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Problem Solver Packs a Punch with High Material Removal Rates

The Walter M4258 porcupine milling cutter with M4000 inserts.

Walter AG is using its M4258 porcupine milling cutter for shoulder and slot milling to combine the benefits of a milling body with those of indexable inserts.

The modular milling cutter has a replaceable front piece. This allows the part of the tool body that typically becomes worn most quickly to be replaced, namely the front and face. These are subject to the most rapid wear because milling cutters are rarely used over their whole length and bending forces are greatest here. The positive-locking connected interfaces in the front piece ensure that precision is maintained. Good chip clearance and internal cooling ensure high process reliability and safe chip evacuation. Walter Capto™ C6 and C8 have been chosen as interfaces to the machine. These are tried and tested, especially in highly universal applications and with any kind of modular machining tool.

While the indexable inserts used continue the trend in saving tool costs, the M4258 is equipped with M4000 system inserts. Square and rhombic with four or two cutting edges, it can be used not only in porcupine milling cutters, but also in face, shoulder, chamfer and T-slot milling cutters. Diverse geometries, such as the D51 anti-vibration geometry, allow the milling cutter to be used in difficult conditions. Tiger·tec® Gold inserts are additionally available on request – these increase the tool life further. M4258 milling cutter and M4000 system inserts provide a solution which reduces storage and procurement costs, while simultaneously conserving resources. This is because the entire milling cutter, including body is manufactured with CO2 compensation. It is suitable for practically all materials, such as cast iron, steel, stainless steels and materials with difficult cutting properties. The modular porcupine milling cutter from Walter is available in diameters of 50–80 mm and is recommended for anyone machining with high material removal rates in unfavourable conditions.

For more information, please contact Spectra Carbide – Tel: 0860 23 23 23.

Lightweight Coromill® 390 Produced Using Additive Manufacturing Reduces Vibration in Long-Overhang Milling

Lower cutter weight increases stability and productivity

In a move designed to offer customers a host of in-process benefits, cutting tool and tooling system specialist Sandvik Coromant is introducing its lightweight CoroMill 390, which features a cutter body produced using additive manufacturing. 

The lighter overall weight of the tool helps to minimize vibration and improve security during machining with long overhang. In turn, the productivity is also increased.

Additive manufacturing offers a superior way of producing complex structures with high precision and without joints. Use of the process can make components lighter, stronger and more flexible than ever before. With regard to tool bodies, additive manufacturing allows for the generation of shapes and features not possible with metal cutting. In addition, virtually any material can be printed, as in this case, a titanium alloy.

”When designing our new lightweight CoroMill 390, material has been tactically removed to create the optimal cutter design for minimizing mass,” explains Thomas Wikgren, Manager Product Application Management, Sandvik Coromant. “This is called topological optimization and it makes the cutter more compact and significantly lighter than a conventional version, thus helping machine shops to boost the productivity of their long-overhang milling operations. Moreover, a shorter distance between the damper in the adaptor and the cutting edge improves performance and process security.”

Process security is paramount in a number of metal-cutting applications, not least when milling with long overhangs, which is a common requirement in components used by the aerospace and oil and gas sectors. Here, the generation of features such as deep cavities can be compromised by vibration, leading to slower production, shorter tool life and poor surface finish. The new lightweight CoroMill 390 provides the solution. Combined with Silent Tools™ milling adaptors, this optimized tooling combination subdues vibration to help maximize productivity and process security in demanding applications involving long overhangs. In addition, the inherent CoroMill 390 concept delivers light cutting action for a smooth cutting performance.

Lightweight CoroMill 390 can perform long-reach face milling, deep shoulder and side milling, cavity milling, and slot milling. The tool is available in 40mm (arbor 16 coupling) and 50mm (arbor 22 coupling) diameter variants. Three or four inserts (size 11) can be specified to suit the application. Differential pitch and internal coolant are provided on all cutters.

 

For more information, please contact Sandvik Coromant – Tel 011 570-9615.

New PVD Coated Grades for Parting Workpieces from ISO P&M Materials

ISCAR is launching new tough PVD grades for parting applications on carbon steels, alloyed steels and stainless steels – IC1010 for medium to high speeds and IC1030 for low to medium speeds.

The new grades are based on TiAlN coating which significantly improves toughness and wear resistance, assuring longer tool life. Both grades exhibit better resistance at unstable conditions and interrupted cut. The new grades are available on TANG-GRIP and DO-GRIP inserts.

IC1030 (M25-M45) (P30-P45)

IC1030 – TiAlN coating overlays the very tough substrate IC28 for wide range of applications at high feeds and low to medium speeds. The grade is recommended for interrupted cut and machining at unstable conditions. The cutting parameters should be same as for IC830.

IC1010 ISO (M15-M30) (P15-P30)

IC1010 – TiAlN coating overlays the sub-micron grade IC08. It is recommended for general parting and grooving applications with medium to high cutting speeds and low to medium feeds, and the cutting parameters should be the same as for IC808. IC1030 is intended to replace and phase out gradually older grades IC328 and 928, while IC1010 will replace and phase out IC308 and IC1028 grades. The current insert range with IC1010 and IC1030 grades is introductory and IC1010 and IC1030 will be expanded in the near future.

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

Renault and Nissan Establish New Research and Development Venture in Shanghai

Renault and Nissan, the French and Japanese automotive alliance partners, recently announced the establishment of a new research and development joint venture in Shanghai, China, the Alliance Automotive Research and Development (Shanghai), Ltd., which will be referred to as Alliance Innovation Lab Shanghai (AIL-SH).

Renault and Nissan each hold 50% of this new entity which will conduct research and development focusing on autonomous drive, connected vehicles and electric vehicles. Technologies pioneered by the innovation hub will be potentially applied to Renault and Nissan vehicles sold in China and around the world.

Under the Alliance 2022 mid-term plan, 12 new zero-emission electric vehicles are due to be launched by 2022, and 40 vehicles are to be introduced with different levels of autonomy and over 90% of vehicles will be connected cars globally. The plan also includes a commitment to operating robo-vehicle ride-hailing mobility services.

Political Parties Commit to Collaborate With Business Leaders

The African National Congress (ANC), the Democratic Alliance (DA) and the Inkatha Freedom Party (IFP) committed to continue working with business leaders to pull the economy out of the doldrums and create much-needed jobs.

The parties – represented by ANC Economic Transformation Committee Head Enoch Godongwana, DA National Chairman Athol Trollip and IFP spokesman and Member of Parliament Mkhuleko Hlengwa – addressed delegates attending the Political Parties Seminar hosted by the Steel and Engineering Industries Federation of Southern Africa (SEIFSA) at the Johannesburg Country Club recently.

The parties collectively agreed that the stagnant economy, high levels of unemployment – particularly youth unemployment – and rampant corruption, among other socioeconomic woes, were of great concern and that Government needed to work closely with the business community to address these challenges. They also agreed that there is a need for Government to work with manufacturing sector leaders to reverse the fortunes of this sector, which has over the years struggled to operate in a low-demand and high-administered costs environment.

In addition to working closely with the business community to grow the economy, Hlengwa said Government needed to invest in infrastructure in the form of electricity and water, among others, to ensure that businesses thrive and subsequently contribute to economic growth. He said it was also of critical importance that the Government overhauls the education system to ensure that the country produces skills relevant to the fourth industrial revolution, as required by the economy.

Trollip said policy incoherence was detrimental to the economy and that the Government should do whatever it takes to address this challenge if investors were to come on board. He said the Government also needs to continue to create sector-specific incentives that reward investing in the local economy and job creation.

Transformation in Practice – Stimulating Value Chain Growth

Production line.

Businesses that are successful in effecting major transformation changes especially with black equity partners, will secure a sustained competitive advantage under the South African Automotive Masterplan 2035.

That is the view of Electrocoat MD, Angelique Adcock, one of a number of women leading companies in the pressured automotive sector.

Angelique Adcock, MD Electrocoat.

Adcock, whose family founded the e-coating business eleven years ago with a loan from a financier, sees transformation as key to future growth. That is why, she says, Electrocoat is engaging with potential black partners for a stake of at least 51% of the business.

“Taking on an equity partner would be a happy and healthy progression for Electrocoat. There are many black business people in the sector that would add great value to the business, she says.

“My family established Electrocoat eleven years ago by lending a significant sum and has subsequently developed the business to the success it is today and as the MD of the company, I am entrusted with its continued success.

“We are not looking for an equity partner with no operational value. The partnership that we are soliciting is one in which each partner has operational value to bring, which is what we believe will ensure the company’s long term success and longevity.’’

Adcock said the principle and imperative of growing black ownership in the supply chain, which is reflected in SAAM 2035, was clear. Transformation presents opportunities for our country and individual businesses,’ she said.

Approached for comment, NAACAM executive director, Renai Moothilal, says the Electrocoat example gave credence to the potential for transformation linked activities to be mutually beneficial and growth stimulating within the lower value chain tiers. “All sector players should be finding ways of unlocking localization opportunities deep into supply chains and simultaneously leveraging transformation outcomes. The policies of the SA Automotive Masterplan process have created the demand conditions to support this.”

Electrocoat, based in Port Elizabeth, supplies coating to a wide spectrum of component manufacturers and assemblers in all sectors and is a supply chain partner to South African based OEMS.

Strong Focus on Innovation, Skills Development and Buy Local

There will be three major focus areas at this year’s Automechanika Johannesburg. The trade fair for the automotive aftermarket takes place at Expo Centre, Nasrec, from 18-21 September 2019.

Each of the first three days is being dedicated to a specific focus area: innovation on the Wednesday, skills development on the Thursday and buy local on the Friday.

This year’s event will mark the sixth time that a world-renowned Automechanika trade fair is staged in South Africa and the second time that it is co-located with the Futuroad Expo, sub-Saharan Africa’s leading professional event for the truck, bus and commercial vehicle industry. Futuroad is the magnet that attracts buyers and suppliers in the region to see new products, innovations, technologies and services while sharing ideas and building relationships across the truck and bus industries. Expect industry heavy weights such as Everstar, MCV, Serco, Tata, UD Trucks and Volvo, to display their latest models.

The number of exhibitors and visitors to the biennial Automechanika Johannesburg trade fair has grown steadily since the first show was staged at Expo Centre in 2009. Some of the Automechanika exhibitors at this year’s show includes Trysome Auto Electrical, Centlube, Aer-o-cure, Diesel Electric, Launch Technologies, Engen, Dixon Batteries and Turbo Direct – to name just a few. This year the organizers are targeting to attract more than 600 local and international exhibitors. A big thrust is being made into Africa to attract more visitors from the sub- Saharan region, following an increase of 80% in visitors from north of South Africa to the 2017 event, when visitors came from Botswana, Kenya, Mozambique, Namibia, Zambia and Zimbabwe.

“Focusing on innovation, skills development and buy local, we have identified three important topics to build on for the first three days of the show,” says Joshua Low, Group Exhibitions Director of Messe Frankfurt South Africa. “We are encouraging exhibitors as well as the organizers of conferences and workshops to link into these themes as they play a vital role in building a strong support base for the automotive aftermarket in South Africa. Our local vehicle manufacturing industry is embarking on a new programme to encourage increased local content, upskilling of employees and the development of innovative products and processes,” adds Low.

The first day of the event will include the Innovation Awards presentation, where innovative ideas from local and international companies will be rewarded.

Automechanika is not only the shop window for innovations in the automotive aftermarket across the entire value chain, but is also the ideal meeting place for all involved in the industry, dealerships and trade stores as well as the maintenance and repair segment. It provides a platform for business and technological knowledge transfer. To this end, the organisers are setting up a businessto- business matchmaking programme to facilitate meetings between exhibitors and potential buyers.

There will also be a host of conferences and workshops, with many organizations arranging these events to tie-in with the staging of Automechanika Johannesburg.

 

Denel and Airbus Review Partnership

Danie du Toit, Group Chief Executive of Denel.

Denel and Airbus have reached a mutual agreement to transfer the manufacturing of aircraft parts for the A400M military airlifter out of Denel, subject to fulfilling applicable legal prescripts.

Danie du Toit, the Group Chief Executive of Denel, says that in light of Denel’s ongoing strategic review of its operations, the two companies agreed that the continued manufacturing of aircraft parts by Denel is no longer sustainable in its current form. Alternative options are now being considered between the two parties.

Denel and Airbus continue to collaborate in other areas and intend to build, expand and strengthen their strategic industrial partnership.

South Africa decided to join the A400M programme in 2005 with an order for several aircraft. Airbus transferred skills and technology to enable Denel to design, develop and manufacture the A400M wing-to-fuselage fairing and top shells. Additional A400M work packages were subsequently awarded to Denel for the vertical tail-plane’s ribs, swords and spars, the cargo deck floor ISO locks and the Central Guide Vertical Restraint System. These items are manufactured at Denel Aeronautics in Kempton Park.

Denel is currently implementing a new longterm strategy to reposition the company and return it to profitability. The new approach includes the exiting of noncore areas of activity, divesting from nonviable core business areas and focussing on viable core business activities that will lead to long-term sustainability and repositioning the core viable business areas to leverage capital and market access as well as focussing on export opportunities through strategic equity partnerships and joint ventures.

Nissan to Produce Next Generation Navara Pickup in South Africa

President Cyril Ramaphosa attended Nissan’s announcement of a R3 billion investment in its facility in Rosslyn, Pretoria to prepare the plant for production of the next generation Nissan Navara pickup.

The move expands the role of the plant as a Light Commercial Vehicle manufacturing hub for Nissan. The Navara will join the popular NP200 and NP300 models, which are already built at Rosslyn and sold in the domestic market, as well as up to 45 pan-African countries.

Production is expected to start in 2020 and will create around 1,200 new jobs directly at the facility as well as across the local supply chain. Depending on market conditions, it is anticipated Navara’s arrival will add 30,000 units to Rosslyn’s current annual production volume of 35,000, creating the need for a new, second shift at the plant.

The announcement made at the Rosslyn plant was attended by President Cyril Ramaphosa, Peyman Kargar, chairman of Nissan’s Africa, Middle East and India region (AMI) and Mike Whitfield, managing director for the Nissan Group of Africa.

The investment in Navara production will result in further modernization of the Rosslyn plant, including a new, flexible production line and additional facilities, as well as training and upskilling of staff.

Working with the Automotive Industry Development Centre (AIDC), a local Government agency that promotes small businesses in the supply chain and skills development, Nissan has identified 15 black-owned companies that it will support in step with its preparations for the new Navara. It plans to partner with these businesses as it ramps up production and increases its spending on local content.

To date, Nissan together with the AIDC has incubated 8 new component manufacturers and related companies from its Broad Based Black Economic Empowerment start up programme. In total Nissan has 318 BBBEE suppliers which make up 34% of the total number of suppliers in South Africa.

Mike Whitfield, managing director for the Nissan Group of Africa, commented: “The new Navara is the perfect model for South Africa and our workforce is ready to build it, supported crucially by the government’s Automotive Production and Development Programme (APDP). Vehicles already account for around 14% of total exports from South Africa. Navara production will allow us to expand Rosslyn’s role as an export hub for Light Commercial Vehicles and contribute further to the local automotive sector, fully in line with the goals in the next phase of the APDP.”

Improvement in Selling Price Inflation for M&E Sector

SEIFSA Chief Economist Michael Ade.

The latest Producer Price Index (PPI) data for intermediate manufactured goods indicating a further improvement in selling price inflation in the Metals and Engineering (M&E) sector for March 2019 is encouraging, says the Steel and Engineering Industries Federation of Southern Africa (SEIFSA).

The data, recently released by Statistics South Africa (Stats SA), shows that the annual percentage change in the PPI for intermediate manufactured goods – which is a proxy for selling price inflation for the M&E cluster – improved alongside the PPI for final manufactured goods. On a year-on-year basis, the PPI for intermediate manufactured goods increased to 6.3 percent in March 2019, from the 3.9 percent recorded in February 2019. The main contributors to the annual rate of 6.3 percent were basic and fabricated metals and chemicals, rubber and plastic products. Contemporaneously, the PPI for final manufactured goods for the broader manufacturing sector also registered an increase of 6.2 percent in March 2019 from 4.7 percent in February 2019.

“Against the backdrop of stalled domestic demand, unpredictable energy supply, ballooning petrol prices which add to increasing logistics costs, the improvement in the PPI for intermediate manufactured goods augurs well for the sub-components of the M&E cluster, which now have more leeway to manoeuvre around high operational and intermediate costs,” SEIFSFA Chief Economist Michael Ade said.

He added that the second-round effects of fuel price increases are usually difficult for small and medium enterprises. Given that businesses in the value chain and service providers – including logistics companies – gradually pass the increases in fuel prices on to their customers, resulting in high operational costs, the improvement in PPI is encouraging.

Ade said better selling prices enable businesses to improve on existing margins and it is, therefore, imperative that a positive differential between input cost inflation and selling price inflation be maintained.

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