sheets, plates, ingots and castings. The range includes versatile multipurpose saws for various materials, plus saws that are optimised for machining aluminium.

The Kastoalu range comprises a number of floor-standing circular saws for use in workshops. They are especially suitable for aluminium, other light metals and plastics. Their high-performance carbide saw blades have trapezoidal flat teeth with a positive cutting angle, ensuring perfect results even at low cutting pressures.

Users have a choice of saw blades with different numbers of teeth depending on the panel and plate thickness. This allows the creation of reproducibly precise, burr-free cut parts. Less work is required for reworking, and the parts can be further processed or installed right away.

There are semi-automatic mitre-cutting circular sawing machines in the Kastoalu U line are
especially good for cutting tubes and profiles to length.

The range includes the semi-automatic models E 12 / U 12, U 14 and U 20, which cover a cutting range from 100 to 200 millimetres (for tubes and profiles), as well as the fully automatic, numerically controlled Kastoalu A 13 with a cutting range of 100 millimetres (likewise for tubes and profiles). The semi-automatic saws are capable of straight and mitre cuts, with an increment-free mitre angle between ±45° and ±90° depending on the machine.

There are models which, in contrast, are suitable only for straight cuts. All the models have a hydropneumatic, infinitely adjustable saw feed plus pneumatic horizontal and vertical clamping elements. An efficient micro-spray lubrication system and an integrated air gun come as standard, and a connecting sleeve for installing a chip suction unit is standard as well. Various roller tracks and measuring systems are available as optional accessories.

The company also produces as separate line for low-cost, high-volume cutting of aluminium, copper and brass. This circular saw is available in two versions, with a cutting range of up to 90 millimetres or up to 152 millimetres (round stock).

The robust machine construction with an obliquely meshing spur gear mechanism, combined with a hydraulically damped measuring stop and a bar pusher that can be moved rapidly into position, ensures precision cutting and very high output. Depending on the application, high-speed steel, carbide tipped or PCD saw blades are used. Material feeding and sorting can be adapted to the customer’s requirements by means of a well-designed modular system.

There are band saw options for all common aluminium materials up to a diameter of 830 millimetres like the Kastotec M bandsaws.

The company also has a series that provide a quick, economical solution for all common aluminium materials up to a diameter of 830 millimetres (round). A spindle-driven material advance slide exactly positions the material to be sawn.

Precision-balanced drive elements permit very high cutting speeds in combination with smooth running that is kind to the tools. Specially designed blade guides support the tool and form short chips that are easy to dispose of. It also has a self-explanatory control system with a clearly structured interface that makes operation much easier and reduces set-up times.

The company also offers solutions for efficient sawing of small aluminium ingots, plates, castings and test strips with a maximum height of 600 millimetres and a length of up to 1,250 millimetres. A moveable material support table ensures quick, safe handling of stock.

Precision-balanced drive elements and specially designed blade guides permit cutting speeds of up to 100 meters per minute and high cutting performance while ensuring a smooth sawing process with minimal tool wear and an optimal operational lifetime. Technologies include a bandwheel housing is designed to optimise the path of flying chips to a suction device. The cutting speed and feed rate are continuously adjustable.

There are also options for efficient sawing of small aluminium ingots, plates, castings and test strips.

For material with large dimensions, there are also options for users like the Kastomaxcut. The gantry-type band sawing machine is suitable for fully automatic sawing of aluminium plates with a thickness of six to 2,000 millimetres. Depending on the version, there are bandsaws can handle ingots with cross-sections of up to 2,200 x 850 millimetres and lengths of up to 4,100 millimetres.

Its heavy-duty design makes it suitable for medium-scale to very-large-scale production. The cutting speed is continuously variable from 300 to 3,000 metres per minute. Even so, the saw runs very quietly and without vibration. The machine can be operated with both bimetallic and carbide blades.

This heavy-duty machine is used in aluminium mills and other facilities. For example, Gleich Aluminiumwerke GmbH & Co. KG in Kaltenkirchen, Germany, uses the saw to manufacture aluminium plates from ingots measuring 2,000 x 4,000 x 800 millimetres.

The company supplies customers in the mechanical engineering, tool-making, aerospace, automotive and construction industries. The machine has significantly increased saw blade lives and reduced downtimes. Moreover, thanks to fully automatic operation the company was able to increase its production while maintaining consistently high quality. The machine is equipped with strong roller tracks and transverse conveyors plus a vacuum transfer unit to handle the ingots, which can weigh up to 15 tonnes.

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The post Something For Everything: The Right Aluminium Saw For Every Application appeared first on Asia Pacific Metalworking Equipment News | Manufacturing | Automation | Quality Control.

Ask any original equipment manufacturer (OEM) to share their critical business challenges, and they are likely to raise common issues such as quality control, efficiency levels, budgeting, and inventory management. However, with the advent of technology and globalisation, modern OEMs are now faced with yet another area of concern – the proliferation of counterfeit products.

Counterfeiting has evolved over the years, from being largely localised operations into highly profitable global businesses with mass production facilities, international sales, and complex global distribution networks. According to the International Chamber of Commerce (ICC), the value of global counterfeit goods is expected to exceed USD 1.7 trillion by 2015.

In the past, counterfeiting used to be more prevalent in consumer goods, but counterfeiters have started to target highly sophisticated and engineered products in recent years, and B2B companies are similarly at risk to product piracy. One such example is in the consumables of plasma cutting systems, such as nozzles, electrodes, and swirl rings.

Counterfeiting In Plasma Cutting Consumables

Plasma cutting makes use of an electrically conductive gas, such as nitrogen and oxygen, to cut through conductive materials. A typical plasma cutting system consists of the power supply, an arc starting circuit, and a torch. The torch serves as the holder for the consumable nozzle and electrode, and provides cooling (either gas or liquid coolant) to the consumables, while the nozzle and electrode constrict and maintain the plasma arc.

Today’s high precision plasma cutting systems are capable of producing cut parts of higher quality at faster speeds, with little or no post-production processes. Yet, a plasma system is only as good as the consumable parts in the torch. Even with the latest advances in technology and torch design, a high performance plasma system can become mediocre when inferior consumables are used.

So what constitutes a counterfeit? Counterfeits are products made in exact imitation of something valuable or important, with the intention to deceive or defraud a customer into thinking that the product is an original. There are various reasons as to why an end user would unknowingly purchase counterfeit consumables. More often than not, the relatively lower price is what attracts them, as counterfeit consumables are known to sell for minimally 30 percent lesser than the original. As counterfeits are usually close copies of the genuine product in appearance, at times, end users may actually be unaware of their counterfeit purchase, and are misled to think that they are getting a good bargain instead.

Going Original

Unlike the OEMs, most customers are probably unaware of the dangers and consequences of using counterfeit consumables. It may also be a challenge for them to identify the counterfeits. Poor equipment performance that is directly due to the counterfeit consumable is mistakenly attributed to the product’s brand instead. In turn, this creates the false impression that the original equipment is unreliable, which negatively impacts the company’s branding, credibility, and reputation.

Here, we highlight five reasons why the use of counterfeit consumables can be more counterproductive than beneficial.

1. Quality
Non-genuine consumables are manufactured only with quick profit in mind. Often times, they are manufactured with techniques that focus primarily on rapid mass production instead of quality. Counterfeit suppliers lack the stringent manufacturing processes found in original products, and they simply replicate the parts used in the most popular manufacturing equipment with no proper quality control and checks. They also tend to use the lowest cost materials that are more prone to wear and tear. As a result, the copies may look the same but they lack the quality and durability that original consumables offer, often resulting in poor cutting capabilities. In most cases, the performance of the counterfeit consumable is inconsistent and unreliable, which significantly increases downtime.

 
Photographs taken at an actual counterfeit consumable manufacturing facility that was shut down in 2014. The factory is unkempt and appears to be poorly maintained. There is a noticeable lack of quality and safety testing equipment.

 
Actual photographs of the manufacturing facility of an OEM (Hypertherm). In comparison, the factory is well organized with clearly segmented work areas, and well-maintained equipment.

2. Performance
Plasma torches are precision devices and the corresponding consumables are manufactured to extremely tight tolerances with critical dimensions. Any deviations from the original measurements will have an impact on the overall cutting performance of the plasma system. While these counterfeit consumables still allow end users to cut metal, there are clear differences or inconsistencies in cut part quality, cutting speed, and consumable life when compared to the originals. Incorrect manufacturing of the consumables may cause internal torch damage or failure.

In addition, OEMs often utilize patented or proprietary technologies in the design of their consumables. For instance, Hypertherm’s “CopperPlus” electrode that doubles the consumable life of standard electrodes, and “CoolFlow” nozzle technology that improves cooling to help maintain the size and shape of the nozzle orifice for longer life. Counterfeit consumables lack the enhanced performance and features associated with these proprietary technologies, which means that customers end up not enjoying the benefits conferred by these technologies, and not realizing the full potential of the plasma system. Hence, the use of counterfeit consumables significantly impacts the overall cutting performance of the system.

Results of an actual cutting trial conducted by an end user with Hypertherm, that compares the cutting performance using Hypertherm’s CopperPlus electrodes versus its counterfeit. The trials were conducted simultaneously on 2 separate cutting tables under similar conditions, on mild steel plate of varying thickness (8mm, 10mm, and 12mm). It was found that the original consumable performed up to 5 times better in terms of cut length and number of pierces.

3. Safety
During cutting, a large amount of energy is required to generate the plasma arc, and temperatures can go up to 25,000 degrees Celsius. To reduce costs, counterfeiters manufacture their consumables with low quality metals. Unlike the originals, the counterfeits may not be able to withstand the high temperatures emitted during plasma cutting, and the torch could possibly overheat as a result. Apart from the choice of materials, consumables that are out of tolerances may also be prone to overheating. Consequently, this might cause the torch or plasma system to malfunction or breakdown, which will significantly increase downtime.

4. After-sales support
Most OEMs provide post-sales technical support for their products. Unfortunately, troubleshooting may not be possible if unknown parts were used in the lead up to a damaged torch or plasma system. Some manufacturers do not provide warranty for torches if the damage was caused by the use of counterfeit consumables, while some OEMs may even revoke the warranty for the entire system. Companies who choose to purchase counterfeit products will inevitably find themselves at the losing end in such situations.

5. Overall costs
Counterfeit consumables may cost a fraction of the price, but they typically also last only for a fraction of the cutting lifespan when compared to the genuine products. As such, frequent replacement becomes a necessity. Additional post-cutting processes like edge reworking may also be necessary due to the poor and inconsistent cut quality rendered by the cheap copies. Irrevocable damage may also occur from the use of counterfeit consumables, causing impairment to a valuable piece of equipment, which could result in irreplaceable production downtime and loss of business.

The true cost of cutting metal is multifactorial and it includes: the quantity of consumables used over a period of time; the time and labour spent on changing the consumables, and on fixing poor or inconsistent cuts; the cost of lost production (during changeovers), lowered productivity, as well as business loss associated with the use of counterfeit products. Factoring in these costs, the initial savings at the time of sale becomes insignificant when compared to the additional expenses in the long run.

Ensuring Optimal Performance

For all the perceived costs savings, counterfeit consumables are, in fact, a huge liability to businesses and are more trouble than what they’re worth. Using genuine torches and consumables for your original plasma cutting system is the only way to ensure optimal performance. Not only do the original products last longer and perform better, they are also machined to the highest quality standards and offer superior results with the latest performance-enhancing technologies. Purchasing a plasma cutting system is a significant investment in itself so why risk it for something that offers so few benefits? The only way to protect your investment is to only use genuine consumables.

There is a need to choose genuine torches and consumables for your original plasma cutting system to protect your investment and ensure optimal performance.

Impact of counterfeiting

End-users
⦁    Poor performance (life, quality and speed)
⦁    Potential downtime
⦁    Liability and safety
⦁    Increased prices versus aftermarket
⦁    Increased cost versus genuine products

Business Partners
⦁    Lost sales
⦁    Poor credibility with end user
⦁    Legal risks
⦁    Lost profit
⦁    Decreased brand value

OEM
⦁    Decreased brand value
⦁    Weakened DVP to channel partners
⦁    Lost profits, revenue and market share
⦁    Lost credibility with end user

Purchasing tips

To avoid purchasing counterfeit consumables unknowingly, end-users can look out for the following signs:
⦁    Poor or inconsistent consumable performance when compared to a genuine product (e.g. only getting 50 percent of normal life)
⦁    Having to pay an abnormally low price for “genuine” consumables or software
⦁     “Genuine” consumables from an unauthorized distributor, an unknown agent, or off the internet
⦁    Discrepancies in the physical appearance of the label, packaging, or product, when compared to that of the original consumable

End-users who suspect that they have purchased counterfeit products should contact the OEM immediately to determine the authenticity of the product and seek proper assistance.

APMEN Fast Fab

The post Behind The Facade Of Counterfeit Consumables appeared first on Asia Pacific Metalworking Equipment News | Manufacturing | Automation | Quality Control.

“We are seeing an increasing demand for high-performance tools for machining aluminium, particularly in the aerospace industry,” says Wolfgang Vötsch, Senior Product Manager for milling at Walter AG in Tübingen. “New aluminium-lithium alloys are gaining in popularity, and these materials quickly overwhelm conventional tools.”

Aircraft components made of aluminium alloys have machining volumes of up to 90 percent, as pockets of varying sizes and depths need to be milled out of the material depending on the size of the component. The components must be machined using the “High Speed Cutting” method (HSC) at cutting speeds of up to 3300 m/minute to ensure cost-effective and high-quality manufacturing.

If the cutting data is too low, this leads to build-up on the cutting edge and therefore rapid wear and frequent tool changes, resulting in high costs due to longer machine running times. Machining operators who specialise in aluminium therefore have good reason to demand outstanding cutting data and tool life from their tools, to say nothing of the fact that high-speed machining in particular requires the highest levels of process reliability.

The tool developers at Walter had these exact requirements in mind when developing the new M2131 ramping mill. They equipped the 90° milling cutter with a new class of indexable inserts that represents the current pinnacle of machining technology for aluminium wrought alloys. The grade designation of these indexable inserts is “WNN15”. This refers to an entirely new PVD variant, manufactured using the “HiPIMS method”. HiPIMS stands for “High Power Impulse Magnetron Sputtering”, which is a technology based on conventional cathode sputtering using magnetrons. The special feature of this physical coating process is that it produces an extremely thick and smooth PVD coating. The advantage of this is that it provides a huge reduction in friction, thereby reducing the tendency to form built up edges. It also provides extremely high resistance to flank face wear and high cutting edge stability. As a result, it provides the best conditions for ensuring the maximum metal removal rate. “Field tests have confirmed the technological advantages of the new indexable inserts in comparison to standard types. Our application engineers have achieved increases in tool life of up to 200 percent with ease. In one case, we even succeeded in reaching an increase of almost 400 percent!” reports Wolfgang Vötsch happily.

To ensure that HSC machining is reliable, Walter manufactures the tool body of the M2131 with the highest possible concentricity. The indexable inserts are provided with integrated protection against centrifugal force. The milling cutter is also pre-balanced. To complete this range of features designed specifically for meeting the exacting requirements of aluminium applications, the tool has internal coolant channels that are suitable both for emulsion and for minimum quantity lubrication. Wolfgang Vötsch concludes: “The aerospace industry is one of our most important key sectors. We have been supplying it with high-performance tools for years. In some cases, we have also developed these tools in collaboration with machine manufacturers. This was the case with the new M2131 as well.”

The M2131 ramping cutter from Walter AG is designed to precisely meet the demands of HSC machining of aluminium materials as well as the latest aluminium-lithium alloys. It has two sizes of indexable inserts, enabling it to reach cutting depths of 15 or 20 mm, which are ideal for ramping and pocket milling. The tool, with internal coolant, is available with a variety of interfaces, including HSK, which is available with an enlarged support face as an option, ScrewFit, parallel shank or bore. Walter produces tool bodies with diameters of 20 to 80 mm or 1″ to 3″.

Indexable insert with the new “WNN15” HiPIMS coating: The M2131 ramping mill is equipped with ZDGT1504…/ZDGT2005 – indexable inserts with corner radii of 0.4-4 mm or 0.8-6.4 mm. Their geometry is optimised for pocket milling. The special feature of this cutting material grade is that WNN15 is a PVD coating applied using the HiPIMS process.

The surface is very smooth and has very low friction, which minimises build-up on the cutting edge during aluminium machining, leading in turn to very high tool life.

APMEN Metal Cutting

The post Ramping It Up appeared first on Asia Pacific Metalworking Equipment News | Manufacturing | Automation | Quality Control.