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Cut Steel Processing Costs With The BLM SC425 Sawing Machine

While the operator needs to position the workpieces manually, thereafter, the clamping and blade motion is automatic.

Overall, the machine has been designed to be simple to operate and to save time when switching from one type of production to another. Adjusting the SC425 requires no tools and adjustment controls are conveniently located within easy reach of the operator.

The SC425’s highly robust construction and small footprint make this machine suitable for the most demanding and continuous applications. The full range of safety devices – as stipulated in international regulations – such as a stop button, electrical overload protection and electrically interlocked accesses – guarantee operator safety under all operating conditions.

The cutting head is equipped with backlash-free helicoidal gears and interchangeable reduction gears. These, together with the two-speed motor, allow 10 different cutting speeds. The cutting head’s stroke can be quickly adjusted by means of a graduated manual control wheel located on the front of the base frame.

The feed can be regulated up to 3,000mm/ min. The work-piece is clamped between an adjustable reference support at the rear of the machine, an adjustable hydraulic clamp in the vertical axis and two front side stops. The rotating table on which the cutting head is mounted can be swivelled  and locked at 9°, both in the left- and righthand positions. There are also positioning stops set at commonly used angles such as 0° and 45°.

Once the cut is complete, the workpiece is raised from the rotating table by two hydraulically operated rollers, one on each side of the machine. This makes it easy for the operator to reposition the workpiece in preparation for the next cut. A closed circuit lubrication cooling system comes into operation during the cutting cycle.

Collection and removal of cutting debris is quick and easy. Cutting chips are collected in an easy-to-remove container located inside the SC425’s base frame.

A threshold control on electrical current being supplied to the motor protects the blade from possible overloading. All the clamping jaws can be easily closed and opened by using a single centrally-located switch. For heightened ergonomic efficiency, the operator can quickly execute all the steps of the production cycle without having to move from his operating position.

This versatile workhorse sawing machine will increase the speed and efficiency of any type of steel manufacturing business. For example, the SC425 can be used for carrying out trim cuts on bent tubes such as exhaust pipes and structural tubing, as it is possible to fit suitably shaped clamping fixtures to the cutting table.

At 90°, the SC425 is capable of cutting round bar to maximum diameter of 145mm and square bar to a maximum of 130mm. The machine is fitted with a 425mm diameter blade which can be powered by either a 1,3kW or 2,6kW motor.

As an optional extra, roller tables for loading and unloading can be supplied as can a micro-lubrication system.

With a footprint of only 1020mm x 950mm and a height of 1,8 metres, this compact yet powerful circular saw will provide both a valuable boost to productivity and an increase in profits for any busy steel manufacturing operation.

For more information contact First Cut – Tel: 011 614 1112

Everising’s Upgraded E- And P-Series Sawing Machines

In response to its customers’ requests, Everising has upgraded its P- and E-series sawing machines so that they can now process steel sections in the 300mm to 800mm range.

The overall aim of Everising with these upgrades is to reduce its customers’ production costs by speeding up actual cutting times.

The P-series also has a user-friendly touchscreen with easy-to-follow graphics, with all cutting parameters clearly displayed on the touchscreen controller. A bonus for operators is the self-diagnostic function which allows for immediate on-screen troubleshooting.

P-series circular saws are fitted with an accurate length index device, which is driven by a servomotor and ball screw. Hydraulic-clamped front and vertical vices hold work pieces firmly in place.

A floating shuttle device and hydraulic sorting chute speeds up production, while a scraper chain type chip conveyor ensures efficient removal of cutting debris. The speed of the blade is controlled by an inverter and is infinitely variable.

The P-series gear transmission driver provides high efficiency and consistent cutting speed. Carbide guide pads are used to strengthen the rigidity of the saw blades, which means not only accuracy, but an extended saw blade life.

Other features include an air filter, a cutting-fluid coolant system, an air compressor, a smart bar collecting system, an air blower for tube cutting and variable vice pressure.

Importantly, the P-series requires only one operator to set up and load the machine. Excessive re-work is avoided as P-series machines give a milling cutter finish with a tolerance of 0.02mm. Remnant or scrap pieces are sorted into a separate bin. With its versatility, a P-series sawing machine could replace a number of other types of circular saws, thereby saving valuable production space.

As with the P-series, Everising’s E-series band saws are CNC-controlled and also feature advanced touchscreen control. To ensure extended machine life, E-series band saws are equipped with high efficiency gearboxes lubricated by a controlled oil-feed system. An inverter controls the variable speed of the blade, which is tensioned hydraulically. An idler wheel motion detector serves to detect blade stalls thereby preventing blade damage.

The robust electronics on the E-series ensure that downtime is minimized, while an anti-vibration roller serves to protect the blade, which is cleaned by two automatically adjusting wire brushes. An advanced quick approach device and an automatic tracking blade guide protect the machine against accidental damage.

All E-series machines are manufactured with a solid steel frame with two pre-loaded linear guides for accurate, repeatable cutting. In addition, E-series machines have a safety device to ensure that blade changes are risk-free.

A dual front and rear floating vice holds work-pieces securely in place, while an out-of-square detector detects any flaws in the operator’s setting up procedure. To ensure there is no swarf build up, E-series machines are fitted with a drainage and chip removal device.

Once a particular job has been completed, the sawing machine’s computerized control system can produce machine utilization analyses for monitoring and optimizing machine usage.

Everising continues to improve the performance of its equipment by evaluating competitor products and responding to international demand. Based on these findings, the company invests in research and development to continually improve performance.

Improved Efficiency Of Aircraft Engines

Combustion chambers of modern aircraft engines produce temperatures of over 2,000 Kelvin during combustion.

This value is several hundred degrees above the melting temperatures of the materials used and certain areas of the thermally high loaded components must be cooled and provided with special thermal barrier coatings, both internally and externally. After landing, the engines cool down again quickly. The constant change of heating and cooling places enormous stress on the components in the engines. Therefore they have to be checked and serviced regularly.

After years of research, Professor Frank Brückner and Mirko Riede of the Fraunhofer Institute for Material and Beam Technology IWS have developed laser-fabricated microstructures that extend the life of the thermal barrier coatings and contribute to a significant reduction in kerosene consumption and pollutant emissions. The research project was performed in close cooperation with the renowned engine manufacturer Rolls-Royce.

At its core, the IWS technology bases on filigree, additively manufactured microstructures.

These are used to build innovative Thermal Barrier Coatings (TBCs) on the turbine components and ensure that a metallic, oxidation-resistant adhesion promoter layer and a ceramic insulating layer are clamped together.

The Fraunhofer researchers have solved a further issue that occurs during the rapid expansion and contraction of the components. The expansion creates mechanical stresses in the insulation layer, which are caused by different expansion degrees of the materials. This can lead to horizontal cracks in the ceramic layer, which could subsequently flake off. The microstructures therefore specifically initiate vertical segmentation cracks in the ceramic layer. These reduce tensile stresses in the material and thus prevent the formation of the dreaded horizontal cracks.

Additive manufacturing technology using single-mode fiber laser

To generate filigree microstructures, the researchers had to further develop existing production techniques. A high-precision single-mode fiber laser generates microstructures down to the order of 30 microns. The columnar arrangement of the microstructures increases the expansion tolerance of the insulating layer.

The knowledge needed to design the structures for the TBCs and for the sophisticated manufacturing processes have not only been gained in practical experiments. “The simulations and the theoretical modeling with which we have worked in addition to the experiments also play a major role in the success,” explains Brückner.

Professor Frank Brückner and Mirko
Riede (from the left) have developed
microstructures that, among other things, extend the life of the thermal barrier coatings. © Fraunhofer

Kerosene consumption drops by 10 percent

The many years of work on the joint research project has paid off. The new technology can further improve the efficiency of the jet engines, along with increasing the combustion temperature. The more efficient combustion results in decreasing fuel consumption by ten percent and reduces greenhouse gas emissions. In conjunction with other measures, there are significant cost savings per year and aircraft amounting to approximately USD 2.9 million.

The joint team of Fraunhofer researchers and engineers from Rolls-Royce has succeeded in transferring the research work into production-ready manufacturing that meets the stringent safety standards of the aviation industry. After first successful test flights of the engines with Fraunhofer IWS technology in November 2015, the official aviation approval of the European Aviation Safety Agency (EASA) was issued. Since February 2018, the engines have been used in long-haul aircraft for the Airbus A350-1000. The Trent XWB-97 is the exclusive propulsion of this aircraft model and the most efficient large-capacity engine in the world today. The Fraunhofer experts expect that other jet engines will also be equipped with the innovative IWS technologies in the future.

For their scientific achievements, Frank Brückner and Mirko Riede as well as Dr. Dan Roth-Fagaraseanu from the industrial partner Rolls-Royce received the 2018 Joseph von Fraunhofer Prize of the Year 2018.

New Kinematics For Milling – Customized, High-Precision Manufacturing

Manufacturers generally must offer high-quality products at low prices in order to remain competitive.

Three Fraunhofer Institutes are therefore working on the next generation of industrial robots which will facilitate cost-effective production processes. The researchers are focusing on developing a new kinematics for milling lightweight materials, metals and steels. The aim: achieving a production tolerance of just 0.1 millimeters all over the robot workspace starting with the very first component.

More and more consumers are demanding made-to-order, customized products. The production facilities of tomorrow will need to be efficient and versatile if they hope to meet increasingly stringent requirements and the specific needs of each customer – all while mastering the pressure of rising costs. High-precision machine tools that impart a certain geometrical shape to workpieces remain the solution of choice. Conventional industrial robots have simply been unable, due to their insufficient precision, to supplant such machine tools. Using robots for milling operations remains particularly challenging. Primarily due to the gear units, low robot stiffness deflects the tool – reducing its appeal for use. Indeed, production staff must comply with extremely tight production tolerances every time they machine lightweight materials, such as aluminium or carbon fiber reinforced plastic (CFRP), as well as metals, and steels.

Customized production, even for a batch size of one

Researchers working on Fraunhofer’s Flexmatik 4.1 joint research project are developing an industrial robot designed for the high-precision milling of lightweight materials. The project partners are the Fraunhofer Institutes for Production Systems and Design Technology IPK, for Manufacturing Technology and Advanced Materials IFAM and for Structural Durability and System Reliability LBF. The researchers must overhaul the kinematics if the robot is to prove successful. Sascha Reinkober, department head at Fraunhofer IPK, explains, “we’re engineering a multi-axis kinematic chain that is specially designed for continuous path processes.” The robot proceeds from point A to point B of the component being machined by traversing a linear unit, a type of rail. “The system simulations we conducted during the design phase indicate that we can achieve a precision objective of plus/minus 0.1 millimeters. This will be possible starting from the very first component, despite the process forces acting on it. Manufacturers can therefore customize production, even for a batch size of just one unit,” says Jan Hansmann, project leader at Fraunhofer LBF. “Under the exposure of process forces, the robot will stray far less from its programmed target path. The robot can consequently drill a hole at the intended spot of the component with far greater precision, for instance.”

To ensure high precision, the team of researchers is developing a new drive concept for individual axes. Partially direct drives are used, which are considerably stiffer during operation than today’s high-tech gear units. And a new climate-control strategy minimizes imprecision due to temperature fluctuations. The robot is also equipped with a CNC control for machine tools. Last but not least, the new Flexmatik features an active vibration control system.

The new designed robot offers key benefits compared to machine tools: the cost of acquisition decreases by as much as a factor of 10 and the energy consumption by as much as a factor of 15. Thanks to its linear unit, the Flexmatik exhibits a workspace on par with large portal milling machines – and better accessibility. Compared to a portal milling machine, the Flexmatik does not require a special heavy foundation. This keeps construction costs lower and grants users flexibility in setting it up. Fraunhofer researchers want to complete a functional prototype by the end of 2018.

Their innovative milling robot can handle a broad range of applications – including the machining of large CFRP structures such as fuselages, the milling of components for gas turbines, and the re-contouring of press tools. “The Flexmatik is a suitable choice for many applications in practically all sectors which use machine tools. But it’s not about replacing machine tools. The Flexmatik can instead be a useful addition that shares workloads. The ultimate goal is to make production processes more costeffective,” emphasizes Sven Philipp von Stürmer, project leader at Fraunhofer IFAM.

Advanced Manufacturing Awards Kick Off In PE

The National Advanced Manufacturing Innovation Awards, is hosted under the auspices of the DTI co-funded, national Composites Cluster with a wide scope including the key drivers of the 4th industrial revolution.

Andy Radford

All companies operating in the advanced manufacturing field, including 3D printing, robotics, automation, AI, laser cutting and etching, CNC machining, software, big data, IOT and composites will be eligible for national recognition.

Companies or organizations may make submissions in six categories including: Scholarly impact in advanced manufacturing, Industry advancement in advanced manufacturing, Export proficiency, Contribution to Import replacement, Composites Innovation and Most promising start-up or newcomer.

Composites Cluster MD, Andy Radford, formerly an industrialist at the CSIR, before the Composites Cluster was established with the support of the South African government, said the awards would play a key role in accelerating the country’s advanced manufacturing agenda.

Radford said the awards, which would be made annually at the African Advanced Manufacturing and Composites Show (with the inaugural event set to take place from November 7-9) would also aim to showcase South Africa’s capabilities and popularise Advanced Manufacturing in industry and to learners.

The National Advanced Manufacturing Innovation Awards will take place as part of the African Advanced Manufacturing and Composites Show which will include a dynamic, interactive exhibition, conferences and factory tours at the Nelson Mandela Bay Stadium in Port Elizabeth from November 7-9.

Organizers say several international delegations have already confirmed, including leading Advanced manufacturing companies from France and Germany, while a focused campaign will draw dominant advanced manufacturers from Africa.

Agni Steel Gets Green Light For Phase 2 & 3 Expansion

Steel recycling and processing plant, Agni Steel SA located in Zone 6 of the Coega SEZ recently received authorization for its Phase 2 & 3 expansion plan from the Department of Economic Development, Environmental Affairs & Tourism (DEDEAT).

Phase 1 consisted of the installation of a set of induction furnaces for reclaiming of scrap metal. The induction furnaces had a capacity of 25 tonnes and produced 90 000 tonnes of mild steel billets per year. Phase 2, which was approved in June 2018, includes the addition of two sets of furnaces and a ladle-refining furnace. The two additional furnaces will run alternately with one being used for melting whilst the other is prepared for the melting process. The additional furnaces will thus double production and produce 180 000 tonnes of steel billets per year.

Once all three phases are completed Agni Steel SA will locally convert the steel billets produced into reinforced steel for local and regional export consumption.

Coega A Template Of Success – World Bank Research Study

The Coega Special Economic Zone (SEZ), located in the Nelson Mandela Bay Municipality, has been selected as one of seven examples of success out of thousands of SEZs around the world, in a World Bank-financed research study into what makes economic zones successful.

By current estimates, there are approximately 3 500 SEZs in more than 130 countries worldwide, employing more than 60 million people, according to the World Bank.

In its recently released report, Special Economic Zones- An Operational Review of Their Impacts, the Competitive Industries and Innovation Program (CIIP) found that the success of an SEZ depends largely on a combination of three factors, including the SEZ programme and its characteristics, the structure and layout of the zone and regional and country contexts.

Rebound In Metals And Engineering Sector Output – SEIFSA Cautiously Optimistic

The Steel and Engineering Industries Federation of Southern Africa (SEIFSA) is cautiously optimistic following the release of production data reflecting an increase in output in the Metals and Engineering (M&E) sector, despite a corresponding decline in business confidence and a volatile rand, the Federation’s Chief Economist, Michael Ade, said recently.

SEIFSA Chief Economist Michael Ade.

The latest preliminary seasonally-adjusted data, released by Statistics South Africa recently, captures an increase in output in the sub-industry, in line with the broader manufacturing sector, which increased by 2,3 percent in May 2018 when compared with May 2017. After adjusting for the sectoral weights, the data indicated that production in M&E sub-sectors increased by 6,2 percent in May 2018 on a year-on-year basis and by 10,8 percent on a month-on-month basis.

“The acceleration in output in the M&E cluster is welcome, albeit with a slight level of apprehension, given the existing global trade war with the potential of constricting global demand, benign local demand and generally low domestic business confidence. However, the improvement in output augurs well for manufacturers in the M&E cluster and is necessary towards lifting the real Gross Domestic Product (GDP) figures for the second quarter of 2018, especially considering that current production conditions are relatively better when compared to some few months ago,” Dr Ade said.

Moreover, Dr Ade said that the rand has been very resilient in the face of headwinds, including prevailing uncertainty in the markets and heightened rhetoric from the world’s two largest economies about trade war.

He is optimistic that the relatively strong rand will help in reducing imported input costs, thereby enabling companies to bolster their margins.

South Africa Keen On Increasing Trade And Investments With Angola

Over 150 captains of industries and key government officials from Angola attended the investment seminar and engaged with the 20-man South African business delegation that was led by Deputy Minister Magwanishe.

Magwanishe told the delegates that South Africa welcomes the efforts directed at creating a conducive environment for enhanced private-sector engagements between the two countries. These efforts would fast-track the mobilization of investment from South Africa through its Trade Invest Africa unit which is mandated to implement an investment-led trade strategy.

Magwanishe further pointed out that South Africa’s share of exports to the rest of Africa exceeds R400 billion, dominated by trade with Southern African Development Community countries, of which Angola is amongst the largest trading partners. He added that total trade between South Africa and Angola in 2017 stood at R25 billion.

“We call upon the South African business community to take advantage of advanced economic and diplomatic relations that augur well for further investment in Angola and Angolan companies to invest in South Africa,” said Magwanishe.

The Director-General of Ministry of Industry Angola Mr Luis Ribeiro challenged the South African businesspeople to invest and help build the industrial parks across the 18 provinces in Angola. He added that government was looking at dedicating one or two parks to South African investors under their development of industrial parks programme, similar to how Distell and Nampak had already located in their Industrial Development Zones.

Delegates also received project prospects on the 2018 – 2022 Railway Project plan from the Angolan Institute of Railroads on Railway Projects. Additional projects in the air traffic control and air navigation sector were presented for South Africa’s consideration.

The Angolan Investment Promotion Agency (APIEX) presented Investment Opportunities which the dti’s Trade Invest Africa (TIA) and the Export Credit Insurance Corporation (ECIC) of South Africa responded to.

Mercedes-Benz Invests 600 Million Euro In Expansion Of East London Plant

Mercedes-Benz Cars will produce the next generation of the C-Class in East London and expands the plant with an investment of 600 Million Euro.

This includes the construction of a new paint shop and a new body shop, an upgrade of the assembly shop and new logistic warehouses. Overall the new buildings comprise an area of approximately 100 000 sqm, this reflects an addition of two thirds of the already existing buildings for the passenger vehicle production. The new workshops will incorporate environmental friendly and state of the art technologies.

“With the investment of 600 Million Euro we are significantly expanding our plant in East London and equipping it for the future. The decision to have the new generation of the C-Class built in East London reaffirms the plant and Mercedes-Benz South Africa. The investment is also a sign of our commitment to South Africa and efforts to revive economic growth as well as the socio-economic development of the East London region,” stated Markus Schäfer, Member of the Divisional Board of Mercedes-Benz Cars, Production and Supply Chain, during the visit of President Cyril Ramaphosa to the Mercedes-Benz plant in East London.

Commenting on the investment by Mercedes-Benz Cars, President Cyril Ramaphosa stated, “a central priority for government this year has been to encourage significant new investment in our economy, necessary to realise economic growth, employment and reduce inequality. The announcement by Mercedes-Benz Cars to inject R10 billion into the South African economy signals to the positive momentum we are making to realise the ambitious target of raising R1.2 trillion in new investment. This investment by Mercedes-Benz Cars endorses South Africa as a favourable destination for investment and correspondingly, demonstrates our determination to work with all social partners to seize the opportunities that are opening up for greater investment and faster growth.”

The year 2018 marks the sixtieth anniversary of Mercedes-Benz passenger vehicle production at the East London plant. Over the years, the plant has evolved as a significant contributor to South Africa’s trade balance and an economic multiplier for East London.

The investment of 600 million Euro will be used for a wide expansion of the plant. Many different parts of the plant are affected by the expansion, both Green- and Brownfield. The new body shop is designed for higher capacities and features more than 500 Internet of Things – ready robots laying the foundation for Industry 4.0 readiness. 700 tons of steel will be installed for the addition of three lines in the assembly shop. This expansion will take place in the current building. Utilizing new methods, the new paint shop will be more energy efficient and more environmental friendly. Overall, the energy consumption per produced vehicle will be further reduced with 25% in the East London plant. This is in line with the plant’s initiative for a green production. Other examples include on-site battery storage container, rain water harvesting on rooftops, water storage of 1 Million Litres and the creation of green corridors.

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