EuroBLECH Bulletin

News from the Organisers

EuroBLECH 2012 – Booking status reflects further recovery of the industry

The EuroBLECH Team would like to wish all exhibitors, visitors and friends of EuroBLECH a very happy, healthy and successful 2012!

This year’s EuroBLECH, from 23-27 October 2012, in Hanover, will mark an important milestone for the worldwide sheet metal working industry. After one of the worst crises for the industry some three years ago, there was a much livelier atmosphere during the previous exhibition in 2010, where the sheet metal working industry started to invest again. Now, for this year’s EuroBLECH, we are sure to witness clear signs for the prospect of mid-term planning within the sheet metal working industry.

Despite a certain general incertitude, the current economic situation of companies in this industry sector is rather positive. Nine months ahead of the industry’s leading international trade exhibition, EuroBLECH 2012, a total of 1140 companies from 37 countries have already reserved their stands. More than 80,000 square metres net exhibition space in EuroBLECH’s eight exhibition halls is already taken. In comparison: at EuroBLECH 2010 a total of 1455 exhibitors covered a net exhibition space of 78,600 square metres. EuroBLECH 2012 is therefore set to be bigger than the previous event, thus reflecting a further recovery of the sheet metal working industry and a thoroughly positive outlook.

Hall planning is currently in full swing at the organisers’ office; companies that haven’t reserved their stand space for the World’s No 1 Sheet Metal Working Technology Exhibition yet, should contact the EuroBLECH team as soon as possible.

http://www.euroblech.com

Positive feedback for first BLECH Nordic

With 129 exhibitors from 21 countries and 5,350 trade visitors from 31 countries, the first BLECH Nordic, Sheet Metal Working Exhibition, was a thoroughly successful launch event. The exhibition was held from 4-7 October 2011 at Stockholmsmässan, where it was co-located to Techniska Mässan, Sweden’s renowned Technical Fair. The overall feedback for the first BLECH Nordic exhibition was very positive. It seems that Mack Brooks Exhibitions have filled a void by offering a targeted industry event for a market with a distinctive demand for high-end products and future-oriented manufacturing solutions.

With their products and services on display at BLECH Nordic 2011, the exhibiting companies gave a comprehensive overview of machines, tools, systems and services for the entire sheet metal manufacturing process. The large variety of live machine demonstrations was a major visitor attraction at the show. There was also a series of sheet metal research and new technology seminars on each exhibition day about the latest developments in sheet metal forming; simulation and process optimisation; laser and water jet cutting as well as joining technologies. The seminars were well received by the visitors and added to the professional flair of the technology exhibition.

BLECH Nordic is part of the series of BLECH events that Mack Brooks Exhibitions is organising for selected target markets. The visitor audience at BLECH Nordic 2011 was therefore mainly a regional one. While a good half of the exhibiting companies were foreign exhibitors that used this industry platform to target the Nordic sheet metal market, almost 90% of the visitors came from the Nordic countries.

The next BLECH Nordic Sheet Metal Working Exhibition is set to take place in 2013 in Stockholm. Two further BLECHevents will be held in 2013, both for the third time: BLECH Russia 2013 will take place from 12-14 March 2013 in St Petersburg, and BLECH India 2013, from 17-20 April 2013 in Mumbai.

http://www.blechevents.com

Events at EuroBLECH 2012

International Seminar on Hot Stamping – Where the experts in press hardening technology meet!

For the Centre of Excellence on Hot Sheet Metal Forming Technology CHS2, established between the University of Kassel, Germany, and Lulea University of Technology, Sweden, it has already become a tradition to organise its hot stamping seminar in the course of the biennial International Sheet Metal Working Technology Exhibition EuroBLECH in Hanover. In contrast to the CHS2 Conference Series, which addresses hot sheet metal forming technology from a more scientific point of view, this seminar series is dedicated to industrial application of press hardening and/or hot stamping.

The significant growth and on-going globalisation of technology makes it even more important than ever to continue this tradition also in the course of the upcoming EuroBLECH 2012. This time, however, jointly organised with the GRUNDIG AKADEMIE and with an extended line-up of presentations and contributions from the most renowned key players in industrial hot stamping technology.

http://bit.ly/EuroBLECH_GrundigAkademie
http://www.chs2.eu

Technologies

Automotive industry still the driving force in sheet metal working technology

We may not know where the journey is taking us, but we would nevertheless like to be making it in a safe, comfortable and economical car - that at least seems to be the attitude currently prevailing amongst consumers around the globe. Despite the fact that the world economy is seeing crises come thick and fast, automotive values on the stock market remain surprisingly stable, with international companies repeatedly posting excellent results. The automotive industry is still the driving force in sheet metal working technology, this means that prospects in this sector continue to look bright, in spite of a looming weakening of the economy.

Several future-orientated car concepts have, at least for the time being, been taken out of the running - micro cars like India's Nano are performing poorly, even on their home market, whilst electrically-powered mobility and hybrid technology are still struggling to gain mass market acceptance. Even for modern subcompacts demand is limited. So it looks as though, for the moment, the future still belongs to the family-sized five-seater with its combustion engine, offering safe, economical transport for both day-to-day and holiday requirements. This sector is becoming increasingly efficient, with sheet metal working playing a vital role in this context. Lightweight construction has by now made huge progress, following the realisation that the key to success is low vehicle weight combined with the high strength provided by innovative materials.

Ground-breaking innovations included tailored blanks, for example, which were only made possible through laser technology (and to which tailored coils and patchwork blanks have subsequently been added), and hydroforming, as well as new joining processes, which combine high, targeted strength with improved productivity. High-tensile thin steel sheets, formed via press hardening, now constitute state-of-the-art lightweight design on the mass market too and a new trend is increasingly coming to the fore - materials combining sheet metal and plastic.

Two of the articles in this issue of the EuroBLECH Bulletin focus on this subject:

http://bit.ly/Rehau-Front-End-Brackets-for-Mercedes
http://bit.ly/Light-e-Body-lightweight-designs-for-electric-vehicles

Rehau using new production process to manufacture front end brackets for Mercedes M-Class

Polymer specialist Rehau, based in Cullman in North America, is using a new production process to manufacture the front end brackets for the Mercedes M-Class being built at the Daimler factory in Vance, Alabama, USA. These brackets are made up of two components: steel panels, which serve as stiffening elements, and plastic, used to overmould the steel. Although this brand new technology requires extremely tight production tolerances, it does offer major benefits - the component weighs around 25% less and many functional elements can be integrated. The overmoulded front end bracket carries the intercooler duct, the headlight modules, the windscreen water container, the horn, the anti-collision radar module and the air intake. It also supports the bonnet.

Image: The front end bracket for the Mercedes M-Class consists of an innovative combination of steel sheet and plastic. Source: Rehau

http://www.rehau.com

Light-e-Body project develops multi-material lightweight designs for electric vehicles

Simply substituting lighter materials for heavier ones is usually neither economically viable nor technically the best solution, just as adapting conventional vehicles for electric operation is also unsatisfactory. What is required is a comprehensive approach to lightweight design; and tailor-made multi-material and assembly systems constitute a promising start in this context. The battery can also be incorporated into the structure, thereby contributing towards the strength and safety of the vehicle. What happens in concrete terms is that metallic materials and plastics are combined in the best possible way, enabling the weight of the car body to be reduced. Moreover, the hybrid design, which features localised strengthening, also allows further weight reductions to be made. Determining the most suitable joining technology and its interpretation constitutes a major challenge in this context, because of the combination of materials involved.

Image: Light-e-Body - an extremely lightweight car body using extra thin steel and aluminium sheet, together with plastic panels (Source: RWTH Aachen)

mailto:lesemann@ika.rwth-aachen.de

Trumpf CoolLine - safe processing of filigree workpieces in thick steel

Localised cooling of the workpiece during the cutting operation makes new complex contours possible and substantially increases process safety when handling thick mild steel. During processing the special nozzles on the cutting head spray a fine fog of water around the workpiece, coaxial to the laser beam. The evaporation of the water cools the material around the laser beam, thereby maintaining an almost constant temperature during the cutting process. New complex contours are possible and the machine can be used with greater process safety in what were previously considered critical applications.

Image: The water cooling on Trumpf's CoolLine allows filigree workpieces to be cut, even in thick mild steel. Source: Trumpf

http://www.trumpf.com

LVD Company introduces CNC turret punch press for large workpieces

LVD Company, based in Gullegem, Belgium, introduced the Strippit P-1525 200kN (20 metric ton) CNC turret punch press, designed to efficiently handle large or oversized workpieces to 1524 x 2500 mm (60" by 98.4"); larger sheets can be processed with clamp repositioning. The press can deliver as many as 270 strokes/min. on 25.4 mm (1") centres, and 600 strokes/min. in nibble mode. The machine provides a ±0.1mm (0.004") finished part accuracy and ±0.05mm (0.002") finished part repeatability. Material thickness can be 3.5mm (0.135") max. in mild steel and 6.35mm (0.250") in aluminium.

A servo-driven hydraulic ram offers control of ram position and LVD claims the highest punching rates in this machine class. The advanced hydraulic drive system is designed to minimise noise and shock to increase machine longevity and reduce tool wear. The P-1525 features a versatile 21-station thick-style turret and every station accepts shaped or round punches and dies. Three 50.8mm (2") auto-index stations are standard, and a generous feed clearance of 25mm (0.984") between upper and lower turret allows production of forms such as lances, louvres, embossments or card guides.

Image: The new Strippit P-1525 200kN CNC turret punch press, designed to efficiently handle large workpieces to 1524 x 2500mm without repositioning. Source: LVD Company

http://www.lvdgroup.com

New dual helical scrap choppers now available on full Red Bud Industries lines

New dual helical scrap choppers are now available on full Red Bud Industries lines (slitting lines, multi-blanking systems, and cut-to-length lines with edge trim systems), backed by the company's 5-year warranty. The new scrap choppers utilise a scissor type cutting action, which allows the units to operate more quietly with a controlled and smooth cutting action - both knives are attached to a set of rotating drums powered by an electronic drive. This design means the rotation of the drums/knives is precisely maintained, reducing both sound levels as well as wear and tear on the scrap choppers themselves. Each knife has four edges which can all be used before the knives need to be sharpened. Knife removal/replacement is simple, thanks to the one bolt fastening.

Image: Improved scrap choppers for Red Bud Industries lines. Source: Red Bud

http://www.redbudindustries.com

Thermal Arc revamps line to greatly improve weld speed

PowerMaster PLUS: Thermal Arc, a brand of Thermadyne Industries Inc., revamps its line of advanced digital synergic pulse MIG equipment to greatly improve weld speed, offering extremely favourable welding characteristics. Synergic pulse MIG welding links the pulse welding parameters to the wire feed speed to achieve optimum welding conditions across the full range of wire feed speed for a given wire size.

Now PowerMaster PLUS technology brings several new enhancements to this process:
• Deeper penetration, thanks to high plasma pressure in the arc
• Welding speed increased by up to 30% for greater profitability
• Easy to use in manual welding applications, due to incredibly stable arc
• Reduced undercut as a result of the very short arc length.

The Powermaster PLUS series is a complete range of high-technology digital micro-processor controlled Synergic Pulse MIG Welding Equipment, designed to meet the rigorous demands of a wide range of welding applications. Systems are available in 320-500 amp configurations, as air or liquid cooled packages. Systems suitable for robotic applications are also available.

Caption: The upgraded PowerMaster SP synergic pulse MIG welding systems by Thermal Arc. Photo: Thermadyne

http://www.thermadyne.com

Thermal Dynamics launches two new high precision consumables sets

Thermal Dynamics, a brand of Thermadyne Industries Inc., launches two new high precision consumables sets for 15 and 30 amp bevel and robotic cutting, which offer increased cut quality. The new consumables enable outstanding results to be achieved on very thin materials at lower cutting speeds, when used in conjunction with a high precision ultra-cut power source and XTR robotic plasma cutting torch. When the torch is attached to a spring loaded torch mount, cut quality is comparable to results achieved by laser cutting. Cut quality on thin materials can be further improved by using the advanced gas management technology of Thermal Dynamics’ Automatic Gas Console.

Thermal Dynamics has been in operation for over five decades and offers a complete range of plasma arc cutting systems from highly portable single phase units for DIY work to the most sophisticated high speed, plasma cutting systems for high precision fabrication.

http://www.thermadyne.com

Wilson Tool introduces its EXP punch technology

Wilson Tool introduces its EXP punch technology, manufactured from the company's Ultima premium tool steel, to give extended wear resistance. This is said to be the first tooling in the industry to offer standard holders with universal punches. EXP punches for thick turret presses offer increased productivity and reduced waste. The standardised concept also reduces storage space requirements compared with conventional punching tools. According to the company, the new EXP punch holders fit in all styles of A- and B-station thick turret assemblies, and are available for most thick turret tooling units.

http://www.wilsontool.com

News from the Industry

Audi Group planning biggest investment programme in its history

Over the coming years, the German Audi Group is planning to invest substantial amounts in its factories as part of its biggest investment programme in the car maker's history. This includes a body shop, paint shop and press shop, which are to be added to the existing engine and vehicle assembly line at the Hungarian Győr plant by 2013. However, the investment programme focuses primarily on the company's German locations.

“From 2012 to 2016 we are planning to invest almost € 8 billion in Ingolstadt and Neckarsulm, because these domestic sites and their employees are the foundation on which our international success story is based,” said Axel Strotbek, Financial Board Director at AUDI AG. In China Audi are also in the process of strengthening their production capacity: in addition to the plant in Changchun, the group will be building a new factory in Foshan. An area of 100 hectares has been designated for a complete car plant, including pressworks, bodyshop, paintworks and assembly.

The site, which will be owned by a joint venture of Audi, FAW and Volkswagen, is to commence production in 2013 and will have some 4,000 employees.

Image: Major investment will upgrade Audi's Hungarian factory in Győr by 2013. Source: Audi AG

http://www.audi.com

GfK Expert reports Austria's Major Domestic Appliances (MDA) market back on track

According to a report from the consumer research experts in late October 2011, the Austrian MDA industry posted growth of 2% in the cumulated year 2011. Most MDA segments contributed to the positive trend with dishwashers and cooking devices performing particularly well. Washing machines continued to decline, while freezers and tumble dryers also struggled to increase their turnover.

http://www.gfk.com

Metal forming research in the UK

The Manufacturing Technology Centre (MTC) is a £40.55 million investment by Advantage West Midlands and the East Midlands Development Agency to create a world-class manufacturing research centre. It is located at Ansty Park near Coventry and opened in late 2011. There are four initial research partners: University of Birmingham, University of Nottingham, Loughborough University and TWI Limited. There are also three founding industry members: Rolls Royce, Airbus UK and Aero Engine Controls.

The centre will concentrate on assembly, fabrication and joining technologies, and act as a bridge between university development and testing work and full production business. As a major development, the MTC plans to install a very large gantry system (previously used to assemble aerospace structures) as a flexible research platform that can be used to trial new and innovative manufacturing processes. The MTC will also equip the installation with two new KUKA KR240 R2900 Ultra ceiling mounted robots and the installation is scheduled for completion by late March 2012.

http://www.the-mtc.org

Schuler receives largest order in the company’s history

In the course of 2011 the Schuler Group received an order from BMW for a total of seven press lines with ServoDirect technology. Three high-speed servo press lines will be installed at its stamping plants in Leipzig and Regensburg, Germany, and Shenyang in China. At the same time, BMW reserved four of the same press lines for its German facilities. The order volume is easily in the three-digit million euro range.

At around 85 metres each in length, the press lines boast a total press force of some 9,000 metric tons. In up to six separate operations, the sheet metal (with thicknesses of up to 2.5 millimetres) is then drawn, bent and blanked into the desired car body shape. With over 20 strokes per minute, the lines are among the fastest in the world and can produce at least 20 per cent more parts per minute than conventional press lines. Presses with ServoDirect technology feature electronically controlled torque motors, which act directly on the press gearbox. The main benefit: the slide movement can be individually programmed for each die. As a result, the press can also accelerate or decelerate the slide during a stroke and thus optimise the forming process. The presses can process around 600 metric tons of steel per day.

http://www.schulergroup.com

New publication from the Steel Information Centre:

"D 545 roof tiles made from steel - smart solutions for all types of roof."

Increasingly, roofers and building contractors are turning to steel roof tiles as a high-grade alternative to traditional roof claddings. They are light, sturdy, durable, easy to fit and optically virtually indistinguishable from their more weighty competitors. In its new paper 'Roof tiles made from steel' (D 545), the Steel Information Centre shows projects carried out in residential and commercial buildings, as well as agricultural construction. The German language publication can be downloaded from the internet.

http://www.stahl-info.de

Dimeco's fully electric NC punching technology working from coil or with blanks

Fully electric NC punching technology working from coil or with blanks - from batch size 1 and in countless variations.

Dimeco Alipresse's automatic turret punching machine Linapunch® MC-E combines outstanding efficiency with maximum productivity and low energy consumption. Two synchronised Siemens electric servo motors work via a straightforward knuckle joint and a central punch plate to create the stroke movement on the Z-axis at a rate of up to 200 strokes/min when punching and 400 strokes when contouring, each with a punching force of 200kN. Upper and lower dead points are fully programmable, making for optimised force ratios and extremely short cycle times. There can be up to 52 'thick turret' standard cartridge tools, which enable any point of the sheet metal to be reached as it moves through the machine along the X-axis. Two strikers are positioned independently but virtually simultaneously above the selected tool and the punch plate carries out the stroke. In addition to the nine servo axes of feed and basic machine, additional axes can be programmed via the Dimeco Simostar control system, which provides swift and precise co-ordination. Punching software can be entered via a network link or a USB stick, but programming is also possible during production. The Linapunch® MC-E turret punching machine can easily be integrated into existing profiling lines.

Image: Dimeco Alipresse's Linapunch® MC-E - fully electric and highly flexible sheet metal working. Source: Dimeco

http://www.dimeco-alipresse.com

Major order from the automotive sector for KUKA

According to an announcement by the parent company, KUKA Systems has received an order from a German premium car manufacturer to install a new production system at the car maker's factory in the south-east of the USA and to upgrade existing assembly lines without shutting down the plant.

The project is worth a medium double-digit million euro figure and includes the design, construction and commissioning of framing lines, which will be used to produce car bodies for various SUV models. The group's US subsidiary KUKA Systems Corp. will provide site supervision for the project, which is expected to be completed by mid-2014.

http://www.kuka.com