Advanced Materials Today Sep/Oct 

 Advanced Materials Today Sep/Oct 2010


Durma (SA) (PTY) LTD
Tel: (011) 827-0639
Fax: (011) 827-0643
Email: sales@durma.co.za
Web: www.durma.co.za
Copyright
All rights reserved. No edi-
torial matter published in
“Advanced Materials Today”
may be reproduced in any form
or language without written
permission of the publishers.
While every effort is made to
ensure accurate reproduction
the editor, authors, publishers
and their employees or agents
shall not be responsible or in
any way liable for any errors,
omissions or inaccuracies
in the publication whether
arising from negligence or
otherwise or for any conse-
quences arising therefrom.
The inclusion or exclusion of
any product does not mean
that the publisher or editorial
board advocates or rejects its
use either generally or in any
particular field or fields.
Sep/Oct 2010
Contents
Cover Story Afrimold Exhibition
4 Don’t Move a Muscle 25 Afrimold Here to Stay
Castings, Forgings, Furnaces and Corrosion
Refractories 28 Stop Corrosion of Profits
8 Shopping Industrial Style
Fabrication
Machining 32 How Safe is a Safe?
11 Getting Machining Right
Industry News
TDM Today 33 Industry News
(Tool, Die & Mould Making)
Endorsing Bodies
17 CEO’s Comments
• SAIMechE (SA Institution of Mechanical
18 Auto Industry Innovators
Engineering)
21 Training Up a Storm
• AFSA (Aluminium Federation of SA)
23 Help for SMEs
• CorriSA
• NTIP
The monthly circulation is 6 034
Proprietor and Publisher:
PROMECH PUBLISHING DTP: Zinobia Docrat and
Sean Bacher
Tel: (011) 781-1401
Fax: (011) 781-1403 Disclaimer
E-mail: editorial@promech.co.za Neither PROMECH Publishing
Website: www.promech.co.za
nor its endorsing bodies are
Managing Editor: responsible for the opinions
Susan Custers expressed by individuals.
Editor:
Raymond Campling Printed by:
Advertising Sales: Typo Colour Printing
Di Bluck Tel: (011) 402-3468
Advanced Materials Today Sep/Oct 
COVER STORY
Don’t Move a Muscle
Byron Gueffroy (centre) and Robbert van Rijssen (right) of Rijva
Quality Machines with Johnny Barecchia (left)
If you are in the market for sheet metal working ma-
chines don’t spend a cent until you have seen the
latest range of Durma machines from Durmazlar, a
division of Rijva Quality Machines.
T
he equipment offers twice the value when
compared to current market offerings. Firstly,
it’s designed and built in Europe, arguably
by the most exciting manufacturing facility
on the continent. Secondly, the machines are priced
well below equivalent machines with similar build
quality and components.
The brand is well-known across the globe, but for
a while now did not get the exposure and back-up
it needed. With the appointment of sheet working
specialist, Rijva Quality Machines as the official
local distributor, this exciting brand will again be
presented to local buyers with the service, back-up
and expertise that it so richly deserves.
The machines are priced well below equivalent
machines with similar build quality and components
Coup for SA
“Rijva has pulled off a coup with its appointment.
The Turkish manufacturer supplies machines of a
quality that can easily compare with the best in the
 Advanced Materials Today Sep/Oct 2010
world. On the other hand, the modern manufactur-
ing operation is able to supply the machines at a
fraction of the price of its European counterparts,”
says Byron Gueffroy, director of Rijva Quality Ma-
chines.
“The South African market traditionally bought qual-
ity machines, but with tough economic times and
rising prices, some were forced to forsake quality
for cheap imports from the East.
“This need no longer applies and whether the buyer
still upholds quality above everything else, or is
price sensitive he or she need look no further than
Durma equipment,” adds Byron.
Always there
Durma’s range of press brakes, guillotines, notch-
ing machines, iron workers, punching machines,
plasma and laser cutters, section and plate rollers,
and band saws are sold on five continents in more
than 80 countries around the world. Its history spans
five decades in which it has grown and captured
significant market share in all the countries where
it is represented.
 COVER STORY

In the Durma range: Although it has

a massive range
• Press brakes of standard ma-
• Guillotines chines, it has a
• Iron workers reputation for de-
livering end-to-end
• Bandsaws solutions for un-
• Plasma cutters usual or oversized
operations. Most
• Laser cutters
recently it pro-
• Section rollers vided a large scale
• Bending and rolling roll, press, punch
and forming solu-
• CNC punching tion to a company
• Notching in Mexico to manu-
facture large street
light poles in a single operation. It has also produced Durma hydraulic bending machine
some of the world’s biggest and most powerful press
breaks, some over impressive spans.
Apart from their role in general manufacturing, the
machines are synonymous with precision engineer-
ing disciplines elsewhere in the world, such as in
the aviation and automotive industries. In South
Africa, the brand already has a fair sized footprint
in general fabrication and engineering, but Byron
expects that mines and power generation facilities
will gravitate towards the Durma brand because of
the flexible options the machines offer.
Come to the party
Now that Durma is represented in South Africa by
Durmazlar, a division of Rijva Quality Machines, the
market will be in for a veritable treat. The company
has built a reputation for providing quality solutions
to sheet and plate working industries.
The company’s product ranges include brand-names
like Voortman, Herrblitz, Toolcraft, Almi, P/A In-
dustries, Ter Hart, RHTC, Dimeco, Darley, Rolleri, Durma CNC punch
Matrix, Costa and Hypertherm. These brands have
taken the company to the forefront of their industry
and the company is comfortably the market leader
in this section of the market.

When a customer comes to us with a

requirement we make sure they get
what they need and not simply what we
have in stock

“The reason for our success is that we are specialists

in the field and despite requests and sometimes
temptation to sell machines into markets we don’t
know, we prefer to stick to what we know. In the
last 15 years this has paid off and we find our-
selves comfortable leaders in the sheet, plate and
structural steel working sector.
In-depth knowledge
“We like to think that we know what we are talking
about and when a customer comes to us with a
requirement we place their satisfaction at the top Durma shears

Advanced Materials Today Sep/Oct 

 Advanced Materials Today Sep/Oct 2010

Rijva represents a number of top brands
of our agenda and make sure they get what they
need and not simply what we have in stock,” says
Byron. “In fact, both directors of the company grew
up watching their fathers manufacture machines
for the sheet metal industry.
Fellow director, Robbert van Rijssen agrees that
specialisation in their field enables the company
staff to provide a better service to its customers.
“With our reach and trusted status in the market
we foresee that the Durma brand will become a
prominent player in the South African market. But,
beyond that, the addition to our existing products
means we are even better able to supply end-to-end
solutions to the industry,” Robbert continues.
Move to automate
He adds that there is currently a strong move-
ment within the industry to automate processes
to ensure that maximum efficiency is attained so
local companies can continue to compete in the
global market.
At present, the company’s sales are being consider-
ably bolstered by companies seeking solutions to
automate their processes.
“We have clients that have realised a vast im-
COVER STORY
Durma machines are used in
general industry with strong
representation in the following
industries:
• Automotive
• Aviation
• Maritime
• Defence
• Power generation
• Construction
• Textile
• Electronic
provement in output by minimising processes and
automating work throughput from coiled steel to
pressing, punching or whatever, to the end product.
This is certainly a trend we are perfectly positioned
to capitalise on,” he adds.
There is currently a strong movement within the industry
to automate processes
Good going
“Since we were awarded the agency for Durma, we
have had a positive response from existing owners
enquiring about servicing of machines and perhaps,
not surprisingly wanting to add to their “fleet” of
Durma machines,” says Byron.
He concludes that the brand will go from strength
to strength and that packaged solutions are avail-
able from Durma in South Africa. “We want to
challenge buyers to compare price and quality of
our machines before they make their final buying
decisions.”
Durma (Pty)Ltd, Byron Gueffroy, Tel: (011) 827 0639,
Fax: (011) 827 0643, sales@durma.co.za, Web: www.
durma.co.za
Advanced Materials Today Sep/Oct 
CASTINGS, FORGINGS, FURNACES AND REFRACTORIES
Shopping Industrial Style
In just six years since management bought out the overseas principals of Metallurg SA to form Insimbi
Refractory and Alloy Supplies, the company has gone from strength to strength to become a one-stop-shop for
anything related to the reconstitution of alloy.
P
ieter Schutte, the charismatic CEO of In-
simbi, laughingly refers to the operation
as the Pick ‘n Pay of the industry because
“clients can shop for everything they need
under one roof, on one account.” He points out that
the primary focus of the company since the buy-out
remains the expansion of products and services
required by clients in order to provide them with
whatever they need whenever they need it, at the
right price in the right quantity.
Anyone in the business of reconstituting metals needs
materials and consumables like a chef needs ingredients
and spices
Pieter Schutte (CEO) and Danny O’Conner (Chairman) of Insimbi
 Advanced Materials Today Sep/Oct 2010
The company has a forty year history in South
Africa and boasts long-standing relationships with
blue-chip mining companies and chemical and
synthetic producers locally and abroad. “Our rela-
tionship with producers is the primary strength of
the company as we are able to provide all the raw
materials required for metals manufacture, casting
and refractory services. In this regard, we also play
a vital and unique role to these companies. Our
marketing and distribution expertise allows them to
focus on their core activity to produce goods that,
we in turn, market, warehouse and distribute on
their behalf,” Pieter explains.
Although its primary activity is trading and ware-
housing goods for distribution, this slick operation
provides a far greater service than initially
meets the eye. It employs highly qualified
technical experts at the coal face of its
operation in sales. And they are expected
to do more than just sell. “An Insimbi
sales engineer is just that, an engineer,
with hands-on experience in the markets
that they service. In this way our clients
benefit from their expertise and advise
in addition to the goods that they sell
to them at a later stage.
“Our product and service offerings are
so broad that a single visit from a sales
engineer may result in raw materials,
components for kilns and furnaces or
service and maintenance contracts
being offered to a client. Although the
customer will deal with different sales
engineers for these products, they will
sign one contract and get the goods from
under one roof.”
Cooking up a storm
Ever the joker, Pieter compares the
industry to a kitchen in an attempt
to underpin the vast array of services
offered. “Anyone in the business of
reconstituting metals needs materials
and consumables like a chef needs in-
gredients and spices. In this kitchen we
can supply the oven’s components and
linings, the baker’s gloves and toweling,
the raw ingredients and the spices to
make the recipe unique.” He goes on
to explain that the company has eight
divisions, namely foundry, non-ferrous,
refractory, specialty, steel, rotary kiln,
 CASTINGS, FORGINGS, FURNACES AND REFRACTORIES

textiles and secondary aluminium. Beyond this, the Zimasco, Zisco, Lonmin and Scaw.
value add chain includes sourcing and supplying
Specialty
foundry equipment and consumables, rotary kiln
Through its expertise in shaping and milling products
supplies and maintenance, mechanical servicing
to conform to grades and specification of clients,
of refractory and machines, refractory bricks and
the company has built up considerable expertise
non-ferrous supplies such as copper, nickel, alu-
in producing materials that are made to unique
minium. Specialist chemicals are also supplied
requirements. The speciality division mills and
to metals, glass, cement and other refractory
related industries.
Steel manufacture is a highly specialised process with
Foundry many different grades available to suit different
The division supplies heavy, light and automo- requirements
tive foundries with a wide range of
consumables and hardware. Through-
out the duration of the recession the
heavy foundry industry has remained
a mainstay for the division with good
growth as a result of infrastructural
spend, while the mining and automo-
tive industries have seen some decline
due to falling demand for vehicles and
commodities. The division holds the
agencies for Nimag, Assore, Xstrata,
Sasol, Exarro and Amplats. Its most
notable customers include Scaw, At-
lantis, Halburg Guss and Steloy.
Non-ferrous
The supply of hardware and consum-
ables to the aluminium, non-ferrous,
wheel, lead and coin industries has
been boosted by the company’s acquisi-
tion of a secondary aluminium smelter
which is able to supply custom grades
of aluminium in the form of ingots or
pellet to the industry. Nickel, however, Rotary kiln division
remains the single most
important commodity
that the division supplies
to clients that include
the South African Mint,
Mozal, Hulamin, Borbet
and BHP. Agencies in-
clude Amplats, Xstrata,
Sasol and LSM.
Refractory
Insimbi is probably best
known for its refractory
supplies and services.
Its refractory division
is one of the leading
suppliers of refractory
bricks in the country and
its value-adding know-
how and design abilities
are well utilised within
the steel and platinum
industries. It has the
agencies for Refratech-
nik, Rath AG, Laizhou
and Ametsa. Customers
include Bindura, Cisco, Insimbi also undertakes maintenance

Advanced Materials Today Sep/Oct 

 CASTING

produces powdered alloys for use in the manufacture

of welding supplies and for final lens polishing and
other chemical applications. It holds agencies from
Sasol, Assore, LSM and Xstrata and supplies customers
including Afrox, Promax and General Optical.
Steel
By far the largest contributor to the company’s overall
turnover comes from the steel division. Steel manu-
facture is a highly specialised process with many
different grades available to suit different require-
ments. Ingredients including bulk raw materials, micro
alloys and fringe elements are supplied in the form
of pig iron, ferro manganese, titanium, molly, nickel,
copper, aluminium, as well as cored wire and more.
Metallurgists provide an invaluable input into client
processes and as a result large volumes are moved to
steel producers on a monthly basis. The division has
agencies for Injection Alloys, Assore, Exarro, Amplats,
Sasol and Xstrata. Major customers include Mittal,
Columbus, Cape Gate and Highveld Steel.
Rotary kiln
This division supplies refractory products and me-
chanical services to industries using rotary kilns and
driers. Kiln maintenance and rehabilitation of old or
mothballed plants recently has lead to the separation
of the supplies division and maintenance section. It
holds agencies from Refratechnik, Phillips Kiln and
Ketten Wulf. Customers include Cimpor, PPC, Afrisam,
Lafarge and Sappi.

The company will look for value in the

market and is looking to acquire companies
and assets

Textiles
In 2008 staff were afforded the opportunity to buy
into and own 51% of the textiles division and form
a subsidiary company under the banner of Insimbi
Thermal Insulation. The remainder of the shares are
held within the group and the subsidiary supplies
and fabricates heat-resistant textiles to all industries
where heat or steam is part of the process. Major
customers include Eskom, BHP, KCM, Konkola and
Xstrata.
Year ahead
Insimbi’s outlook for the year is positive. The company
will look for value in the market and is looking to
acquire companies and assets that can add value to
the operation and its customers. Pieter sums up the
company’s prospects for the year, “The past year’s
recession was not the first one that the company
has had to endure and through previous lessons
learned, we can actively go into the market with
products and solutions that will benefit our clients
and increase outputs as well as consumption. This
year we will focus on growing our customers to grow
our market share.”
Insimbi, Pieter Schutte, Tel: (011) 902 6930, Fax: (011) 902
5749, Email: pschutte@insimbi-alloys.co.za

10 Advanced Materials Today Sep/Oct 2010

 MACHINING

Getting Machining Right

Materials used in the making of tools, dies and moulds dictate the type of metal removal machines that can
be used to manufacture cost effectively. The difference between using fit-for-purpose machines and run-of-
the-mill machines not only shows on your bank balance, but can also mean the difference between making a
profit or a loss.

A
trend that has emerged among South
African machine shops is that machine
purchases aren’t always made according
to the work they will perform, but rather
what machine is in stock at the supplier. Some-
times little, if any, forward planning is done and the
machines are bought solely to service the orders at
hand rather than for future expansion.
This goes hand-in-hand with the findings of the
benchmarking study undertaken by the National
Tooling Initiative Programme (NTIP) (of the Tool-
making Association of South Africa) that found lo-
cal manufacturer’s approach to be too narrow and
centred on too few clients. One of the symptoms
therefore, is that shops get into a comfort zone and
make do with the first usable machine, rather than
the right machine for the job.

A fair percentage of buyers do shop for

whatever is in stock

Right for the job

Tongtai vertical machining centre
“Advanced Materials Today” raised the matter on a
recent site visit with Alroy Savides of PBS Machine
Tools and asked about his experiences. Although
Alroy says many companies carefully specify ma-
chines, a fair percentage of buyers do shop for
whatever is in stock.
“We see it all the time, where a call comes through
and we get asked a few basic questions like bed
size of a machining centre. Then the buyer wants
to know the speed of the spindle and whether we
have any in stock.
“We often speak to buyers who are ill informed and
want to buy machines that we know will not be
suitable for the purposes they intend to use them
for. This is particularly true in the TDM industry
where you often need machine tools that are capable
of holding precise lines, boasting high-speed and
powerful spindles for working with tool steel.
“All too often we hear later that the person bought a
machine that was not capable of efficiently making
the items required and all too often they lose a lot
of money. Finding a machine that is effective and
efficient should be the first priority,” he says.
Hurry-up and wait…
He continues that any lathe or milling machine can
remove steel. What really counts is how efficiently

Advanced Materials Today Sep/Oct 11

12 Advanced Materials Today Sep/Oct 2010

and accurately it can do this. Some people don’t
realise that some machines are designed to “rough”
and others to “rough and finish” specifications. Still
other machines are built for precision engineering
while others are built for general engineering.
“If you are looking for precision to within tenths or
hundredths of a micron don’t expect any old machine
to deliver the goods. In real terms, the difference
between making moulds for quality high-speed
injection moulding processes, for example, and
low volume blow moulds for small-scale packag-
ing is vast.
“You’ll need a specialised machine with a strong,
high-speed spindle and ability to keep close toler-
ances for the first job, and will need a lesser machine
for the latter. Likewise, a cheap machining centre
may suffice for the blow moulding job, but it will
never be efficient nor effective at making quality
moulds from hardened tool steel.
MACHINING
“Again, conversely, a precision machine will be
able to make rough moulds, but then the cost
of operating the machine will probably not be
effective. It is a case of buying the right tool for
the right job while bearing future requirements in
mind,” says Alroy.
It is rare that a single supplier will always have the right
tool for the right job for every application
Establish the requirement
Ever practical, Alroy goes on to suggest that buyers
ask some hard questions of the sales people they
are dealing with before buying a machine tool. But,
before setting out to meet them face to face he has
the following advice:
• Study your current operation, try to accurately
assess it, and envisaged future requirements. Look
at current work and possible future contracts.
Tongtai mold and die machine
Advanced Materials Today Sep/Oct 13
14 Advanced Materials Today Sep/Oct 2010

Tongtai vertical 5-axis machining centre
• Research and specify requirements such as
power, precision, skills available to operate
specialised machines vs more basic machines
and metal removal or cutting rate.
• When specifying. bear in mind the types of
materials that will be machined and research
best practices for the materials involved.
Questions to ask
Here are some questions to ask your machine tool
supplier:
• What is the overall speed of operation of the
machine including tooling changes, turret speed,
predictive machining ability? High-speed ma-
chining means more than just the cutting rate,
it requires overall high-speed operation to be
truly quick.
• How fast is the controller and how much control
or accuracy is enough for the job?
• How powerful is the machine and how does
the torque transfer to the workpiece to deliver
MACHINING
efficient cutting or removal of material?
• What is the availability of spares, service and
after sales back-up?
Single vs multiple supplier
A difficult question to ask any machine tool
supplier is whether a single supplier scenario is
preferable to having multiple suppliers. Alroy is
of the opinion that it is rare that a single supplier
will always have the right tool for the right job for
every application.
“There comes a time when you just cannot supply
the right machine for a specific job whether the
client’s requirements are just too simple, or just
too specialised. In cases like that we normally
advise our clients and in some cases will procure
the machine for them, but to say one brand suits
all is a stretch,” says Alroy in conclusion.
PBS Machine Tools, Alroy Savides, Tel: (011) 914 3360,
Fax: (011) 914 3366, Email: alroy@pbsmt.co.za, Web:
www.pbsmt.co.za
Advanced Materials Today Sep/Oct 15
16 Advanced Materials Today Sep/Oct 2010
Produced by:
PROMECH PUBLISHING,
P O Box 373, Pinegowrie, 2123
Republic of South Africa
Tel: (011) 781-1401
Fax: (011) 781-1403
Email: editorial@promech.co.za
Website: www.promech.co.za
Managing Editor Susan Custers
Editor: Raymond Campling
Advertising Di Bluck
Circulation Catherine Macdiva
DTP Zinobia Docrat/Sean Bacher
Disclaimer
PROMECH Publishing does not
take responsibility for the
opinions expressed by individuals.
Printed by:
Typo Colour Printing
Tel: (011) 402-3468/9
Copyright
All rights reserved. No editorial
matter published in “TDM To-
day (Tool, Die & Mould Making)”
may be reproduced in any form
or language without written
permission of the publishers.
While every effort is made to
ensure accurate reproduction,
the editor, authors, publishers
and their employees or agents
shall not be responsible or in
any way liable for any errors,
omissions or inaccuracies in
the publication, whether arising
from negligence or otherwise
or for any consequences aris-
ing therefrom. The inclusion or
exclusion of any product does
not mean that the publisher or
editorial board advocates or
rejects its use either gener-
ally or in any particular field
or fields.
CEO’S Comments
The recent Afrimold exhibition created a firm platform from which the local
TDM sector can showcase its capabilities.
T
he TDM industry will use the Afrimold
platform over the next five years to
streghthen the capacity of the local
industry. The Toolmaking Associa-
tion of SA (TASA) and the National Tooling
Initiative Programme (NTI) hosted several
of its member companies and exposed the
sector to the extensive skills development
programme being piloted at seven institu-
tions across six provinces.
The 175 students currently on the programme
had the chance to interact with the industry
and see some of the exciting technologies
and career opportunities offered within the
sector. The industry, on the other hand,
was pleasantly surprised by the quality
and positive attitude of the TDM Powered
Programme students, resulting in a growing
interest from companies to participate in
the programme.
All 175 students have been placed within
the industry for their “on-the-job” training
phase of three months as part of the comple-
tion of their pre-apprenticeship orientation
programme.
Localisation project
The big news from the NTI, however, is the
launching of the Tooling Localisation Project
in August 2010, which will aim to:
Localise tooling developments for products
designed and developed through South African
innovation, and attract specialised technol-
ogy tooling companies from the international
arena to set up businesses or joint ventures
in South Africa, to specifically support the
new Automotive Investment Scheme (AIS).
The focus will be on speciality tooling which
is currently not manufactured in South
Africa and where the technology quality
standards and the international OEM and
toolmaker relationships will prevent local
tooling companies from competing.
The strategy is that these high technology com-
panies entering the South African environment
will stimulate the upstream and downstream
supply chain
and will fa-
cilitate tech-
nology and
skills trans-
fer.
Appren-
ticeships
The next
phase, NTI’s
“TDM Pow-
ered” new
Dirk van Dyk
competency
based ap-
prenticeship programme, to be launched
in January 2011, will start with an intake
of 490 students countrywide at the partner
institutions, that will complete the first
phase of their apprenticeship training. This
programme is set to firmly re-establish
the apprenticeship system to populate
the skills value chain for the TDM sector,
in the production of artisans, technicians,
engineers and specialist skills required by
the TDM sector.
The strategy is that these high
technology companies entering
the South African environment
will stimulate the upstream and
downstream supply chain
The recent establishment of the Mpuma-
langa Tooling Initiative structure will form
the basis for the NTI to establish a TDM
cluster in Mpumalanga in partnership
with provincial governments and industry
stakeholders. This new structure will be
formally launched in October where the
intervention projects of the NTI in Mpuma-
langa will be showcased.
National Tooling Initiative, Dirk van Dyk, Tel:
(012) 643 9360, Email: dirkvd@ntipweb.co.za,
Web: www.ntipweb.co.za
Advanced Materials Today Sep/Oct 17
TDM COMPANY PROFILE

Motorcars are complex

pieces of machinery with
thousands of individual
parts and components fit-
ted to the main structure
and engine. Manufactur-
ing and supplying parts
for this industry is poten-
tially lucrative, but only if
done right.

Auto Industry Innovators

T
he operation needs to be geared towards
upholding quality levels at all times and
producing items to the exact specifications
of the international motor manufacturing
giants. Moreover, it is about customer relationships
and the ability to satisfy their requirements and
assist in adding value to their operations.
Ramsay Engineering is such a company that has
diversified its product offerings. Commercial direc-
tor, Mark Gutridge,
A rapid prototype
tells “Advanced Main customers
Materials Today” • Toyota SA Motors
that the compa-
• BMW (South Africa)
ny is a privately
owned, volume • Ford Motor Companyof
manufacturer of South Africa
metal, plastic and • Volkswagen of South
leatherette auto- Africa
motive compo-
nents. In addition, • Land Rover
the company is a • General Motors SA
The finished product
supplier of tooling • Nissan South Africa
and dies.
• Feltex Automotive
“Our core com-
petence is metal • Smiths Manufacturing
stamping which • Visteon South Africa
contributes to 60
percent of our sales
revenue. The other
divisions include plastics, trim, component assem-
blies, accessories, logistics, quality management,
tool and die, product development, total industrial
engineering and training,” he adds.
“This variety of manufacturing processes allows us
to supply a broad range of automotive components.
Customers benefit from our diverse capability as
Fabrication tools and jigs it allows them to deal with one supplier for a part

18 Advanced Materials Today Sep/Oct 2010


comprising different materials and related pro-
cesses,” says Mark.
Relationships are key
Customer relationships have been developed over
more than forty years and Ramsay Engineering is
entrenched as a longstanding, reliable and respon-
sive organisation. Supplier relationships are equally
important to the company.
The company readily accepts challenges and ac-
tively applies innovation and expertise to solving
customer problems. A dynamic approach together
with strong ethics enables the company to live to
the motto of, “Our customers come first.”
Start to finish service
“We are able to supply a comprehensive package,
from the design through to the delivery of the final
product.
“We are committed to the use of cutting-edge tech-
nology and have recently installed new systems in
the metal pressing and tool and die manufacturing
facilities. Ongoing investment in technology and
equipment enables us to improve the output of our
products and services,” says Mark.
He continues by saying that all activities are con-
ducted in strict accordance with the international
requirements of ISO 9001, ISO 14001 and ISO/TS
16949. The principles of total quality management
are applied throughout the company, with all qual-
ity problems being analysed to determine the root
causes and resolved using PDCA cycles.
Tool and die
“We design, manufacture and maintain all of our
metal forming and fabrication tools, jigs, injection
moulds and special purpose machinery. This broad
capability guarantees the continuity of supply to our
TDM COMPANY PROFILE
Tool room
The 1 200 m² tool room includes three
designers, 13 tool and die makers, nine
apprentices, 28 machine operators and
three CMM operators.
Machines include:
• 10 CNC milling machines
• 3 CNC wire eroders
• 2 CNC spark eroders
• 5 surface grinders
• 9 universal milling machines
• 6 Lathes
Software
• Cimmatron
• Catia V5 (release 17)
• Solid Works (2010 S/P4)
Main processes
• Metal stamping and forming
• Plastic injection moulding
• Automotive trim
customers and also facilitates
continuous improvements • Component assemblies
while preserving the value of • Automotive accessories
our assets. • Tool and die
“Our second principle design • Product development
engineers take our customers’
drawings and use comprehensive project manage-
ment systems to ensure all products are made
within agreed time frames and to specification,”
Mark adds.
The company readily accepts challenges and actively
applies innovation and expertise to solving customer
problems
The company has the ability to undertake first
principle design work using a team of engineers
who work on the latest software packages to create
products that meet customers’ ever more demand-
ing requirements.
Analysis is key
Finite element analysis is undertaken
in the company’s own in-
house climatically
controlled
Advanced Materials Today Sep/Oct 19
TDM COMPANY PROFILE

testing facility.
Off-line commis-
sioning of equip-
ment is done
prior to on-line
use to ensure
that there is a
seamless tran-
sition between
engineering and
production.
A lot of empha-
sis is placed
on maintaining
The workshop is fully kitted-out
skills within the
company and
Ramsay Engineering is able to add value to its
The company has the ability to undertake first principle customers through its technical aid agreements
design work using a team of engineers who work on the and joint ventures it has established with global
latest software companies in various parts of the world. Thule
(Netherlands), PWO (Germany), AISIN (Japan), BATZ
training for the future. As a result, the company is (Spain) and BEW (Spain) are just a few examples.
a Merseta workplace training provider and runs a These partnerships ensure mutual interchange of
number of training initiatives including: Learnership technical expertise and knowhow, thus ensuring
apprenticeships, graduate development, environ- global standards and world-class lead times coupled
mental training, health and safety training. Train with cost efficiencies.
the trainer programs, SSACI programs and school Ramsay Engineering, Mark Gutridge, Tel: (033) 387 1575,
67542 KEW Foundry Ad.fh11 5/3/10 9:17 AM Page 1
career guidance is also offered. Fax: (033) 387 4535, Email: re@ramsay.co.za
C M Y CM MY CY CMY K

KEW

20Composite
Advanced Materials Today Sep/Oct 2010

Training Up a Storm
A fresh batch of toolmakers is being prepared at the South
West Gauteng College in Soweto and trainers are ensuring that
the curriculae has all the right ingredients for the South
African market.
Hands-on training at the NTIP's pre-apprenticeship programme
U
nder the auspices of the National Tooling
Initiative Programme (NTIP) 18 students
are undergoing pre-apprentice training in
order to be ready to start the NTIP’s full
apprenticeship programme next year. At the end
of the apprenticeship programme the students will
qualify as fully fledged toolmakers.
The full course will equip the students with the techni-
cal and theoretical expertise to become fully functional
toolmakers
“Advanced Materials Today” visited the workshop
and found that the South West Gauteng College is
one of several colleges across the country that has
adopted the NTIP’s curriculae, based on a model
adapted from the United States known as the National
Institution for Metalworking Skills (NIMS).
Better training
The full course will equip the students with the
technical and theoretical expertise to become fully
functional toolmakers when they qualify with no
further training needed. This is set to improve on
the current learnerships being offered at national
level and that the industry has found to be insuf-
ficient in meeting its demands.
TDM TRAINING
Roger Skidow
“The NTIP adopted this model following the collective
assertion of the Toolmakers Association of South
Africa (TASA) that the current learnerships being
offered by colleges do not work,” says Roger Skidow,
lecturer and project manager at the NTIP.
He says the new apprenticeship curriculae will
be adopted at colleges and training institutions
affiliated with the NTIP from next year, but that
pre-apprenticeship is geared at improving mainly
township learners’ English and Mathematical skills.
In this way, they will be able to fully participate in
the apprenticeship programme without the disad-
vantage of language barriers or the shortcomings
of education in less privileged areas.
Soweto style
The Soweto college is equipped with all the con-
ventional machines required for the pre-apprentice
programme and first year of the actual apprenticeship,
after which advanced machines such as wire and
spark eroders, CNC machines and surface grinders
will be procured for further training.
“The South West Gauteng College is eager to work
with the NTIP and has committed to forming a long-
standing relationship with the NTIP. The environment
at the college is conductive to the students’ learning
requirements and offers all the amenities needed
by them to be productive,” adds Roger.
“It also offers space to grow and enables us to think
big in terms of future pupil intake. The programme
is in its infancy now, but will no-doubt grow in time
and it is good to be partnered with a college that
offers us this space,” concludes Carlos Barbosa,
NTIP project manager.
National Tooling Initiative Programme, Carlos Barbosa,
Tel: (012) 643 9360, Fax: (012) 663 9418, Email: carlosb@
ntipweb.co.za
Advanced Materials Today Sep/Oct 21
22 Advanced Materials Today Sep/Oct 2010
 TDM NEWS

Help for SMEs

The Western Cape Tooling Initiative (WCTI), in partnership with Swisscontact, a non-profit organisation
founded by the Swiss business and the Swiss government with the goal of stimulating growth in the private
sector in selected developing countries, has developed and implemented a Market Development Programme
(MDP) for the Western Cape Tool, Die and Mould (TDM) sector.

T
he MDP was started to implement initiatives competency and reliability, leading to an increase
and programmes that can respond directly in the volume of business for local tool makers
to the recent finding of the Institute for who will, through the programme, be able to meet
Advancing Tooling (IAT). According to these demanding customer expectations.
findings, the South African tooling sector is under
severe pressure from countries such as China and Additional programme
India, which tend to outperform local suppliers In addition to the MDP, Swisscontact has linked the
substantially, both in terms of levels of on-time WCTI with another USAID funded SME develop-
delivery and overall competitiveness. ment programme, the South Africa International
Business Linkage (SAIBL) organisation. This part-
The primary aim of the MDP is to improve the nership will combine WCTI and SAIBL resources,
which will ensure each SME in the Western Cape
competitiveness of SME clusters in the tooling sector goes through a holistic development programme
for a period of three years. The WCTI will also
Grant Stevenson, WCTI CEO, explains that the make use of the services provided by the Small
primary aim of the MDP is to improve the com- Enterprise Development Agency (SEDA) to imple-
petitiveness of SME clusters in the tooling sector, ment business improvement projects in the sector
thereby empowering them to increase their market where appropriate.
share. The programme came about as a response to
a benchmarking study that found that South African Grant Stevenson, Western Cape Tooling Initiative, Tel: (021)
592 3695, Email: grants@wctiweb.co.za
tool rooms are generally technically on a par with
their global counterparts, but lack management
skills and customer relationship management
(CRM) systems. The programme also offers
specific training to equip SME owners with
the needed business management skills.
Plug the gaps
Grant notes that as part of the programme,
the WCTI will develop a supplier action plan
in which eight selected tool making compa-
nies will receive support over a period of five
months to identify weaknesses and develop
systems to plug the gaps.
These interventions seek to improve managerial
and business systems capacity at a company
level. The overall aim is to establish an in-
dustry that is based on world-class delivery,

Advanced Materials Today Sep/Oct 23

24 Advanced Materials Today Sep/Oct 2010

Afrimold Here to Stay
Suppliers to the tool, die and mould making industry are bristling with excitement at the prospect of the event
becoming an annual feature on the events calendar.
A
lready the Tool-
making Associa-
tion of South Af-
rica (TASA) and
operational organisations
under its guidance including
the National Tooling Initia-
tive Programme (NTIP) and
Intsimbi have thrown their
full support behind future
events. Furthermore, or-
ganisers have reported that
many of the exhibitors are
already booking their space
at next year’s event.
The show is relevant to the
entire industry from ma-
chine tool and consumable
suppliers to toolmakers.
AFRIMOLD EXHIBITION
Good start
This year’s show was held in Sandton and achieved
an impressive debut. The 77 exhibitors were vis-
ible to more than 2 100 visitors and 80% of the
foreign exhibitors have already re-booked for the
2011 show, taking up treble the space they oc-
cupied this year.
The 77 exhibitors were visible to more
than 2 100 visitors
Officially opening the show, Gauteng Economic
Development MEC Firoz Cachalia said a positive
outcome of the global financial crisis was that
Government is recognising that future economic
developments will be dependent upon the manu-
facturing industry. Afrimold was therefore timely,
serving to highlight the role of the tooling industry
as the most critical component behind manufactur-
ing industry development.
Advanced Materials Today Sep/Oct 25
AFRIMOLD EXHIBITION

Exhibition director Ron MacLarty com-

mented that the spirit of the show and
the overwhelmingly positive feedback
from visitors and exhibitors alike took
the tooling industry by surprise.
Long overdue
“Personally, I am over the moon. It has
been a triumph for all who were involved
and it has given the industry both direc-
tion and confidence for the future. This
exhibition should have been held years
ago, such has been the impact. Not only
has it demonstrated the excellence of the
local tooling industry, but it has created
an environment of forward thinking and
progression that was lacking before.”
Ron adds that an Afrimold exhibitor
involved in industrial, mechanical and
electrical design, who had never before
ventured into the public arena in this
way, ended the exhibition with more
than 20 new business leads.
“We also had 100 university students
and apprentices in training come through
to the show and they were able to see
that there is a world out there in which
they can be assured of good jobs, not
just in South Africa, but anywhere in
the world.”

Not only has it demonstrated

the excellence of the local
tooling industry, but it has
created an environment of
forward thinking
Shifting perceptions
Dr Eberhard Döring, CEO of Demat Fairs
and Exhibitions, the founding organisa-
tion of the Mold exhibition concept, said
Afrimold had confirmed that there is a
good future for the general industry in
South Africa.
“The World Cup lead to a paradigm
shift in the international perception of
South Africa, and Afrimold got off to a
wonderful start. I am amazed that it was
able to attract so many quality visitors
in the limited time available to prepare
the show.
“The tool-making and design industry
is critical for South Africa and with this
show we now have the full backing of
the DTI (Department of Trade & Industry)
and the support of the industry itself. It
has been a great success.”
Tasa input
The representative organisation for
The products of entrepid toolmakers
the South African tool, die and mould

26 Advanced Materials Today Sep/Oct 2010

 AFRIMOLD EXHIBITION

Toolmaking Association of South Africa TDM Powered Zimmerman Grinding

Retecon Bohle Uddëholm UV Tooling

industry, Tasa, was strongly visible at the show.
Tasa Gauteng secretary, Henk Snyman says, “This
exhibition is long overdue and Tasa supports it
100%. Our aim is to co-host Afrimold in the fu-
ture and our involvement will be to assist with the
organisation and management of the conferencing
side of the event.”
Tasa’s objective is to reverse the 80% of tooling
that is presently imported into South Africa by
increasing local tooling skills and providing plat-
forms for sustainable, well-paid job creation. Each
qualified toolmaker can create or at least preserve
15 downstream jobs and up to 25 jobs if the total
supply chain is included.
Afrimold, Ron MacLarty, Tel: 072 353 6699, Email: ron@
afrimold.com, Web: www.afrimold.com

Advanced Materials Today Sep/Oct 27


CORROSION
Stop Corrosion of Profits
Corrosion costs the country the equivalent of the contribution
of the entire mining sector every year. By stopping or slowing
corrosion the situation can be turned around and profits and
productivity can be increased.
C
orrosion costs the country the
equivalent of the contribution of
the entire mining sector every
year. By stopping or slowing
corrosion, the situation can be turned
around and profits and productivity can
be increased.
Nowhere is the importance of corro-
sion protection more visible than at
the state owned utilities such as water
and electricity supply. Corrosion had its
hand in decaying infrastructure and poor
maintenance thereof has contributed
significantly to the power shortages
and looming water crisis that everyday
South Africans are living with.
Corrosion prevention is better than
cure
Just like our utilities, industry does not
fare much better when it comes to deal-
ing with corrosion. Lost time and productivity are
incalculable when it comes to failures or production
losses as a result of corrosion.
Corrosion costs the country the equivalent of the
contribution of the entire mining sector every year
Corrosion control
Vanessa Sealy-Fisher, vice president of the Corrosion
Institute of South Africa (CorrISA), tells “Advanced
Materials Today” that the prevention of corrosion
should be prioritised throughout every operation
and should be viewed as part of the general main-
tenance budget.
Fortunately CorrISA has its finger on the problem
28 Advanced Materials Today Sep/Oct 2010
h
and continues to expand its range of training courses
geared at educating business and industry on the
importance of corrosion control. In addition to
existing courses, it will shortly introduce a special
course aimed at non-technical stake-holders within
operations.
Not just rust
“It is important that we educate our business owners
and accountants as to the importance of corrosion
and the benefits of extending the lifespan of capital
equipment, plant, machinery and buildings,” says
Vanessa.
The new course, Not Just Rust, is designed to assist
in the identification of different types of corrosion
and protection through materials selection, coatings
and cathodic protection. It supplements courses
geared toward technical staff within organisations
and corrosion protection specialists. These courses
include:
• Field Joint Coatings
• Fundamentals of Corrosion Control for Water
Utilities
• Cathodic Protection Basics
• Understanding Corrosion
• Corrosion Engineering
• Corrosion Protection of Steel
• General Paint Supervisors
• General Heavy Duty Coatings Applicator
• Corrosion School
Additionally, professionals can sit at the two main
NACE programmes offered by CorrISA namely:
• Cathodic Protection Programme (CP) and
• Coatings Inspection Programme (CIP)
CorrISA, Beverley van Niekerk, Tel: 0860CORRSA (267772)
or (011) 802 5145, Email: mail@corrosioninstitute.org.
za
 FABRICATION

How Safe is a Safe?

For as long as we have kept valuables in safes, so too have enterprising criminals specialised in the art of
cracking them to get their hands on the loot.

F
ollowing the most recent spate of safe crack-
ing cases in upmarket hotels throughout
Cape Town, we thought it a good idea to
look at just how easy, or difficult it is to
get into a good high-security safe. Using modern
techniques and machines we asked ourselves,
“How hard can it be?”
They also didn’t want their brand associated with
criminal activity
In true metal worker fashion we decided to forego
the fine art of deciphering fancy locking mecha-
nisms and decided instead on battering, cutting,
burning, but stopping short of bombing our way
through a high level safe’s defences.
Heavy artillery
So, bring on the heavy artillery. We assembled
the tools most likely to gain quick entry to a
safe. We also placed a time limit of 30 minutes

on opening the safe because we figured that

criminals would have police swarming all over
them if they took any longer.
The tools we assembled included a demolition
drill, cutting torch, thermal lance and an all
steel grinding disc partnered with a powerful
industrial grinder. These tools were chosen from
a cross section of suppliers in the vicinity, who
felt their choice of tool would do the job, but
would not go on record as they didn’t want to
get into trouble.
They also didn’t want their brand associated with
criminal activity. With that out the way we set
off and got our hands on a safe from one of the
most trusted safe manufacturers.
Solid feel
Like the customary tyre-kick when buying a sec-
ond-hand car it is customary to knock the walls
and door to test the solidity of the safe. This one
gives almost no sound feedback and is as solid

Advanced Materials Today Sep/Oct 29

FABRICATION

as a battleship’s hull in dry dock.

It is rated to withstand tampering, fire and explosive
forces and has an outer shell of hardened steel.
Inside, the walls have layers of other materials that
repel different forces and this is top secret stuff
that the technical experts at the company are not
too keen to elaborate on.
Safe to say that the materials are equal to current
technology and are updated in the face of newer
more effective technologies as and when they
become available.
Even turning the heavy piece of
equipment around holding it on the
chuck and using it as a sledge hammer
didn’t work

Demolition drill
Used in the construction industry to smash through
concrete and construction materials, this tool seems
a likely candidate to smash anything when you see
it in operation. It drills and hammers in the same
motion and makes light work of any materials. But,
not a hardened steel safe.
The drill chugged and churned away, hammering
and despite a lot of noise and vibration it was clear
that the hard-plate steel was too much. The safe’s
solid construction didn’t budge, even at the door
and hinges.
Even turning the heavy piece of equipment around
holding it on the chuck and using it as a sledge
hammer didn’t work. As pieces of plastic, buttons
and steel flew around us, the drill was wrecked and Cutting flame
the safe unmarked. Afterwards we learned that some
safes also have the added strength of composites
that can include tungsten and other materials that
are designed to break drill tips.
Enter the dragon
Fire breathing equipment was next on the list.
In James Bond films the villain or hero is able to
cut his way into safes or out of tight spots in the
blink of an eye. Safe in the knowledge that cut-
ting torches, such as an oxy acetylene or plasma
can cut through hard steel, we figured, depending
on the thickness we’d be through and inside with
time to spare.
As the flame spluttered and fired to life, the metal Thermal lance

30 Advanced Materials Today Sep/Oct 2010


almost instantaneously turned bight red and then
yellow, a good sign.
A couple of minutes later we were making steady
progress, carving into the hard steel plate of the side
of the safe. Just then a series of pops and bangs
and some smouldering alerted us to the fact that
something was wrong. A cement or ceramic barrier
didn’t take kindly to our ingress. Moisture seeped
from inside the safe, meaning that continuing would
risk an explosive reaction. In any case, we weren’t
making much progress beyond that layer.
It seems that many safe manufacturers make use
of strong concrete mixes that are poured between
FABRICATION
different layers of the safe walls. In addition, some
make use of refractory materials such as ceramics
and even ceramic fibres compressed in water to
both insulate the contents in the event of a fire and
repel cutting flames.
Cutting disc
With the surface steel already pocked and damaged,
we unsheathed our most impressive machine yet.
A heavy industrial grinder with a diamond tipped
“all steel” cutting disc that could cut through
anything.
The grinder’s powerful motor growled to life and as
it got up to speed, it looked like nothing could stop
it. Sparks flew as it inched into the metal where
it was previously damaged by the cutting torch. A
while later, it began tearing into the filler material,
but at a tediously slow rate.
Although we technically cracked the
safe, the opening was barely big enough
to give access to a drinking straw
Some of the safe’s metal started caking and in its
semi-molten form began gumming up the works.
Other layers that included tempered glass and
different composites took the edge off the disc,
slowing us down even further. As the 30 minute
time limit ticked by we managed to create a tiny
opening and although we technically cracked the
safe, the opening was barely big enough to give
access to a drinking straw.
Advanced Materials Today Sep/Oct 31
 FABRICATION

The slow progress was due to the hard nature of all the
materials used and blunting composite materials that are
specially included to stop a grinder’s progress. Manufactur-
ers also often use soft metal fillers to effectively coat the
disc and cause it to chatter and cut less effectively.
The Jedi’s sword
In recent years, a tool was developed for cutting mixed
materials in emergency situations such as building col-
lapses. The thermal lance can cut through different
metals with ease and even cuts concrete. Its white hot
tip and sword-like appearance earned it the nickname
“Jedi’s sword” and it can surely cut through a safe with
comparative ease.
Our safe gave some resistance and with the combined
power of the thermal lance and all the other tools at our
disposal we gained entry to the safe in just under the al-
lotted time. After letting the hot metal cool off and after
discarding all the safety gear that had to be worn to protect
us against noxious fumes, molten metal and other nasties,
we got our first glimpse of the contents.
But, alas, nothing. Nothing but molten metal where there
were coins, powdery ash instead of notes and crystals in
place of the compact discs containing information on the
JFK assassination.
So what now? Certain safes are made to withstand:
The moral of the • Fire
story is that a
safe only buys you • Water and chemicals
time. With enough • Tampering and mechanical tools
effort, any one of
• Cutting tools and drills
the tools may have
found a way in • Percussion and pressure
given persistence • Thermal devices and cutting flames
and enough time.
New technologies • Explosions
like thermal lances
can gain entry into all but the highest security safes, but
the size of the device, gas bottles and risk of fumes or
explosion in enclosed areas would make it unsuitable for
the vast majority of safe cracking jobs.
Add to this the fact that some safes lock down when they
detect mechanical or heat intrusion and that many carry
spoiling devices or liquids that mark or ruin the contents,
and it is clear that this is no easy job.
As a safe expert points out, the safe is but one barrier.
When something is very valuable, it is usually protected
by electronic safety systems and any number of other
counter measures to deter would be cat-burglars. Even if
they were to get to the safe, it is usually so heavy that it is
almost impossible for criminals to move and if they decide
to crack it on site they would need a long time.
Recent cat burglaries
As for the burglars in Cape Town, it is interesting to note
that they chose to decipher the fancy electronic locking
systems on the hotel room safes rather than use any other
method. Perhaps that’s because they didn’t have a kitbag
big enough to hold the kind of equipment it takes to open
even a relatively simple safe?

32 Advanced Materials Today Sep/Oct 2010

Industry News
New on-site service and support contract on-site engineer, Adriaan Botes. The Puma engine will be
In a contract valued at an estimated R3 billion, Tectra Au- utilised in many vehicle models across the range, including
tomation, in agreement with Bosch Rexroth Electric Drives the Ford Transit, Mondeo, Ranger, Jaguar X type, Land Rover
and Controls, is to provide the Ford Struandale facility in Defender, Freelander and Mazda BT50.
Port Elizabeth with on-site service support for the duration Tectra Automation will train Ford personnel, ranging from
of the Puma Engine Machining project. machine operators to maintenance artisans, to gain a better
The Puma project will entail the export of new four- and understanding of Bosch Rexroth Electric Drives and Control
five-cylinder engines to both Europe and the United States. products.
This new generation, turbocharged, common-rail diesel Tectra Automation, Kevin Lombard, Tel: (011) 971 9400, Fax: (011)
engine utilises Ford’s newest power train technologies and 971 9440, Email: kevin.lombard@tectra.co.za
complies with the latest EU5 emissions standards; bring-
ing matching benefits in environmental compatibility, fuel
efficiency and performance.
Tectra Automation’s relationship with Ford will involve on-
site assistance during the installation and commissioning
of approximately 100 advanced new machines by various
machine builders from abroad. The project will produce an
estimated 220 000 machined components per year, of which
about 75 000 will be used in local vehicle production. The
first production engine is scheduled to come offline in August
2011. The project will create many jobs in the region that Precision water jet cutting
previously starved due to the current economic climate. Precision machine building company MDC Max Daetwyler AG
The on-site support will consist of a close working relation- and specialist water jet company Waterjet AG, in collaboration
ship with all machine builders and Ford personnel by the with NUM, have developed an innovative CNC-based water
project co-ordinator, Jason Saunders, and newly appointed jet cutting machine capable of cutting materials to within

During the installation and commissioning of approximately 100 advanced new machines from abroad at the Ford Struandale facility in
Port Elizabeth, Tectra Automation will provide on-site support to all machine builders.

Advanced Materials Today Sep/Oct 33

Industry News
±1 micron – which is 20 times more
accurate than competitive machines.
The new WOMAJET/microWATERJET
machine is also extremely efficient – it
consumes considerably less water and
abrasives than traditional systems and
looks set to open up entirely new ap-
plication areas for this form of materials
processing technology.
Many of the new product fabrication
materials introduced over the past few
years react negatively to the effects of
heat during machining. However, using a
jet of water to perform the cutting opera-
tion ensures that the material structure
remains unchanged; furthermore, the
technique can be used on virtually any
type of material even foodstuffs, provid-
ing they are not water soluble. In the
light of this, MDC Max Daetwyler, Wa-
terjet and NUM chose to combine their
expertise to jointly develop a water jet
cutting machine specifically for precision
materials processing.
The new WOMAJET/microWATERJET
machine provides a stable, precise
and repeatable manufacturing process
capable of creating complex contours
– it can handle land widths as narrow
as 20 microns (0.02 mm). The machine
uses a very high precision water jet, with
a diameter of less than 300 microns,
and can cut materials at a rate of up to
4000 mm per minute. All three of the
machine’s axes are driven by NUMDrive
C servos; these have a very high power
density, which helps minimise the size
of the control cabinet. Overall control
of the machine is handled by a NUM
Flexium CNC system, equipped with a The new Womajet/microWaterjet machine
NUM FS152i HMI for operator input
commands.
NUM, Email: sales.uk@num.com, Web: www.
num.com

No limits laser cutting

Prima Industrie, through South African agent First
Cut, has introduced its Maximo large cutting system, a
large machine based on Prima’s Platino – an effective A large 2D laser machine, the Maximo has been introduced to the local market
2D laser machine. by First Cut

34 Advanced Materials Today Sep/Oct 2010

Industry News
As a distributor of leading international capital equipment,
First Cut is offering local industry the Maximo system – a
machine that is accurate and speedy for large work areas,
boosting productivity with less downtime,” says Andrew
Poole, director of First Cut.
Essentially, the Maximo is a complete Platino machine,
with its mechanical structure, laser generator, CNC, moving
carriages, optical chain and focusing head. “The machine
also travels on rails over a fixed working table, processing
sheets of any lengths with the only limitation, that of the
space available in the workshop,” adds Andrew.
In technical terms, the Maximo features a further Y2-axis,
allowing the machine to move beyond the Y1-axis stroke.
This means that more is offered to the sheet metal process,
resulting in numerous economic advantages.
“In addition, Maximo can be equipped with one or more
piece supporting tables, with the length determined by our
customer’s demand, and the relevant devices for fumes
extraction and scraps collection,” notes Steve van Wyk,
director at First Cut.
Features of the machine include an adjustable focal position,
allowing a variety of materials and thicknesses to be cut
without manual interventions, and keeping the process ac-
curate in the entire work area; a rapid lens changing system;
an offline 2D CAD/CAM and the nesting software package
for quick, easy and cost-effective programming.
The machine is also equipped with a fast-piercing unit for
thicker, ferrous materials; a laser piercing monitor and the
plasma monitoring and automatic restart.
First Cut, Andrew Poole, Tel: (011) 614 1112, Email: andrewp@
firstcut.co.za
and use advanced multi-axis synchronisation capabilities
to support very sophisticated roll-forming technology to
improve the tool adjustments that can be employed during
the bending cycle.
This enables ultra-precise part shapes, and offers a visual
collision checking programming feature as standard. The Uni-
son machines also feature an open architecture that is easily
adapted to integrate application-specific capabilities.
An all-electric architecture provides tube benders with significant
performance benefits in terms of set-up speed, repeatability,
lower energy consumption and noise reduction compared
with traditional hydraulically powered machinery.
At the heart of Unison’s new Breeze machine range is a real-
time machine and motion system based on the deterministic
Ethernet-compatible Powerlink protocol. A 100 Mbits/second
network links all of the servomotor drives required to control
bending operations. The speed of the network makes it pos-
sible to coordinate the movement of the various servomotor
axes used during bending - such as the carriage, plane of
bend, and clamp roller - more rapidly, allowing Unison to
improve the speed of bending for many common tasks by
typically around 10%.
Unison Limited, Web: www.unisonltd.com

Electric bending
Unison launched a new
range of all-electric tube
bending machines in-
corporating a real-time
Ethernet control system
architecture, and a new
release of programming
and control software.
The machines take
the advanced shape
forming capability and
flexibility of servomo-
tor-controlled bending
to a new level. The
new UK-built Breeze
machines bend faster The Breeze machines bend faster and boast multi-axis synchronisation capabilities

Advanced Materials Today Sep/Oct 35

Industry News
Apex Strip Curtains installed in a workshop
Welding and grinding safety
Many companies have discovered, too late and to their detri-
ment, that the Department of Labour is practising zero toler-
ance with companies that do not comply
with the health and safety regulations
stipulated in the Occupational Health
and Safety (OHS) Act, particularly with
regard to environments hazardous to
worker health.
“Welding and grinding are among the
most notorious culprits for causing
nasty accidents, not only in the imme-
diate environment, but in the broader
workplace, by spreading noxious fumes
and endangering the eyesight of those
in the immediate vicinity,” Wim Dess-
ing, managing director of Apex Strip
Curtains, says.
However, there is a certain resistance to
providing solid wall barriers to counter
UV radiation and weld splatter because
of the cost and practicality, particularly
in confined spaces. “Some manufacturers
resort to makeshift protective structures,
erecting wooden or metallic partitions or
even hanging opaque canvas sheeting
from the ceiling and crossbeams,” Wim Andy Koursaris
continues. “None of these measures
complies with the OHS Act and all fall far short of total
worker protection and safety.”
The answer lies in installing welding and safety screens
which not only protect from weld splatter and fumes, but
also from harmful UV radiation.
Manufactured from a specially formulated PVC material
which extensive SABS tests have proved to be superior to
conventional materials, Apex Welding and Safety Screens
36 Advanced Materials Today Sep/Oct 2010
come in various configurations to
suit a variety of individual require-
ments. “The most popular version
has a freestanding frame, allowing
easy handling and portability,”
concludes says.
Apex Strip Curtains, Wim Dessing,
Tel: (011) 452 8723, Email: www.
apexstrip.co.za
Welding stalwart recognised at SAIW
Awards
The Southern African Institute of Welding (SAIW) recognised
exceptional achievement across a broad spectrum when
it presented its annual awards
recently.
The Institute’s highest honour, the
Gold Medal Award, went to weld-
ing stalwart Prof Andy Koursaris in
recognition of the impact he has
made on training welding engineers
and his contribution to the develop-
ment of the Institute.
Introduced in 1966 this award
recognises a company or an
individual who has significantly
contributed to welding technol-
ogy or to the Institute. In SAIW’s
62nd anniversary year they were
pleased to have a winner who
is widely acknowledged for his
contributions to both.
Born in Cyprus Prof Koursaris
came to South Africa in 1975 and
joined Wits University carrying out
research which lead to his PhD. He
became a lecturer at Wits in 1979
and remained with the university
until his recent retirement in June this year.
For the last 10 years or so Prof Koursaris has been the coor-
dinator of the Wits/SAIW welding engineering programme. He
took over the programme when it was undergoing significant
change and has been primarily responsible for its rationalisa-
tion and alignment with the International Welding Engineer
programme of the International Institute of Welding. The
programme still runs successfully and has produced well in
Industry News
excess of 100 welding engineers. half, the sector was
The Harvey Shacklock Gold Medal Award for best Technical employing approxi-
paper went to Morris Maroga of Eskom for the paper ‘Mate- mately 63 800 peo-
rial Selection and Design for Supercritical Boiler Pressure ple. This corresponds
Parts’ which was presented to the SAIW Technical Meeting to a fall of almost
in October last year. 10% compared to
the preceding year. In
Top student Mark Sloan received the Phil Santilhano Award the last few months,
which is presented to the best student on the Institute’s however, there has
flagship courses in Welding Supervision and Inspection. been discernible sta-
Mark achieved distinctions in both the Level 1 and Level 2 bilisation.
Inspector courses. Since completing the inspector courses he
has also gone on to successfully complete both Competent There continue to
Persons courses and the ASME Codes course. be imponderables,
Wilfried points out,
Southern African Institute of Welding, Jim Guild, Tel: (011) 298.2100, such as setbacks on
Fax: (011) 836.4132, E.Mail:guildj@saiw.co.za, Web: www.saiw. the US market, the
co.za
anticipated slowdown
in China’s growth or
risks in the financial
market.
German machine tool orders hit the ground
German Machine Tool
running Builders’ Association,
In the second quarter of 2010, order bookings in the German Tel: +49 69 756081-0, Dr Wilfried Schäfer
machine tool industry showed another unexpectedly steep Fax: +49 69 756081-11,
rise, of 71 percent. Domestic demand soared by 81% while Email: vdw@vdw.de, Web: www.vdw.de
export orders were up by 66%.
During the first half of 2010, overall demand was 58% up on
the preceding year’s figure. Domestic customers ordered 51%
more than in 2009, while export orders rose by 61%.
“The order engine is running at full throttle again,” comments
Dr Wilfried Schäfer, Managing Director of the VDW (Ger-
man Machine Tool Builders’ Association) in Frankfurt. “The
steepest slump in the history of the machine tool industry Sheave wheels for India
has now been followed by the highest growth rates we’ve KEW Foundries was awarded the contract to supply the
seen since the early 1970s.” What he finds particularly Shaft Sinkers group with sheave wheels to be used on the
gratifying is the high rate of growth in domestic demand largest joint sector hydroelectric project in India – the Teesta
during the year’s second quarter. This, he adds, shows that Hydroelectric Project for Teesta Urja Limited. The project
production output has found its feet again in wide sections marks an expansion of the Shaft Sinkers operations portfolio
of German industry. into arenas outside of commodity mining, and is the first
Other important statistics for machine tool trends are also Shaft Sinkers project to be conducted on Indian soil.
pointing upwards. Capacity utilisation has climbed from “KEW Foundries is our preferred supplier when it comes to
its nadir in the middle of last year, at 65.9%, to 76.3% in sheave wheels,” says Petra Dippenaar, Group Procurement
June of this year, while the order backlog, following its low Manager, Shaft Sinkers. “With the success and safety of a
point of 5.6 months in October 2009 has recovered to 6.9 project hinging on critical components such as sheave wheels,
months in June of this year. it makes nothing but perfect business sense to utilise a sup-
In view of the downsized total capacity, however, this may plier which has consistently delivered the highest quality
be regarded as encouraging. At the end of the year’s first products, and has a proven record of excellence.”

Advanced Materials Today Sep/Oct 37

Industry News
KEW Foundries has worked together with METS, the mining
and engineering technical services division of Shaft Sinkers,
to design and develop the sheave wheels for the project. In
total 43 sheave wheels have been supplied, with diameters
ranging from 960mm to 2 555mm. Comprising the order
are four Kibble sheave wheels, nine stage headgear sheave
wheels, five sliding sheave wheels and 25 stage sheave
wheels.
The diameters of the 43 sheave wheels supplied for this project range
from 960mm to 2 555mm
The project, located in India’s Sikkim province, involves the
sinking of two pressure tunnels known as the Teesta – 1 200
MW Pressure Shafts, which will both have final diameters
of 5.4 metres and total depths of 630 metres. The tunnels
are expected to take two years to sink.
KEW Foundries, Jaime Goncalves, Tel: (053) 841 0474, Fax: (053)
841 0473, jaime@kewfoundries.co.za, www.kewfoundries.co.za
Conveyors manufactured
Swiss manufacturer Beutler Nova, a subsidiary of the
Schuler Group has supplied a C-frame press with a press
force of 250 metric tonnes to local company, Lorbrand for
conveyor manufacturing.
Located near Johannesburg, Lorbrand had already been
manufacturing on two Beutler Nova presses since late 2007
– both C-frame presses with forces of 100 and 250 metric
tons. The third press has been installed to produce rollers
for conveyor belts, which are needed in gold mines. The
mines are located between Johannesburg and Pretoria and
have been dormant for over 70 years. They are now being
reactivated as a new chemical separation process and much
higher gold price has made them economic again.
38 Advanced Materials Today Sep/Oct 2010
“We are in close contact with our South African customers,”
explains Hans Schaerli, CEO of Beutler Nova. Within the
Schuler Group’s Blanking and Forming Systems division he
is responsible for the South African market and is regularly
in the country.
“We work closely with our representatives Retecon in
Kempton Park which helps guarantee optimum customer
support. We are currently negotiating two other projects
with South African customers,” adds Hans Schaerli.
Retecon, Hans-Peter Neth, Tel: (011) 976 8600, Fax: (011) 394 2471,
machines@retecon.co.za, Web: www.traconsa.co.za
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Index to Advertisers
AFSA 6
Afzelia Inside Back Cover
Ceradvance 25
Chemserve 29
Craft Machine Tools 15, 22, 30, 37
FirstPro Tooling 23
Goscor Outside Back Cover
ILS 14
KEW Foundry 20
Opticore 10
Orlik Metal Chemicals 32
PBS Machine Tools 24
Rely IntraCast 32
Retecon 16
Rijva Outside Front Cover
Robor Inside Front Cover
Toyota Forklift 12
Uretech 7
Urethane Moulded Products 28
Universal 27
Advanced Materials Today Sep/Oct 39
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