WFTI SPRING 2020 FLIPBOOK EDITION

Wire Handling RMG Straighten & Cut machines haveintroducedmany revolutionaryconceptsincluding variablefrequencyACdrives, 3diearborsandourpatented “CLUTCHLESS” cuttingtechnology. Fig. 2 — Payoff units from the AHT series. RMG Model 14 Straighten & Cut Machine units with separate protective features in front With hundreds of machines in the of the straightening machine with consoles and field, the Model 14 has become a wire clamping unit. workhorse in the Wire Mesh and POP Display industries. “This enables each payoff unit to be loaded indepen- dently of the other. For example, processors can use • Broad wire diameter range of two different diameters on the payoff units without 1.3mm (.050”) – 6.4mm (.250”). requiring much set-up work. • Easy-to-adjust single offset variable pitch arbor. “WAFIOS offers this solution for wire diameters • Fast wire changeovers. from 3 to 10 mm. The WAFIOS H series Performance • Fully independent variable speed control over payoff units are new additions to the portfolio. The payoff units are produced in China, where WAFIOS the arbor and feed rolls allows operators to quickly operates its own production facility located in the maximize throughput and quality for each application. city of Zhangjiagang. • Reduced learning curve for new operators. • Real time, Micro-Fine length control system for “As ever, the engineering processes take place at greater accuracy. the company’s Reutlingen, Germany, headquarters, harnessing the design expertise that has been estab- www.rmgfelm.com lished there over many years. 14343 Industrial Parkway South Beloit, Illinois 61080 “The WAFIOS Performance payoff units are cur- [email protected] 815.624.2500 rently being provided to customers offered in three Spring 2020/Wire Forming Technology International 49 expansion levels. These are the H3, H3V and H7 Performance payoff units (see Figure 2).” www.wafios.com ContinuFeTdI...

Wire Handling Roundup Revolutionary New Straightening Modules sent the essence of the straightener product. They are for use in the Production of Fasteners reduced to the absolute minimum, just like the world- famous toy bricks from Denmark. Marcus Paech of WITELS-ALBERT GmbH, Berlin, Germany, says, “The handling, productivity and value Alternating mounting of straightening modules retention of components for straightening process on base plates in two planes. materials are of essential importance. The saving of resources and the aspects of sustainability and flex- “The majority of famous designers follow the design ibility of products influence the economic efficiency concept of simplicity. The results of our efforts over the during the life phase and will decide in the future on months are simple as well, but nevertheless offering the use of the products. an impressive variety and great possibilities. “With this in the background, the technical design of • Just one type of module per size is used for a straighteners and straightening systems, their manu- facture in well adjusted quantities and the exploita- straightener or a straightening system. tion of the technical possibilities of the straightening • Manless and fast mass production of straighten- process are important influencing factors, which offer scope for creative reflection and further improvement ing modules ensure a good availability and price of the understanding of the process. for customers. “As a manufacturer of components, WITELS-ALBERT • Revolutionary new straightening modules series GmbH is committed to this environment and presents for use in the production of fasteners. a revolutionary new concept for the design, manufac- • Simple and fast assembly of straightening mod- ture and use of straighteners and straightening sys- ules and straightening modules to straighteners tems with the introduction of the SM series of straight- and straightening systems. ening modules. Inspired by the very popular toy bricks • Enlarged straightening ranges (min. and max. from our northern neighbor, Denmark, which have process material diameter) with smallest possible been part of a cleverly designed modular system for roller spacing. generations, WITELS-ALBERT GmbH transfers the • Optimization/extension of straightening ranges basic idea of discretization to the design, manufacture (min. and max. process material diameter) by and use of straighteners and straightening systems. means of easily adjustable roller spacing or ex- The bricks of the straighteners and straightening sys- works adjustable roller spacing, e.g., for process- tems of the future are the new straightening modules ing specific profiles or tubes. of the SM series, which are optimized in every detail. • High flexibility with regard to the number of roll- ers per plane. Concept design of using SM series • Sale of straightening modules with or without straightening modules. basic and cover bars. • Client-side design of specific base and cover bars “This optimization is accompanied by the project for specific applications. planning, the design and concerns in particular the • Scalable design for straighteners and straightening production of the module bodies by modern CNC ma- chines without personnel employment as well as the assembly of the straightening modules, straighteners and straightening systems in short time. The calcula- tion results of the project planning determine binding specifications for the designs that focus on simplicity and minimization of the number of individual parts. That is why SM series straightening modules repre- 50 Wire Forming Technology International/Spring 2020

Wire Handling systems in terms of roller spacing and number of rollers. • Compatible accessories for straightening mod- ules for ensuring straightening processes in up to four straightening planes per straightening system including inlet and outlet guide blocks. “Using straightening modules, the SM series pow- ers the generation of value-added products. It gives freedom for customer innovations, as other con- figurations can be created by using the possibilities the straightening modules offered and by adding accessories and peripheral equipment. “WAirte aForlmoiwngeTrecchonoslto,gyoIuntrerncautiosntaolmersAhprailv2e7, t2h02e0 freedom tWoirienHfalundelinngce the production design and to be more aAgsitlraei.g”htewnwanwd c.wut imteaclsh-inael'bs eprrotd.cuoctmivity is increased by 15% - 20% with the correct wire payoff equipment. Rockford Manufacturing Group has developed solutions that improve operator setups, product quality with Hredeucaedvdyow-Dntimue.ty Powered TRMuGr’ns Htaeabvyl-DeustyBPoowoeresdtTPurnrtoabdlesuacrettihve mitoyst durable available. We KhpoaivwreekerelidmPtiurnroanttseadsbletehrseipnorotfhbelRemmoaarctkikcetcf. hoTahrinedsseaMtnudrnbateanlbtsluecsfuhararcevnteutlfyurluilysneadguotonGmmarotoisctup (sRpeMed cGon)t,roSl toousytnhchBroenilzoeitth,e IfeLed, rUateSwAit,h sthaeystsr,aig“hAtensatnrdaciugthten atmymoonaau2ccdrhh0oiicnn%peeue.rwtawBtiyomthiritstcahhoaeclnathuthaisncieehngioceetfhvo’elesarlrtreghpaeeedrrcbocetenodswidtluspoi.orfcBsettsheiicepbvalwaueitsiypyreeeotrhfiffrosefosrmmeeinqpatnhcoucewreiewepfraeremoisdgmehteutdtnrhoneftbta.tphbyRreloeo1dcsuo5cscitkl%ta,iro-tn faondrdstoMp aautnomuaftaiccatlluyrthinerge isGnrooinuteprachtiaosn rdeqeuvireedlowpiteh dthesoopleurattioor,ns tkheeaptinigmthpemrosavfeelyoinpferornattoofrthseeptroudpucsti,opn rmoacdhuincetwqheureatlhietyybewlointgh. reduced downtime. Model 6450 VF powered turntable. MELC SERIES OF STRAIGHTENING “MROMDEGL’6s45H0 VeaFvPyO-WDEuRtEyD PTUoRwNeTrAeBdLETurntables are the MACHINES: most durable available. We have eliminated the • Maintenance Free Hyperbolic Rollers’ Rotor Straighetning System (Patented) problematic chains and belts currently used on most • Perfect Unmatched Straightening, powered turntables in the market. These turntables Outperforming All Other Methods have fully automatic speed control to synchronize • Processing Up To 50mm Low Carbon Wire, 36mm Stainless Steel, 28mm Re-Bar the feed rate with the straighten-and-cut machine. By • No Material Surface Damage (Frictionless isolating the lead end of the wire from the weight of Straightening) Material Waste Elimination the coil, your operator can achieve the best possible • No Straightening Adjustments & Minimal Labor Requirements performance from the production machine with the • Automatic Coil Opening, Wire Feeding & use of larger coils. Because these powered turntables Coil-End Extraction start and stop automatically, there is no interaction • Zero Operator Involvement required with the operator, keeping the operator EUROBEND GmbH Alexander Str. 1 safely in front of the production machine where he D-90547 Nürnberg-Stein GERMANY or she belongs.” Tel +49 911 949 89 80 [email protected] www.rmgfelm.com WFFTTII www.eurobend.com Spring 2020/Wire FormingTechnology International 51

Case Study: Failure Analysis of Springs for the Rail Industry by: Failure analysis and testing services help Holly Greenhalgh companies understand why springs fail and Marketing and Events Coordinator what steps can be taken to improve spring life. Institute of Spring Technology Henry Street, Sheffield South Yorkshire, S3 7EQ, UK www.ist.org.uk The Institute of Spring Technology (IST) has been of one such failure will be summarized in this piece long held as the center for excellence within the spring to highlight the techniques used in our investigations. industry. Producing invaluable resources since 1942 Figure 1 shows a typical failure received. The compres- has earned IST an exceptional reputation for techni- sion spring was the outer spring of a nested configura- cal know-how, impartiality and professionalism in tion with a failure located roughly one coil from the the field of springs and spring technology. Delivering end coil, located at the bottom of the suspension set up. software, testing, training and consultancy are at the core of its services. Although software and training Fig. 1 — A typical failure received by the IST. have not been part of IST’s offering since the organiza- Figure 1 shows that protective coating had been re- tion began, failure analysis and testing have, helping moved from several areas, especially the coil-to-coil po- companies for over 70 years to understand why a sition near the failure, and evidence of rust throughout spring failed and what steps can be taken to improve the spring. Figure 2 shows a fracture face, indicating its life. In this article, IST explains what a typical failure rust was present not only where the coating had been analysis looks like and what it entails. removed, but also on the fracture face, making it dif- ficult to identify the root cause of failure. Propagation Springs are often critical components and are found in marks from a fatigue failure are visible through the cor- a huge number of products across many sectors includ- rosion on the surface, emanating from the coil-to-coil ing medical, oil and gas, aerospace, automotive and position, indicating failure occurred from damage in rail. Until a spring has failed, the true impact is never this position. It would be easy to say the spring failed fully understood in how vital a role these components due to fatigue, initiating from damage at the coil-to-coil play. Understanding springs is our business and as an position, but that might not be the case. impartial association and not-for-profit organization, we are at the heart of the spring manufacturing indus- Fig. 2 — One of the fracture faces. try dedicated to supporting businesses worldwide. Focus on the Rail Industry IST has built a close relationship with the rail sector over the years, mainly driven by the high volume of springs needed. Guided by this need, rail industry pro- fessionals are always looking to find ways to improve a spring’s performance, find out why a failure occurred and what preventative measures can be taken. The train industry, like most transport sectors, has safety critical springs where failure could lead to property damage, injury and in the most serious cases, death. Thanks to redundancies and safety procedures, the failure of one spring is unlikely to cause any dam- age or injury. However, it can have a huge financial impact with rolling stock being taken off track for maintenance. Therefore, spring failure not only needs to be understood by determining the mechanism of failure and the root cause of that failure, but recom- mendations need to be made to reduce the risk of failure occurring again. We have performed several failure investigations for the rail sector, mainly focusing on nested springs within the suspension system in the bogie. An example 52 Wire Forming Technology International/Spring 2020

More to the Story... and damage seen throughout the coil-to-coil position. If the spring had not failed due to a surface defect, this SEM, EDS and microstructural analysis are also im- wear would have probably caused premature failure. plemented to determine if there was anything else The damage seen in this region was not as significant that could have led to the failure. Further examination as the matching region at the other end of the spring. showed that the damage seen close to the initiation was This indicated that the orientation of the spring within most likely post failure damage as it was only present the seats also might not be optimized and should be on one of the fracture faces. SEM imaging (Figure 3) examined further to reduce damage to the surface and highlighted a small surface defect at the apex of the the coating on the spring. initiation indicating that the failure might not have been due to damage or corrosion, but to a material Long Experience in Failure Analysis defect. Micrographs of the material showed that there were larger than expected surface defects and large While there are several facilities worldwide that can carbides had formed close to the surface. Due to the number of issues we found with the spring, perform failure analysis on mechanical components, it was not clear exactly what had initiated the failure: corrosion pit, damage, microstructural abnormalities very few of them have the over seven decades of ex- or surface defect. However, in our experience the fail- ure most likely initiated at the surface defect shown in perience in spring design, manufacture and failure Figure 3, and it was accelerated by corrosion, and the damage to the bar was caused post failure. that we have. We truly understand every process of a Fig. 3 — SEM image of the initiation point of the failure. spring, from design concept through to wire choice, Based on this analysis, recommendations were sug- gested to not only reduce the possibility of future standards, production methods, final use and how it failures of this nature, but also to improve the spring to limit reoccurrence of any of the issues seen. performs in situ. This knowledge means we can iden- Carbide formation and poor surface quality indicate that either the raw material was not up to standard, tify the source of a failure and suggest improvements, or the processing parameters used during hot coiling were not optimized. We recommended spot checking giving the customer the performance from a spring the material as it entered the facility, and we were able to recommend processing variables to reduce the while reducing the likelihood of future failures. probability of hot coiling causing defects in the mate- rial. A nondestructive check of the final product was IST continues to work closely with the rail industry and also suggested to reduce the chances of poor-quality springs reaching the market. supports its needs as the demand on the rail network Although the damage at the fracture face was deter- mined to have been cause post failure, there was wear grows. This industry plus many others could benefit from IST’s custom software, Spring Calculator Profes- sional (SCP). Already used by hundreds of companies globally, SCP has simplified a large portion of spring design and validation helping to highlight potential problems before a spring is even made. Extensive fatigue life and relaxation predictions built into the software are unsurpassed and invaluable for users validating springs for use under real-world constraints. www.ist.org.uk • www.springcon2020.com WFTI Company Profile: The Institute of Spring Technology (IST) is recognised as the spring industry’s most authoritative and influential voice for spring design, manu- facturing, training, test- ing and failure analysis. We are a unique centre of excellence for spring technology, enjoying an unrivalled pedi- gree and reputation stretching back to 1942. We have a fantastic reputation for metallurgy and steel-mak- ing knowledge, it only seems right that home of IST should be in Sheffield in the UK. We are right at the heart of the global spring making industry, covering all aspects of research and development, software, problem solving and testing. Our software, Spring Calculator Professional (SCP), is rec- ognized as the smartest spring design software worldwide. It is packed with an impressive range of international design standards, materials data, relaxation prediction and fatigue data available to everyone as standard. SCP can predict the behaviour of a spring under different environmental and oper- ating conditions. Hone your design to see how it will perform under real-world conditions like limited space and visualise your work with 3D modelling and working animations. More info at www.ist.org.uk. Spring 2020/Wire Forming Technology International 53

Presentation of a Study and Realization of a Special Machine by: Eliminating slow production, long Jean-Marc Baudrand changeovers requiring qualified 31 rue Laure Diebold 69009 Lyon, France personnel, high maintenance costs, www.baudrand-new-tech.com long downtimes and unreliable quality. Baudrand New Tech is proud to present its ability Double rotary straightener. to develop special equipment to meet specific needs, which is an area that many machine manufacturers are neglecting. The French company is currently witnessing a renewed interest in process integration. As its Managing Direc- tor says, “It seems to us that European wire forming companies, in general, and French in particular, are increasingly turning away from subcontracting. Ap- parently their suppliers’ margins of maneuverability are at their minimum, and they cannot go any lower. The only solution to reduce costs is now to integrate added value, therefore to manufacture in-house when volumes justify it. And volumes justify an investment more quickly than one might think: a production ma- chine is often paid for in two to three years maximum, if not within a year.” An Equipment Design Challenge Indexable rotary table - two views (above and below). Baudrand New Tech was approached a year ago by a ing to speed up the feeding, bending and chamfering producer of special technical staples used in the con- operations. The production rate is set at 120 staples veyor belt industry. per minute. The process for this machine is as follows: • Two coils of wire are placed on two motorized The aim was to replace the existing old wire bending machines. The use of obsolete technology imposed unwinders. high maintenance costs and long downtimes. The company’s production was slow, changeover times were long, they required highly qualified personnel and, moreover, the dimensional quality of the products was not stable. This is a textbook case—the disadvantages cited are often found when standard production equipment is designated to carry out, as far as possible, a specific production. In order to cover the high volumes of staples required on the market, and to substantially improve produc- tion, the decision was taken to opt for a custom- developed machine. The custom machine provided by Baudrand New Tech is capable of processing wire up to 3.5 mm diameter, with total developed staple lengths up to 100 mm. The products leave the machine directly with both ends chamfered at 30°. The raw materials come from two coils of wire, each of which are placed on a motorized dereeler with a capacity of 1000 kg, so as to double the production rate without having to bear the inconvenience of hav- 54 Wire Forming Technology International/Spring 2020

feed rollers, with quick clamping and opening. Each set is driven by its own motor. To avoid any possible slippage in the wire feed, the encoders take their rotation directly from the running raw materials. • The cut-to-length wires are fed and held on an in- dexable rotary table with horizontal axis. The table moves the cut wires to an end chamfering station and then to a bending tool. Each step is validated by sensors. The operator can control and monitor the entire process via a colour touch screen. Videos of the machine in operation will soon be placed on Baudrand New Tech’s website. www.baudrand-new-tech.com WFTI Parts made on the Baudrand New Tech machine. Company Profile: A specialist in equipment for industrial production • The wires pass through a double rotary straight- of metal wire and strip, Baudrand New Tech offers ener, whose mechanical positioning is ensured spring forming machines, multi-slide benders, mesh by a motorized system, digitally adjustable and and reinforcing armature welding equipment and reproducible. straightening-and-cutting lines as well as special ma- chines. Baudrand New Tech provides design, manu- • The main machine processes the wire in discon- facturing, assembly and tooling adjusting for many tinuous mode, and the unwinders feed the raw brands. Also offered is second-hand equipment from materials at fairly continuous speeds. In order to diverse manufacturers, available and guaranteed. synchronize the two systems, a double raw mate- www.baudrand-new-tech.com rial accumulation loop has been created between the two sub-assemblies. • Each wire feed is provided by a double set of four Spring 2020/Wire Forming Technology International 55

Spring Coiling Roundup compiled by the Editors at Wire Forming Technology International Suppliers have responded to our call for the state-of-the-art in spring coiling equipment and technology. New Spring Machine Solves Difficult 14 axis feedback at the same time) and can be custom- Challenges for Larger Size Springs ized depending on customer’s requirements. Constantine Grapsas, President, AIM Inc., Addison, “Reduced setup time: New, innovative machine design IL, USA, says, “AIM Inc., an active machinery exporter, minimizes the set-up time required. All the tables and is proud to announce our partnership with PLUS- tool holders include measuring scales allowing short PRINGS CO., a Taiwan-based manufacturer. The set-up time, repeatable between changeovers. NX-500F spring machine is an exciting new product created to solve difficult manufacturing challenges in “Great Flexibility: The NX-500F with three compound larger size springs. With this machine, spring making tables enables eccentric working without additional is possible with high-speed, high-precision and high- tooling requirements. In addition, it creates a larger power capability at an affordable price and with great work zone providing more flexibility. The concept of AIM support. the Triple Compound Table (TCT) system minimizes the tooling cost and creates a simple way to cope with “AIM product offerings will include new spring ma- complex products and accelerate set up. chines, complementing its existing lines and extend- ing the solutions available under one roof. The new “Efficient and Modular High Production: Reduced set-up spring machines are manufactured with top-shelf time and tooling cost, stable and high-speed output components at the PLUSPRINGS facility with the co- guarantees successful business. The extraordinary operation of AIM Inc. experts, in most cases, common design structure allows manufacturing of highly with the existing AIM machine components. AIM will complex bending sequences. The Triple Compound be stocking replacement parts and provide prompt Table (TCT) provides higher processing speed, and support to all of our customers’ needs from our North the measuring scales create the convenience of tool American and European facilities. positioning repeatability and ease of tool manage- “The NX-500F spring machine is a unique solution ment. NX-500F is one of the unique solutions tailored tailored to the demands of the wire forming indus- to the demands of wire forming industry. try. It incorporates a Triple Compound Table (TCT) System and provides efficient and reliable production “Versatile, Powerful and Reliable: The base NX-500F with reduced set-up times and great flexibility. It is model includes 11 axes. Total of six axes situated on equipped with nine to 25 axes while being able to the three individual compound tables controlling X handle 0.5 to 5 mm spring wire, with an 8 mm (5/16\") and Y movement; one axis for wire feed, one axis for capacity coming soon. Options include a servo cut- wire rotation, one axis for quill rotation and two servo ter, double spinner, servo stamping, external feeding spinners. The new design concept allows the opera- device, Easydur Camera inspection system (maximum tors to materialize their ideas and at the same time provides a larger work zone for easiness of service. The system can be upgraded to a maximum of 25 axes, equipped with up to 14 feedback sensors and multiple camera inspections with active corrections. “Demonstrations, parts and service are available in the company’s Chicago, IL, USA location. “AIM Inc., with head- quarters in the USA and with a second location in Europe, is committed to innovation, top qual- ity and rapid response tech support. The com- pany manufactures the broadest line of wire bending machines in the world, from below 1 mm to over 25 mm wire diameters. AIM uniquely qualifies as the premier wire automation company. The AIM, Inc. motto is, ‘Forming our future with yours’.” www.AIMmachines.com / www.plusprings.com 56 Wire Forming Technology International/Spring 2020

Spring Coiling Roundup Formers & Benders with ing Industry 4.0 standard. A simple user-friendly inter- New Software Infrastructures face combined with refined input controls streamlines the spring editing process and enhances production Billy Z. Lin, Operations Manager, VINSTON US efficiency. Implementation of fine-tuned algorithms CORP., Wheeling, IL, USA, says, “In anticipation of with increased computation power for finer motor emerging Industry 4.0 standards, VINSTON and JYF control. Wireless network connectivity together with will be introducing new software infrastructures in an embedded camera system also offers real-time 2020. The formers and benders will keep the existing remote production monitoring. This also allows users user-friendly interfaces, but will offer additional mod- to submit and receive technical correspondence in a ular options to facilitate easy replications of standard timelier manner. By Adopting EtherCAT technology, it sections of components. Network capabilities and a opens the possibility to expand production capabilities camera system will provide easy documentation and within the JYF control system.” technical inquiries. The new infrastructure will also www.vinstonus.com facilitate more multi-media notes regarding current projects such as critical point designations and video documentation. Aggregate data on machine run time, set up and idle durations will become available at the server level. Tooling Design Solves Spring Coiling Challenges “The JYF coilers will be implemented with a rede- Ambrose Fickel of Automated Industrial Motion signed central control interface. Along with refined Inc., Fruitport, MI, USA, says “Automated Industrial input controls, the spring editing process will be sim- Motion (AIM) is a world-class leader in the design plified and provide increased production efficiency of spring coiling equipment and tooling. For over 35 through faster computations and finer motor controls. years, we have been working across various indus- Wireless network connectivity and the adoption of tries to solve some of the most difficult spring coiling EtherCAT technology will facilitate more real-time challenges. New and unique tooling designs were production monitoring and aggregate data collection. often required to solve many of these challenges. The Precision Torsion Roller Point is one such solution. “Wire Formers/Benders: The new VINSTON wire formers/benders will introduce the newest software “Roller points have long been used in place of fixed system. The new system will facilitate requirements of the emerging Industry 4.0 standard. The user-friendly points to reduce forming pressures and increase pro- interface will be complemented with additional modu- lar options to facilitate easy replications of standard cessing speeds and surface quality. The benefits of sections of a component. Network capabilities and a camera system will provide easy documentation and using a roller point are even more pronounced when technical inquiries. The new infrastructure will also facilitate more multi-media notes regarding current coiling soft materials. Experienced coilers will tell projects such as critical point designations and video documentation. Also, aggregate data on machine run you however that the traditional roller point has its time, set up and idle durations will become available at the server level. drawbacks. Firstly, the yoked roller cannot be used to “Spring Coilers: The new JYF spring coilers will now be create torsion springs because the straight leg interfers outfitted with a redesigned central control system. The new system will facilitate requirements of the emerg- with the yoke as the leg rotates during forming. An- other limitation comes from the roller itself because it will introduce variation in a coil due to a fluctuat- ing contact point with the wire. Furthermore, roller points are more costly to produce and more difficult to replace than a traditional fixed point. And finally, the larger size of the roller as compared with a fixed point, will reduce the processing speed when torsional movements are required. Continued ... Spring 2020/Wire Forming Technology International 57

difficult spring coiling challenges. New and unique tooling designs were often required to solve many of these challenges. The Precision Torsion Roller Point is one such solution. Roller Points have long been used in place of fixed points to reduce forming pressures and increase processing speeds and surface quality. The benefits of using a roller point are even more pronounced when coiling soft materials. Experienced coilers will tell you however that the traditional roller point has Spring Coiling Roundupits drawbacks. Firstly, the yoked roller cannot be used to create torsion springs because the straight leg interferes with the yoke as the leg rotates during forming. Another limitation comes from the roller itself because it will introduce variation in a coil due to a fluctuating contact point with the wire. Furthermore, roller points are more costly to produce and more difficult to replace than a traditional fixed point. And finally, the larger size of the roller as compared with a fixed point, will reduce the “Using the information gathered from industry expe-processing speed when torsional movements are required. rience and working to solve the shortcomings of theUsing the information gathered from industry experience and working to solve the shortcomings of the standard yoked roller AIM developed the Precision Torsion Roller Point. (Patent Pending) This all new standard yoked roller, AIM developed the Precisionroller point features a cantilevered roller with integrated shank and an offset groove. The straight legs of a standard torsion spring can swing freely past the face of the roller. Rollers are available in all wire sizes Torsion Roller Point (patent pending). This all newand custom groove profiles are possible. roller point features a cantilevered roller withA revolutionary aspect of this new design is the shank which creates a tight fit between the roller and inte- bearing while at the same time allowing for easy and quick roller changeout. Rollers can be changed in grated shank and an offset groove. The straight legsas little as a few seconds. The tight, rigid connection results in maximum stiffness; essential for precision coiling, while at the same time allowing for a compact design; necessary to reduce travel when torsional of a standard torsion spring can swing freely past themovement is required. face of the roller. Rollers are availableFinally, because rollers use the same bearing and holder, the invested tooling cost in all wireis significantly less sizes than traditional roller points. AIM is excited about making the Precision Torsion Roller Point available to and custom groove profiles are possible.our customers and look forward to partnering in your success! AIM’s Precision Torsion Roller Point “A revolutionary aspect of this new design is the shank, which creates a tight fit between the roller and bearing while at the same time allowing for easy and quick roller changeout. Rollers can be changed in as little as a few seconds. The tight, rigid connection results in maximum stiffness; essential for precision coiling, while at the same time allowing for a compact design; necessary to reduce travel when torsional tungsten and other materials. Machines are available to cover wire diameters from 0.0010\" to 0.0420\". We movement is required. offer the most advanced CNC control systems with interactive HMI interface, process monitoring features “Finally, because rollers use the same bearing and and fully integrated automatic parts handling systems holder, the invested tooling cost is significantly less based on specific user needs. than traditional roller points. AIM is excited about making the Precision Torsion Roller Point available to its customers and looks forward to partnering in your success!” www.aimcoil.com Multi-Axis, Single-Point & “Also, The KINECOIL Division continues to support Two-Point CNC Spring Coiling Equipment the Sleeper & Hartley spring coilers and torsion ma- chines worldwide and still offers the Model 7900 and Mark Russell, Sales Engineer , KINECOIL Division, 790 high-speed mechanical coilers for high-volume Kinefac® Corporation, Worcester, MA, USA, says, production needs where CNC is not always necessary. “KINECOIL Division, Kinefac Corporation, a wire coiling technology leader, offers multi-axis single- “Our Process Development team works with custom- point and two-point spring coiling equipment for a ers in the early stage of product development to design wide variety of industries. coil attributes that are technically feasible.” www.kinecoil.com “We also introduced our new Two-Point/Single-Point KineCoiler multi-axis CNC coiling system designed to produce springs using wire diameters from 0.0050\" to 0.030\" at the level of precision required by many of today’s demanding tight-tolerance applications. “We also continue to offer our Single-Point MicroCoil- er System designed to produce very precise small coils and springs using wire diameters from 0.0010\" to 0.0060\". With nearly 20 years of experience working with ultra-fine wire, our engineers and technicians work with the customer in developing engineered solutions for fine wire coiling applications including spring design, tooling development and prototyping. “KINECOIL also offers turnkey engineering solutions for spring design, development and prototyping us- ing common spring wires as well as platinum alloys, 58 Wire Forming Technology International/Spring 2020

Spring Coiling Roundup Newly Redesigned Spring CNC 2-Axis & 5-Axis Spring Coilers Coiler Models Capable of 100,000+ PPH Information from A&D Trading LLC, Rock Creek, Jessica Morgan, Marketing Coordinator, FENN- OH, USA, says, “A&D Trading LLC supplies the spring Torin, East Berlin, CT, USA, says, “FENN is proud and wire forming machinery available from Primera to offer a variety of metal forming equipment includ- Precision Taiwan CNC Spring Machinery. ing both single and dual-point Torin spring coilers. FENN’s newly redesigned FZ-10 and FZ-810 have the “A&D Trading is also the USA Agent for the equipment capacity to produce over 100,000 PPH. Wire ranges for offered by SHINKO. the FZ-10 are 0.008\" to 0.028\" (0.20 to 0.70 mm) and for the FZ-810 are 0.010\" to 0.040\" (0.25 to 1.0 mm). These “The equipment available from A&D Trading LLC models include state-of-the-art programming and are includes 2-axis spring coilers, 5-axis spring coilers, available in four, five or six axes. CNC spring coilers, two-dimensional wire benders, and three-dimensional wire benders as well as the “We have also redesigned our FZ-100 model, wire company’s Auto Decoilers and SCADA production range of 0.003\" to 0.015\" (0.076 to 0.38 mm), primarily control system.” www.adtradingllc.com used for medical solutions and micro-electronics. To- rin’s latest software combines many high-tech features Spring Coilers Providing paired with its classic CNC-style programming, mak- Cost-Effective, Long-Term Performance ing training easy for current Torin operators. Information from BB Spring Technology Srl, Casnate “FENN includes training with the purchase of every con Bernate (CO), Italy, says, “BB Spring Technology new coiler, either at our East Berlin location or the cus- was founded in 2014 by specialized engineers and tech- tomer’s facility. We make support a priority and offer nicians in the production of spring coiling machines. remote access support and diagnostics as well as on- Our initial core business was to support the Bobbio site service calls and complimentary phone support. brand machines worldwide. Seeing the market’s need Our team of local, factory-trained service technicians for a quality spring machine, BB Spring introduced its are here to maximize your uptime and productivity. first new coiler in 2016. “Our engineers have more than 30 years of experi- ence accrued in the spring field, always keeping up with new technology and supporting our company vision of: ‘innovation, development, superior service and quality’. “Our primary focus is to meet the stringent and unique demands of our customers, thus requiring the most advanced engineering and manufacturing, all at a competitive price. All mechanical parts of our coilers are manufactured in Italy, with guaranteed European raw material, ensuring a superior quality product that will continuously perform at an exceptional level over the long term. “Wire Machine Systems located in Fort Wayne IN, USA, is the North American representative of BB Spring Technology.” www.bbspringtechnology.com / www.wire-machine.com “The Torin line of coilers can produce a variety of High-Speed Spring Forming Machines spring types including compression, extension, tor- sion, magazine, belting, rings and wire forms with Information from Forming Systems, Inc., Schoolfcraft, wire diameters ranging from 0.003\" to 0.750\" (0.076 MI, USA, says, “Forming Systems, Inc. represents to 19 mm). All of FENN’s Torin coilers are designed HTC Spring Machinery, a world leader in design and and built in Connecticut in the USA.” development of high-speed spring and wire forming www.fenn-torin.com machines. “HTC specializes in precision 2, 4, 5, 8, and 12-axes CNC production machines for the manufacture of compression, extension, garter, torsion, double torsion Spring 2020/Wire FormingTechnology International 59

Spring Coiling Roundup springs and wire forms. HTC is recognized for supe- on assisting manufacturers of spring and wire forms, rior performance, service, reliability and continuous metal stampings and OEMs producing their own product development. Spring forming equipment is in-house production with cost-effective innovative, offered for wire sizes ranging from 0.06 to approxi- manufacturing solutions and technical support. From mately 18 mm.” www.formingsystemsinc.com turnkey, ready-to-go machines to fully customized solutions suited to manufacture your complex part or Spring Coilers Feature Cutting-Edge assembly, Gibraltar Corp. will help you find the right Mechanical Systems & Control Technology solution to fit your needs and budget. Andreas Sigg of WAFIOS AG, Reutlingen, Germany, “Gibraltar represents Simco Spring Machinery Co. says, “The FUL series of spring coiling machines meets Ltd., one of the oldest and most respected machinery the highest standards. In combination with a high trading companies in Taiwan, which focuses on high- degree of user-friendliness, the machines are designed quality and affordable machinery solutions.” with maximum productivity and quality in mind. www.gibraltar8.com Coiling Machines Ranging from Simple to Complex Systems Information from RK Trading Company, Elk Grove, IL, USA, says, “RK Trading offers a broad range of products ranging from simple and inexpensive basic machines to technically sophisticated coilers and formers. Distinguishing characteristics of all of these products include their user-friendly programming, versatile features and rugged construction. “The models that end in a ‘6’, which include the new “Herdon spring coiling machines available from RK FUL 166, represent the latest stage of development and Trading Company include: feature cutting-edge mechanical systems and control technology.” www.wafios.com • CSC Series Spring Coilers in 2, 3 and 4-axis mod- els, are an affordable alternative to conventional CNC High-Speed Spring Coilers mechanical coilers. With high rates of production while maintaining a high degree of accuracy, they Information from Simplex-Rapid Srl, Milan, Italy, are a moderately priced entry into CNC machines. says, “Since 1948, Simplex-Rapid has been present on Available in models ranging from 0.8 to 5 mm all world markets thanks to its production of spring max. wire size with single or double point coiling. making machines. The company has been constantly increasing its market share over the years, thus pro- • CA Series Coilers are up to 6-axis coilers with gressively increasing the size of its own factory, which touch screen programming and spring templates. presently covers a footprint of some 25000 m2. They have an integrated Micro Studio Camera Gage System and four cut-off types including “Simplex-Rapid spring coilers include CNC coilers straight, swing, elliptical and twist. These ma- FX-series for high-speed production of right-handed chines are available for wire sizes from 3 to 20 mm. springs 0.1 to 3.00 mm (0.004\" to 0.012\"); CNC coil- ers MX-series for high-speed production of right/ • HCS Series Coilers are high-speed 5-axis coilers left-handed springs 0.1 to 3.00 mm (0.004\" to 0.012\"); for high-volume jobs. They also have an integrat- Multi axes CNC coilers MC-series (12 axes) for critical ed Micro Studio Camera Gage System and offer compression springs 0.1 to 8.0 mm (0.004\" to 0.032\"); four different cut-off types including straight, CNC coilers MT-series for producing both springs swing, elliptical and twist. These machines are with straight or shaped shanks RH and LH bends and available for wire sizes from 0.8 to 8 mm. springs with nonround section; and CNC coilers GX- series for garter springs.” www.simplexrapid.it “Since RK’s inception, the company has rigorously Cost-Effective Spring Forming adhered to the following principles: providing its cus- Solutions for Spring Makers & OEMs tomers with technically advanced, well-constructed Information from Gibraltar Corp., Northbrook, IL, USA, says, “Founded in 2005, Gibraltar Corp. focuses machines at reasonable prices, dealing with customers in a highly ethical manner, honestly and with integrity and providing exemplary after-sales service both in parts, service and technical support.” WFTI www.rktradingusa.com 60 Wire Forming Technology International/Spring 2020

It’s Not Funny!!!! by: Dr. Roger N. Wright Light-Bulb-Quality Roger N. Wright, LLC Developments 600 State Street Lawrenceville, IL 62439 USA E-mail: [email protected] www.rnwinc.com The incidents and technical situations in these Their host readily understood, but added: columns were, in fact, encountered in the author’s “Even so, the procedure is much worse than it professional practice. Names and places have been appears.” “Why is that?” inquired the executive. changed in some cases to protect the guilty. “Well, for one, it must be understood that the light bulb burned out long ago.” In the middle of the 20th century, a group of manufactur- ing executives was touring a “third world” wire produc- And so it goes. tion facility, with an eye to acquiring some increased production capacity. They approached an area where Once upon a time a light bulb symbolized an idea, pre- scrap was being melted, en route to creating an inex- sumably a good idea. Over the course of time the wire pensive feed stock. The scrap was being loaded into a industry has had numerous light-bulb-quality develop- large cupola by an operator positioned on the “back” ments, especially in regard to high-value-added prod- side of the vessel. Unfortunately, the operator could not ucts such as tire cord, magnet wire, lamp filaments and really see the level of scrap that had been accumulated welding wire. in the vessel. That is, the operator could not really tell when the desired level of charge had been accumulat- Identify some light-bulb-quality developments in your ed. This problem was, however, “solved” by positioning segment of the industry: a helper at a location where the top of the charge could be seen. The helper would note when the top of the • Are the light bulbs still burning, charge was at the desired level, and would then turn on or burning as brightly as they once did? a signal light-bulb that could be seen by the operator, who would then stop adding to the charge, and so on. • Is the technology still working correctly? One of the executives took an interest in this proce- • Is the system in place, but no longer used dure, and proudly remarked to the group: properly? “We wouldn’t have such a control system ar- • What are the perspectives of labor, rangement in any of our plants. There is a lack management and the market place of precision, unnecessary staffing and a general regarding your light bulbs? failure to use modern process control.” Good luck!!!! FTI After 15 years of authoring Strength of Steel columns covering “hard core” engineering materials relevant to the production and processing of wires and wire products, Wire Forming Technology Intrernational (WFTI) columnist and metallurgy expert Dr. Roger N. Wright is sharing lighter and practical anecdotes in this new series of columns, called It’s Not Funny!!!! For more than forty years, Dr. Wright (MIT '65 & '69) has provided consulting and technical services in metallurgy and metals process- ing. Clients have included many of the world’s leading corporations, as well as major technical operations of the US government. More- over, Dr. Wright has had extensive experience in litigation support, working with both defendants and plaintiffs. He is highly active in industrial education, and he created the popular WireDrawing 101® www.rnwinc.com short course. His book, Wire Technology – Process Engineering and Metallurgy, Butterworth-Heinemann (Elsevier), Oxford, 2011 (ISBN 978-0-12-382092-1), is readily available from the publisher, as well as from major on-line sources. If you are looking for practical, clearly-stated information and analysis, based on the most rigorous engineering and scientific principles, visit www.rnwinc.com. Contact Dr. Wright at (618) 943-1029 or [email protected]. Spring 2020/Wire Forming Technology International 61

Innovative Spring Wire Induction Tempering Lines by: Spring wire induction temper (IT) lines offer Shawn Martin increased throughput and environmentally Inductotherm Heating & Welding Ltd. friendly water quenching medium for high Thermatool House, Crockford Lane strength spring wire that provides greater Basingstoke RG24 8NA, UK consistency for the end user. www.inductothermhw.com Radyne spring wire induction temper (IT) lines are What Are the Current revolutionizing the spring wire industry. Traditional Methods of Manufacture? methods of hardening and tempering spring wire have proven shortcomings. The Radyne IT line is highly Traditional methods of manufacturing springs in- automated, runs continuously, provides for increased volve heating discrete lengths of wire in a furnace, throughput and contains an environmentally friendly up to temperatures in the region of 1000°C. The hot water quenching medium. These factors combined wire is wrapped around a mandrel in order to create mean high strength spring wire with greater consist- the wound spring. While the wire is still hot, it slides ency for the end user. free of the mandrel and drops into an oil quench tank in which the steel hardens. After exiting the quench What is Spring Wire & tank, the hardened spring is tempered, possibly in a How is it Used in the World? batch furnace. Spring wire is a common name given to a range of Recently, oil tempering (OT) has been developed as steel wires prominently used in the manufacture of a continuous process. This involves heating the wire industrial and automotive springs. through a very long furnace, which is either gas fired Inclusive of low-alloy manganese, medium-carbon and or electrically heated. The wire is then passed through high-carbon steel wires, spring wire is a hardened and an in-line oil quench tank, hardening the steel. Subse- tempered steel alloy with exceptional yield strength. quently, the wire then runs through a tempering zone. Other materials are incapable of undergoing deforma- Typically, this requires the use of molten lead baths. tion without losing their parent shape. Spring wire OT lines are not without their intrinsic operational and differs as it retains its physical shape after undergoing environmental issues. an appreciable amount of strain. It is an inherently resilient material with excellent elastic behavior. What Are the Main Challenges with Spring Wire Production? How is Spring Wire Important to Businesses or Consumers? Traditional methods of hardening and tempering high-carbon spring wire have inherent limitations. The Businesses and consumers require spring wire for consistency of mechanical properties achieved through numerous applications including general mechanical the heat treatment process is jeopardized by direct springs, automotive suspension systems, garage door fired heating methods. This is because it is increas- springs, automotive engine valves and even aircraft ingly difficult to maintain target temperatures. There engines. are also additional costs associated with the handling Higher-strength spring wire with a greater reduction and disposal of quench oil. Environmental regulations of area not only increases the fatigue rate and life ex- limit NOx and SOx emissions, require pollution control pectancy of these end-use products, it also supports devices and impose permitting fees as higher operat- cold coiling processes as additional heat treatments ing efficiencies are mandated. Direct heating and lead are not performed after cold coiling. baths also introduce contaminants and the finished product typically requires additional heat treatment after it has been formed into an end-use product. What is the Solution? Radyne spring wire IT lines harden and temper high carbon spring steels such as SAE 9254, achieving a tensile strength of 2000 MPa with a reduction of area greater than 40%. The innovative modular system runs at a continuous 62 Wire Forming Technology International/Spring 2020

line speed of up to 165 mpm for 7 mm spring wire Radyne TFi IGBT inverters and and up to 28 mpm at 17 mm. Throughput capacity can induction heating coils. reach up to three tons per hour. Also, one and half and two ton variations are available, thus providing even line to produce highly uniform spring wire with un- more flexibility to our customers. precedented strength and hardness consistency. The system accommodates a wire diameter range of 7 to The Radyne solution is backed by a guarantee that 17 mm with a throughput capacity of up to three tons covers dimensional distortions, surface finish, defects, per hour across all diameter sizes. ultimate tensile strength and consistency. It addresses Mechanical Handling Unit. The payload used to feed problems associated with traditional processing the spring wire IT line undergoes a series of treatments. methods as it runs continuously, but efficiently. The The associated mechanical handling unit of the Radyne inclusion of an environmentally clean water-quenching spring wire IT line acts to straighten, draw, brush and system helps mitigate the regulations surrounding wash the wire. Operators simply butt-weld adjoining spring wire production. This system produces a wire coils of the payload to supply a continuous feed to with a consistently high tensile strength. Produced the line. Advanced PLCs maintain tension without spring wire is readily used for cold coiling into a necking or any undesired deformation. The handling finished product, eliminating the need for additional unit includes: heat treatment. • Rotating payoff with integral dancing arm/damper. The Spring Wire IT Lines Continued... Radyne spring wire IT lines are composed of a closed-loop handling system, in-line drawing blocks, industry-leading induction heaters, environmentally clean water quenching systems and a highly modular and automated PLC with decentralized communica- tion modules. The system maintains preset specifica- tions at each stage of the hardening and tempering INDUSTRY 4.0 READY BB-20MM phone +39 031 536584 8.00 – 20.00 mm .310 – .787 inches fax +39 031 2170001 MACCHINE AVVOLGITRICI SPRING COILING MACHINES sales department [email protected] service department [email protected] BB Spring Technology SRL Via G. Puecher, 28 22070 Turate (CO) ITALY bbspringtechnology.com ASPI REVISIONI WIRE MACHINE SYSTEMS PAYOFFS UPGRADES North America Sales Jay Griffith [email protected] 6032A Highview Drive Fort Wayne, IN 46818 +1 (260) 483-9269 wire-machine.com Spring 2020/Wire Forming Technology International 63

Induction Tempering Lines...continued • Automated pinch roll/straightening module. • Advanced PLCs/handling systems eliminate plas- tic deformation throughout quench/tempering. Water quenching system. Induction temper coils. Induction Hardening. Induction hardening uses multi- tempered wire is quenched again to enable mechanical ple induction heating coils to ensure product quality. handling. A thin protective oil film is applied to the The first section elevates the temperature of the wire finished wire to inhibit corrosion. from ambient to the curie temperature, approximately 700°C. The post-curie section further elevates wire tem- Eddy current sensors automatically locate and shear perature to a suitable hardening temperature. This is off the butt-welded joints before the wire is collected followed by a smaller induction unit that equalizes the on the take-up windmills. target temperature from the wire’s surface through its core, alleviating any residual stress. The process allows Advanced Controls —The spring wire IT line is moni- the wire to undergo an allotropic phase transformation tored and controlled by a modular and automated PLC (i.e., a metallurgical change in the metal). system with decentralized communication modules. This includes an advanced digital control system utiliz- The system uses the Radyne TFi IGBT inverters, which ing Dual Core ARM Processors. Monitors and controls are the power workhorses for the IT lines. The TFIs are are used for the pinch roller tension, mechanical drives, highly reliable offering fast response and high heating line speed and power output to induction coils. rates that work in harmony with the induction heating coils. They provide heating capacities up to 560 kW, Materials & Advanced Capabilities — Cold coiled with a nominal output frequency of 10 kHz to 50 kHz. processing of the produced spring wire allows users to form complex shapes and geometries like concave Optical pyrometers inspect wire temperature, ensuring springs, convex springs and other nonparallel geom- a highly uniform thermal profile of the wire surface. etries. Such geometries far exceed the capabilities of traditional manufacturing. The spring wire IT line can Water Quenching. The water quenching system process a wide range of carbon steels and exotic alloys consists of a 6 m trough of filtered, circulated and including high-carbon steel, silicone alloyed steel, temperature-regulated water. The system does not chromium alloyed steel and vanadium alloyed steel contain any oils or polymers, thereby eliminating pol- lution and combustion concerns, and disposal costs of Conclusion quench oils. This ensures that it is a fast, environmen- tally friendly and effective solution with cost-saving The Radyne spring wire IT line produces a defect-free, advantages. hardened and tempered spring wire with guaranteed strength consistency and reduction of area and hard- • It achieves a martensitic structure with a Rockwell ness. Benefits are increased production capacity, higher hardness in the region of 62 Rc. yield rates, greater flexibility and an eco-friendly quenching medium. The Radyne system supports the • It minimizes potential for quench cracking. trend toward cold coiled processing allowing manufac- turers to produce complex shapes and geometries for • The entire wire length experiences consistent numerous end-use applications including automotive quench parameters. suspension springs, garage door springs and general mechanical springs. www.inductothermhw.com WFTI Induction Tempering. After the phase transition, the wire is induction tempered. The hardened steel wire Company Profile: is induction heated from ambient to 450°C. A second Inductotherm Heating & Welding Ltd. is the European manufac- series of induction circuits equalize the thermal profile turing/technical headquarters for Thermatool, Radyne, Banyard through to the core of the spring wire. These induction and Newelco—leaders in induction heating and welding technolo- coils are powered using Radyne Flexitune IGBT power gies. Inductotherm serves a diverse range of applications, such as HF supplies, which are used to match process require- welding, cutting and seam annealing of tube and pipe; general induc- ments and ensure temperature equalization. The hot, tion heat treatment and hardening; induction heating for forging and extrusion applications; pre-heating prior to coating of API grade line 64 Wire Forming Technology International/Spring 2020 pipe; wire processing systems; low-frequency heating of nonferrous materials; quench and temper systems; offshore field joint processing; and induction coil design and repair. www.inductothermhw.com

Plan now to participate in SpringWorld® 2020! Join your colleagues at the industry’s premier event. SpringWorld provides a unique opportunity to network with other spring manufacturers, wire formers, and OEMs. • The premiere spring show since 1960. • One-on-one discussions with others who share your concerns offering new insights • A global showcase for suppliers to the spring and wire for your business. form industry featuring attendees from 18 countries. • Attend free educational seminars offered by • See the newest technology available to improve your exhibitors and industry experts. productivity, quality and service. We’ll see you at presented by www.casmi-springworld.org SpringWorld® 2020 October 7-9 Donald E. Stephens Convention Center Rosemont, IL

Full Speed Ahead to the Perfect Spring by: Spring coiling machine line offer numerous options and Andreas Sigg programming made easy in order to provide the highest WAFIOS AG productivity, quality output and user-friendly operation. Silberburgstraße 5 72764 Reutlingen, Germany www.wafios.com The FUL series of spring coiling machines, available mechanical systems and control technology. from WAFIOS AG, meets the highest standards. In combination with a high degree of user-friendliness, There were previously seven models available, cov- the machines are designed with maximum produc- ering spring wires ranging from 0.12 to 8 mm—the tivity and quality in mind. The models that end in a models FUL 16 to FUL 86. With the recent addition of “6”, which include the new FUL 166, represent the the FUL 166 (see Figure 1) for wires from 6.1 to 16 mm, latest stage of development and feature cutting-edge WAFIOS is significantly expanding the upper end of the range. The features are largely identical to those of the smaller sister models (see Figure 2). Wire is transported via feed rollers with pneumatic clamp- ing for all machines—the FUL 16 is the only model where the operator carries out clamping manually using spring assem- blies. The larger the machine or wire diameter, the more feed rollers used (FUL 16 to FUL 46: two pairs; FUL 56 to FUL 86: four pairs). The pneumatic contact pres- sure can be adjusted on the Fig. 1 — The FUL 166 spring coiling machine is the latest high-end WAFIOS model screen for each pair of rollers. for wire diameters from 6.1 to 16 mm. Right: The central control system consists of This concept makes it possible console trolley with PC and WPS 3.2 EasyWay programming system, 24\" touchscreen to achieve feed speeds of up to and hand-held operating device. 220 mpm. The lack of hydraulic systems here offers a major advantage. Pneumatic com- ponents require significantly less maintenance. As a result, the cutting and coiling unit has also been designed without the use of hydraulics. The FUL 166 is the first WAFI- OS spring coiler with six pairs of feed rollers (see Figure 3). However, the full complement is only required for wires with a thickness greater than 14 mm. For thinner wires, the machine fitter equips the machine with fewer rollers as is appropriate. Fig. 2 — Overview of the FUL line of spring coiling There are two possibilities as machines from WAFIOS and the ductile wire diameters. far as the number and design of the feed rollers are con- cerned—either fewer pairs with a large diameter, or more with a smaller diameter. Large rollers are heavy. In order to 66 Wire Forming Technology International/Spring 2020

force can be increased to such an extent that even the smallest of spring indexes can be realized. Whenever extreme forces are involved, stability is an absolute must. The entire modular machine assembly complete with infeed and coiling body is therefore con- nected to the base. A crossbeam also serves to increase rigidity. Furthermore, the shape and cutting slides have been designed in a particularly robust manner. The mandrel box now features ex- changeable wear plates, which significantly increases the service life. The FUL x6 machines provide eight CNC axes as standard, covering both the basic functions and options to suit customer re- quirements including in-feed, cut, vertical Fig. 3 — The FUL 166 is the first spring coiling machine available from pitch, parallel pitch, height adjustment of WAFIOS with six pairs of feed rollers. Far right: cutting device and mandrel slides, mandrel displacement and PTP coiling finger. shape/coiling unit (2 axes). Additional axes can be installed on most models such as a make handling as easy as possible, WAFIOS decided on six pairs of rollers that were smaller in diameter. 4-axis coiling unit (2 axes), a spring leg unit, or a 3D former for complicated torsion springs, or Along with the new FUL 166, other WAFIOS coiler alternatively a PTP coiling finger (2 axes) for varying models available for the production of suspension the spring pitch. The FUL 166, however, is not intended springs are the FUL 175 model (up to 17 mm), the for torsion springs. This option is only available for the FUL 183 (up to 18 mm) and as the largest suspension smaller models. spring machine to date for up to 20 mm oil hardened In order to cut the wire to size, the FUL 166 offers the and tempered wire, the FUL 203. straight cut and the additional torsion cut variant. This is still possible if the spring index is tight (wm<4) (mean Easy Handling spring diameter/wire diameter). However, it does require a CrSi spring steel with a certain brittleness. The feed rollers are fixed to their shaft in two ways— With the additional scoring functions—a WAFIOS via positive locking with three driving pins and via patent—torsion cutting is possible even with a value force locking with a preloaded central nut. In the event of wm>4. The scoring process uses a carbide-tipped, of wear or if the spring wire thickness is changed, it is CNC-controlled mandrel. Torsion cuts leave behind extremely easy to carry out necessary modifications. burr-free, almost flat cuts that are perpendicular to the wire axis, which is an advantage for some applications. Minimizing the (dis)assembly work is a design prin- ciple that runs through the entire machine. This also The machines also meet high standards when it comes applies to the slip control, for example, which only to quality control. This task is entrusted to the WA- needs to be moved out of the work area rather than FIOS Vision System (WVS). The springs produced being dismantled. The basic idea is clear—minimize are measured in terms of length and diameter using changeover time to maximize machine availability. a camera and backlight during production operation and the process is regulated. The system also controls The machine safety concept is perfectly in line with the sorting of the springs. this principle, simultaneously providing high acces- sibility and the best possible protection for operators. The protective hood opens electropneumatically. The Programming Made Easy lower protective cover can be used in three positions: on the far left for access to the coiling and cutting unit; The programming of the different functions and axes on the far right for access to the feed rollers and cut- is left to the high-end programming system WPS 3.2 ting unit; and in the center for production operation. EasyWay. The name speaks for itself. User-friendliness and easy learnability were key priorities during the Numerous Options development phase (see Figure 4). Entering a spring for production is an intuitive process, The FUL 166 is a real powerhouse, and it has to be, no matter how complex the structure may be. In the with wire thicknesses of up to 16 mm. The in-feed case of chassis springs, for example, the pitch may vary, Spring 2020/Wire Forming Technology International 67

Full Speed Ahead to the Perfect Spring ...continued terface is also available as an option, enabling modern digitization scenarios to be realized in the context of Industry 4.0. Last but not least, a VPN Connect interface provides secured external access to the con- trol system, allowing maintenance work to be performed remotely if required. Functions for the Control System The iQautopitch, iQbestspeed, iQcockpit and iQcontrol functions are available for the FUL- x6 line. They enable further improvement in productivity and quality. Fig. 4 — The intuitive WPS 3.2 EasyWay programming system effort- iQautopitch: If an existing spring is to be lessly guides the operator through the steps required to achieve the produced again, it must be measured and desired spring type. The large 24\" multi-touchscreen also contributes the coiling machine adjusted accordingly— often a time-consuming task. This function greatly toward safe and reliable operation. automatically calculates pitch and diameter parameters using measured values and saved reference springs. This can reduce machine downtimes. iQbestspeed: Calculates optimum operat- ing point and production speed. Optimum quality in spring production is achieved at a particular coiling speed. The software varies the processing speed for several springs and finds the optimum setting fully automatically. iQcockpit: Machine monitoring using a mobile device (smart phone, tablet, etc.) via WLAN or UTMS regardless of location. En- sures access to production data. Fig. 5 — Interface of the optional iQcontrol system, which together iQcontrol: Monitors spring length with a with the WVS camera system (WAFIOS Vision System), monitors the dual camera system, even during production. Deviations in length occurring during coiling spring lengths during the production process. are immediately communicated to the control system and corrected. Length variation is re- duced so no springs with incorrect length are passed as acceptable parts. www.wafios.com WFTI the spring axis may be bent, a cone or barrel shape Company Profile: may be required—everything is possible. The system supports the programmer step-by-step by suggesting WAFIOS AG is a global leader in the manufacture prefabricated form elements and querying param- of wire and tube working machines, along with sig- eters until the desired spring type has been specified, nificant activities in the cold forming industry. The and the program can be calculated. The hardware is WAFIOS Group thinks and functions internation- selected accordingly. It consists of a new console trol- ally. Everywhere in the world, the name of WAFIOS ley with PC and 24\" multi-touchscreen, which can be is known as a reliable partner in the wire and tube operated via touch gestures like a smart phone. It also processing industries. includes a hand-held operating device, which is also equipped with a touchscreen for precise selection of The many subsidiaries, which are a part of the WA- all functions during set-up operation. FIOS Group, along with the company’s many sales agencies are based in different countries on almost all Further control-related highlights are provided by the continents. The tight network of WAFIOS agents and iQ functions, which are available as options. These more than 70 commercial agencies cover more than allow productivity and performance to be further 100 countries. www.wafios.com optimized (see Figure 5 on next page). An OPC UA in- 68 Wire Forming Technology International/Spring 2020

SMI Technical Update by: The first basic training module, compression spring design, C. Richard Gordon was taught as part of the 2019 SMI Metal Engineering Expo Technical Director event held October 1 to 3, 2019, in Pittsburgh, PA, USA, and Spring Manufacturers Institute (SMI) at the 2020 West Coast Spring Manufacturers Association 2001 Midwest Road, Suite 106 (WCSMA) meeting held February 20 in Buena Park, CA, Oak Brook, IL 60523 USA USA. Student feedback was excellent from both classes, with Cell: +1 574 514 9367 student suggestions being incorporated into future offerings. Email: [email protected] www.smihq.org Two additional basic training modules, extension spring design and torsion spring design, have been completed and Founded in 1933, The Spring Manufacturers Institute (SMI) plans are being made to offer these classes, along with the serves, supports and educates North American precision compression spring design class at this fall’s 2020 CASMI spring manufacturers in their pursuit of competitiveness in SpringWorld® event at the Donald E. Stephens Convention world markets. Center in Rosemont, IL, USA. Each spring type will be taught in a separate four-hour session. Courses are organized as SMI is an association of companies that manufacture springs focused, real-world spring design training programs. and their suppliers. Collectively, SMI members work togeth- er to meet the key issues of the industry worldwide—quality, The courses combine classroom-taught content with practi- materials, technology and government regulations. cal hands-on use of SMI’s world-famous Advanced Spring Design 7 (ASD7) software. SMI provides many services including producing the quar- terly magazine, Springs, a variety of technical publications, For each spring type, students will learn: spring design software, industry data, seminars, meetings, safety and regulatory compliance and technical assistance. • The seven-step spring design process In 2013, SMI initiated a strategic planning process, which • Definitions and terminology identified a need for increased technical training and sup- port. To help meet this need, SMI retained my services (C. • Design theory Richard Gordon) as Technical Director to help springmakers with their metallurgical challenges such as fatigue life, cor- • Design stress analysis rosion, material and process-related problems, and technical advisor, Gary Van Buren, to assist with spring design and • How to input engineering design data into problem-solving issues. SMI member companies receive two the ASD7 software complimentary hours of technical assistance per year as a member benefit. Services are also available to nonmembers • Important ASD7 tolerancing criteria for a fee. Classes benefit students by increasing their spring design Failure Analysis Program knowledge and their company by having an SMI trained associate as part of their team. A spring failure analysis program was developed to meet the needs of SMI member companies and is also available For more information, please see the SMI website listed be- to nonmember companies. We use several laboratories and low or call Dina Sanchez at +1 630 495 8588. www.smihq.org work with the requesting company to select the laboratory, which will best meet its needs for spring failure analysis, to WFTI identify the root cause of the failure for effective corrective action. C. Richard Gordon (Rick) currently serves as Techni- cal Director for the Spring Manufacturers Institute. Training Classes and Materials He has over 45 years’ experience in the steel and wire in- dustries. Since retiring in 2016, Rick formed an engineer- Training was identified as a critical need during the SMI ing, quality and technology consulting company focusing strategic planning process. Gary and I have worked with the on process optimization, best manufacturing practices, SMI technical committee to develop spring design training quality systems and training. He previously worked at programs. There are three course levels: fundamentals, basic Gerdau Long Steel North America’s Beaumont, TX, and advanced. USA and Perth Amboy, NJ, USA steel mills as Technical Service Metallurgist. He also worked with the National Fundamentals courses were developed with new hires and Standard Company managing groups in the areas of nontechnical staff in mind. Basic classes are designed to R&D, quality and process technology for carbon steel and meet the needs of production and technical staff including stainless -steel wire products. In addition, Rick worked for engineers, designers and inspectors. Advanced courses ad- Baoan International Investment Co. Ltd., a Chinese dress a higher level of expertise for engineers, designers and trading company in Covina, CA, USA, and the US Steel other technical staff. Corporation in Chicago, IL, USA; Waukegan, IL, USA; and Monroeville, PA, USA. He is a graduate of the Il- The training program consists of 14 courses: three funda- linois Institute of Technology with Master’s and B.S. mental, seven basic and four advanced. Two fundamentals degrees in metallurgical and materials engineering. training modules, “Spring Fundamentals” and “Overview of Spring Making Materials”, are available to the public on Rick is currently Chairman of the ASM International the SMI website. SMI member feedback for these modules Notre Dame chapter. Rick is also a member of ASTM, has been very favorable. TMS, and Wire Association International. Spring 2020/Wire Forming Technology International 69

State-Of-The Art Spring Making Technology & Research by: All content, timing and location subject to change. Dr. Andres Weinrich ICST National Committee Chair www.federnverband.de Technical springs are usually invisible parts of our ICST Organizer everyday life. Technical springs make our lives easier and safer. Technical springs can be used in simple toys The International Committee determines the location or in very sophisticated medical technology, but they and organizational responsibility for the International are also irreplaceable in both traditional and modern Conference on Spring Technology. Furthermore, it pro- measurement technology. motes the dissemination of knowledge and research activity in the area of spring technologies and allied You will also find springs in all kind of vehicles and processes. The International Committee consists of even in building technology. Springs are and remain the following: a very effective energy storage element with a high degree of efficiency. The environmental conditions • Wolfgang Hermann, VDFI e.V., Germany (Inter- where springs are used can be very different from national Committee Chair) very low to very high temperatures, from vacuum to acidic atmosphere. • Thomas G. Armstrong, Duer/Carolina Coil, Inc., USA The essential foundations of technical springs are ex- tensively researched and understood. However, the • Dr. Richard Dignall, Institute of Spring Technol- demands and requirements of the spring also increase ogy, UK continuously. • C. Richard Gordon, Spring Manufacturers In- The improvements in research knowledge are mean- stitute, USA ingless if they cannot be implemented under industrial conditions. Therefore, a close cooperation between • Kim Jin-Young, Daewon Kang Up Co., Ltd., research and the spring manufacturing industry is a South Korea matter of special importance. • Kouji Nakamura, NHK Spring Co. Ltd., Japan This diversity as well as the increasing demands placed on quality, dimensional accuracy and higher durability • PhD Cheng Peng, China Productivity Center for require an improvement of this “simple” machine part, Machinery, China whose main property is to store mechanical energy. And such ongoing improvement must be allowed for • Francesco Silvestri, Associazione Nazionale dei the demands of the future. Mollifici Italiani, Italy During the International Conference on Spring Technolo- • Prof. Jun Zhang, China Spring Corporation gies (ICST), September 14 to 16, 2020, being held at the Limited, China InterContinental Düsseldorf in Düsseldorf, Germany, you will not only be able to attend academic lectures, Additionally, the Local Committee of Germany is re- but you will be also able to gather information about sponsible for the peer-review process of the abstracts production technologies and measuring techniques and papers. The Local Committee is as follows: from exhibition booths. • Dr. Andres Weinrich, VDFI e.V. (Local Committee In addition, the conference attendees will have the and Conference Chair) opportunity to interact with engineers from around the world in the banquet event that will be held after • Prof. Dr. Robert Brandt, University of Siegen the lectures. • Dr. Michael Hellmann, C.D. Wälzholz GmbH The International Committee—the conference organ- & Co. KG izer, will be happy if engineers, technicians, research- ers and other business people engaged in spring and • Dr. Marcus Klein, State Materials Testing Insti- related industries as well as their suppliers and cus- tute Darmstadt (MPA)/Chair and Institute for tomers, will participate in the second ICST, and looks Materials Technology (IfW) forward to welcoming you. • Prof. Dr. Ulf Kletzin, Technische Universität Ilmenau • Prof. Dr. Vladimir Kobelev, University of Siegen/ 70 Wire Forming Technology International/Spring 2020

Muhr und Bender KG Institute, Wire Forming Technology International maga- zine and smi metal engineering eXpo. • Dr. Rüdiger Lux, Westfälische Drahtindustrie GmbH To learn more, contact Dr. Andres Weinrich by calling • Prof. Dr. Eckehard Müller, University of Applied +49 2331 9588 57, faxing +49 2331 9587 51 or emailing Sciences Bochum [email protected]. • Dr. Peter Thoma, SCHERDEL GmbH www.icst2020-germany.de WFTI Hosted by VDFI e.V., the International Conference on Spring Technology will include exhibitors Weiler, Stresstech, Raajratna and Erre Inox. ICST is sponsored by Dörken/MKS and Drahtwerk Wagener. The event partners include Wire Draht, Spring Manufacturers Spring 2020/Wire Forming Technology International 71

Spotlight On Straightening & Cutting by Mike McNulty, Editor Wire Forming Technology International Alloy Wire International Traditional straighten-and-cut (S&C) machines are used to produce straight, cut lengths of wire, rod, strip, bar or 87 Dewey Ave. Warwick, RI 02886, USA rebar, and independent straightening devices are used 1-866-482-5569 at the entry of spring coilers or wire forming machines. In both cases, the straightening process has the primary [email protected] job of removing the cast in the wire, rod or bar that has alloywire.us.com been created in the coiling or spooling process. In other words, the straightener aims to restore the wire, rod, wire and cable equipment strip or bar to its original form. COMETO SRL Via Cabella Lattuada 41 Straightening 23841 Annone Brianza Lc Italy +39-0341-263090 [email protected] Wire, rod, strip or bar that has been wound onto a spool or into a coil will not lay flat or stay straight when it is www.cometo.ws unwound or fed into a machine. Straighteners take out the www.youtube.com/user/Cometosnc cast or loop of the material, so it can be processed or used properly. Three common straightening methods are roller, EUROBEND GmbH rotating and oscillating straighteners. Roller straighteners Allersberger Str. 185, Geb. G-3, use opposing rollers in one or more planes to straighten the material while rotating and oscillating straighteners 90461 Nürnberg, Germany use dies, bushings, rollers, etc., to accomplish the task. Tel. +49 911 9498980 With roller straighteners, the number and size of the roll- Web Site: http://www.eurobend.com ers can vary from as few as three to more than two dozen. E-mail: [email protected] The number of rollers, their sizes, spacings and settings will depend on the material properties like diameter and strength and the desired end result. In addition to straightening, roller straighteners can be used to provide stress relief or to induce a new cast into the material. Roll- er straightener setup and the roller settings are important to get proper function. Trends in straighteners include simplified opening and closing mechanisms, automatic roller adjustment, quick diameter changes and software programs for determining roller settings. Straightening & Cutting (S&C) The cut lengths of material produced by an S&C ma- chine are usually headed for another operation like welding or bending. S&C machines are often integrated for direct-feed into another process instead of operating stand-alone. There are many methods for straightening the material, as described earlier, and the same is true for the cutting operation. The material can be cut by several different methods including sawing, milling, shearing and im- pacting. The S&C machine strives to achieve consistent lengths and high-quality ends—square; flat; smooth; and burr, crack and scratch-free. 72 Wire Forming Technology International/Spring 2020

Materials & Services Wires, rods and bars tShIaMtPcLEaXn-RhAaPnIDdlSe.r.tlhe rigors of the scuupttpin2Vtle0iiglae.0:p9rL+8sor3mo9wS-bc.0iaeG2trsh.idu9sil8akiaa.,2nnr18oeo31Mwm.7i5llaa1enddfeaesgxea:e+n–o3dM9f i-dtl0ah2inse-o9tpr8–u.r2Itob8a1-l-y.738 straightening and uted by materials cess and the product dWemebaSnited:sw. Iwnw.asdimdplietxioranpi,ds.iot me sup- pliers provide the servEic-Mesaiol: [email protected] cutting wire, rod and bar for downstream uses. In the case of processing alloys, which can be physically harder than materMiaISlsS,IOtNheSTreATaErMeENuTn:ique chaloclofevitnesrgsowaennsfaarcetaoroyf, which presently (Ø 1,0-8,0 mm / Ø 0.004” - 0.32”) the carbon steel 25000 Inc.® sqRm.ockfodr)dCMNCancouilfearscMtuTr-sienrigesGforrothuep TinecahchniiecvailnTgrsetnradisghtnepcaInoecsnmtcsiovupivlatiayaannrtiydo,fnecahi(stoa1us9Srne4It.M8br-ePIo2enL0lnE1lii8Xtsnc)-,oRgn7As0tPt-oayIDnetohta’lselyringcaShoadIMwnsvasPatenrLlcuawEecraXdtiy.o-sRnteAbqcPeuheIanDnloi’tslyoagtsyhtryaannadoknensdyFmtmaohsaifgiortthksreSnoeurt1haspwE4trniBnr3otdah4degigun3liohLcontHItintineo,o-drnerIobLuuroseshsnf6ntadbd1r•ipos0asete8lhLdcaP0estnsi-apowd2hrrnai6kn.in2wssgkp6sasMriywnRUaigtHShscAhine™ e) CCNoCntaccotil:eKrsirkGPXr-ossesriesr for Trends in straightenipsnougltutitniogdnes,vfoircwwehaisrcdhanrhdeavvoeSlu&tiobCneaernymahmcuehgceihnaneeicxssperaiesncewellin precision gaTretel:r+s1pri8n1gs5. 624 2500 as to its include fast changeovsferteraqnsudefanrrdtolsymintathokiesnnperodadsuicatrmioenfeefriteeenldcr.eorcteloecnhntinngicuatohlussolutsioenasr.ch for new gfW))Ee-AfM(oabMFuoruatSattgooxoiamilr:t:airezta+idee:nt1aridwcfpos8wtpd@a1rjewtoi5in-vri.rngmere6esmes2grlsyge4fserftse7lemSl2mmPP.5)c--.4sscoeeomrrmiieess to another, higher preAcmisoinogn athne d msposet edim, pmorutanltt iplIne 1w98i9r,eby taking over SECEM improviSnienmodpvaledtixor-nRisvapeid,ainnlterdot d/uuocserdmPeLntCiobny cosmnpaetccrhioainlliezsse.dfoinr the production of SECEM line: operation and straightening and Additional developmethnetspaitnenctlufodr ethtehfelyifnogllcouwtofifngc:utting metal wire and tube in system (1960). More recently ferrous and non-ferrous materials • MstriarriogrhetdenminagchminaerP(e1crv9ohso9gel6iur)tnat,iuomenpmsasriiyntpg(llaearfcenteadldaizneAdtduoGtorgrmaiepbaghotthtiihhccte-rhw(r)epaimatnohtaedfrhnkfeytaeepdbdrelyrbsotrlaiciingrchorteellanssi)n,egdthesygsratoenumdp a) Straightening machines APR- series for extra thin wires and enhanced plant flwPerhxoicighbraimlidtryaGsetaincnearlldaytioernffiedsucocifeetwnatcrheye, thdinirffoetruheengtihastepdeciitfsicprofideuldctioonf range tubes from 0.1 to 1.0 mm wire (0.004” to 0.04”) face-to-face positiomnacihninge stoet-uaplltoimwe. operators twoortkoinog.l- b) Straightening machines RTA- up both machinescTwahmeitefhrirasot uscyotsntnetrmoele-indwteaigsnragintettdrooddwuigcieatadllk apInrreocui2s0ino0nd0, APR project (i.e. series with hyperbolic rolls straightening and and hydraulic cut-off for steel long benches to acacseaswsotrhldeprsevtireawiginhyetaern2e00r0. . cutting systems for wire  0,1 to and non-ferrous metal wires Thanks to the “Initial Tension 1,0 mm (Ø 0.004” to 0.04”) was from 0.8 to 16 mm (Ø 0.032” • hRyoptoerrbsotlriaciagllhytepnroinCppfirogoolsenbstlsdierbyomleslsstttoeDeeroemelvvlaerictroectedole”lmceteh(ro2san0l0litohnt4hel)seotugieintsaiyutidaaislltohfa(tcaAdotkumieduepnesasmnetayoosrvse-rPigufAreoPtm)-.TeTcthhheannoVklSoisagwiLiestososmbard–ia01.633”–)S2E0C09E8MS. Giuliano Milanese erseixssetuecluntticneygsatrisnawigbehelttleteanrsbcdctieooniefnsmmfitlegswt).iprreoieraanenennnistigsmdaithomhnifectozeoeueennnfsitddtrrpisoonrtilimfnngagignnaiqdtaicoa(ufhtil.tehattie.ehnlnieestaltaiyohnssdneyat aomnwsmmathedtnnrieesdatedtiicgpitvimcohremaotrnlejyeeane-ct,tpihhntp,eignlSicEnwaeCtiriemoeEdnMos(ses)tlbleianocnetthdrocdfnafoioTfinfcrreenwlrat:ehoin(rni+wndezt.3i.9WSUSE0EaeAS-2lbSLAme9TEs,8SaCOS2iiotla:8OefUnf1:iiFacnL7eFdwTf5aIoECw:1a@REnw•I:dsA.isFmNisameOpxrlp:v)e,il+cxeMerx3ari9palcaeip0dnni2.dotie9t,.ri8tIt2a8ly1738 since continuous Wadithjuthsistmfeaetnurte oit fis tphoessisbtleratoighatnedntuibnegup to  16 mm (0.63”) cpnooenintertodolfeathdned.wviareryf,eeadt ,atnhye desired mechanism is not amount PRODUCT LINES: • Integrated functiooinfncrseinmisteiaunltchtenoasrisondderincarewmoreidnnetrg,toitcolSdIMrPoLEllX--RAPID line: USA Exclusive Agent: NIMSCO ipnogi,nrtein-bge, npdroinfigli,negnraecdaqcunosirrddehimnahgevonitl.negtod, rriilbtlhibenign.gs,pcrihngamaf)esCrpiNenCegdc,oiplerrodFuXc-tsioenriesoffor DavenpNoIrMt,SICAO5L2C8C07, USA Trhi:gigh+ht 1 55613153T9R1E0M4O0N0T•AFV:E+N1UE563 391 0403 DaEv-emnpaoilr:t, iInOfWo@A n5i2m80s7co–.cUo.Sm.A. COMPANY HYSTORY: handed springs Jerry Jacques • In-line diagnosis oSfinwcei1r9e48qSuIMalPiLtEyXa-RnAdPIDsihzaes fo(rØau0,t1o-3-,00 mm / Ø 0.004”- Jerry Ashdown contwbreooerlnld. successfully present on all 0.012”) matic process markets thanks to its b) CNC coiler MX-series for high production of spring making speed production of right and TEL N° 001-563-391-0400 • Modular design omf accohimnesp. onents for simplifiedlefut hpa-nded springs FAX N° 001-563-391-0403 grades and changecToshnesintanctclayompinpacabrneiyalsitinigehsaist.s been (Ø 0,1-3,00 mm / Ø 0.004”- E-MAIL: [email protected] market 0.012”) http://www.nimsco.com • User-friendly adjupsshrotagmrereessnoivvteeslryainnthcdereaqsyuineigacrskth, ecthshiuzaesngec)osMveuerlirteissa. x(1e2s CNC coilers MC- axes) for critical • 100% electronic speed changes and control. compression springs • Integration of software programs for machine setup and operation. • Miniaturization. WAFIOS Machinery Corporation 27 NE Industrial Road • Length extremes: short and long parts production. Branford, CT 06405 USA • Servo-drive control. Midwest Technical Center • Versatile feeding and collection systems. 9830 W. 190th St. Unit D Mokena, IL 60448 USA • Alternative roll materials and coatings that extend the life of straightening rollers. Email: sales@wafios.us Web: www.wafios.us • Precise feed controls. WFTI Ph: (203) 481-5555 Spring 2020/Wire Forming Technology International 73

PRODUCT SHOWCASE New Universal ditionally, automated, repetitive handling, in-line testing, moni- tests can be run in hours rather toring of parameters from other Testing Machine than days, helping to eliminate sensors—like thermocouples and Single-column system operator error, improve operator strain gauges—and customization A new single-column universal safety and reduce cost. of user interface. Microsoft Office testing machine provides ultra- integration allows for a seamless high-speed testing along with The LS5HS features a travel of transfer of data to Excel and Word flexibility, reliability and highly 800 mm and a crosshead speed using custom or pre-defined tem- accurate test results. The new range from 0.01 up to 2032 mmpm. plates. What’s more, test results machine can provide results for Its throat depth of 150 mm pro- can easily be sent to a colleague. all materials testing applications vides a large working area, and Data can further be exported to up to 5 kN, supporting test types the load accuracy of ±0.5 down LIMS, SPC or other data manage- such as tensile, compression, bend, to 1% of load cell value provides ment systems. Lloyd Instruments, friction, tearing, peeling, insertion/ a high dynamic range, reducing a brand under AMETEK Sensors, extraction, creep/relaxation and the number of load cells required Test & Calibration (STC). many others. to cover the force range. www.ametek.com With a test and return speed The universal testing machine of 2032 mmpm (80 ipm), the new can be used as stand-alone con- LS5HS testing machine improves trolled by a console. For more throughput and saves valuable advanced testing, the NEXYGEN- time in production as well as qual- Plus software can be added and ity testing functionalities, where test results can automatically be productivity can be optimized. uploaded for easy analysis. As the LS5HS universal testing machine is designed to automate To facilitate the increasing need workflows, robots can be coupled for automation in manufacturing, to the machine to speed up the NEXYGENPlus offers powerful testing process even further. Ad- utilities for system integration including automated sample High-Throughput Rotary the test frame, controller and software. The control- Table Spring Force Tester ler features a Windows operating system with a high resolution color, multi-touch display, Wi-Fi, Bluetooth The L.S. Starrett Company, Athol, MA, USA, a lead- and USB 2.0 port(s). The Rotary Table Springs Force ing global manufacturer of precision hand tools/gages, Tester has L2 Plus software featuring analysis tools a broad range of force testing, metrology equipment to measure and display results on a single graph. and more, has introduced a newly designed Rotary Once this is complete, the results are automatically Table Springs Force Tester. The system is setup to test measured and placed on all of the test runs within a multiple springs in a single setup without the need for batch. Displays include full graphs, split graphs with additional operator input as required when springs are data tables, or as a data table complete with statistical tested one by one. The batch testing volume produc- calculations or tolerance results. tion approach saves time and significantly increases test throughput, while freeing up the operator to attend Visit the website below to see a video and to find to other jobs. more information. Multiple springs can be loaded and tested in the Ro- www.starrett.com/rotarytable tary Table Force Tester System, and the system will provide a pass/fail report on each spring. Detailed information on each spring is also available including free length, spring rate and critical load and distance points. Different rotary table options are available to accommodate a customized number of springs in a single setup. The Rotary Table Springs Tester solution features the Starrett FMS-1000-L3, a single-column force measurement system optimized for high-volume pro- duction and quality control testing. The FMS-1000-L3 frame has a 1000 N (225 lbf) testing capacity, ideal for tensile or compressive testing. The system includes 74 Wire Forming Technology International/Spring 2020

PRODUCT SHOWCASE Torsion Springs tion of pop-up covers on various through to full sized units of over Offer axial energy & control players, cameras, instrumentation 50 mm. These are covered by huge New torsion spring is designed and more. depth of stock, which ensures for applications where axial rota- rapid one-off order delivery and tion requires control. These com- Company offers a total of sev- timely production scheduling, in pactly wound ex-stock springs en angle sections for its torsion music wire or 302 stainless steel. look like a common compression springs in all standard ex-stock spring mounted on a rod or into sizes, both left and right-hand In coming to a custom specifica- a cylinder, but are activated by wound, which also facilitates us- tion, the company believes design- radial leverage on their end legs. age in pairs to provide a balanced ers will benefit from the guidance force at each point, so ensur- provided on the “Spring-i-pedia” Common applications involve ing that the returned piece seats site: springipedia.com where rel- the need for a pre-loading to act as properly. They are available in evant formulae and other informa- a counter-weight, e.g., a rear tail- plated music wire and passivated tion can be found in establishing gate or garage door. Other typical stainless steel. Torsion spring ends design parameters for torsion applications include clothes pins, can be bent, twisted, hooked or springs. Lee Spring, UK. clipboards, window shades, coun- looped to suit project needs, and terbalance mechanisms, ratchets are offered in a choice of 90°, 120°, www.leespring.co.uk and various types of machine 180°, 210°, 270°, 300° and 360° components. Torsion springs are free-leg position. Specialist design used for hinges, counterbalances engineers are also ready to help and lever return applications and with custom leg end style choices as couplings between concentric including straight torsion, straight shafts such as in a motor and offset, hinged and hook ends. pump assembly. Many electron- ic devices utilize small torsion Specialist miniature torsion springs to provide smooth opera- springs are available with an outside diameter from 2.62 mm, Tablet for use with its Tablet Provides LD Series Easy Material Testing materials Lloyd Instruments, a brand under AMETEK Sen- testing sors, Test & Calibration (STC), introduces a new tablet for use with its LD Series materials testing machines. machines with capacities ranging from 5 to 100 kN. The tablet is designed for users who are looking for Test results can be viewed either as a graph or in an easy, reliable digital materials testing solution a tabular format showing multiple test results. The where no computer or knowledge of programming results are automatically saved, offering the user language is required. the ability to recall them at a later time to analyze or continue testing a batch run. When combining the tablet with one of the LD Series Test results can be exported into both PDF and .csv materials testers from Lloyd Instruments, the machine files. Data storage can easily be done internally or is turned into a standalone test machine that loads all on an external server, which provides efficient pro- data directly into the tablet. The 2-in-1 functionality cedures for documenting yields, product quality, and of the tablet offers the user the flexibility of placing performance. the tablet directly on the test machine or unattached The new Lloyd Instruments tablet can be password next to the machine. protected and features two levels of user access: supervisor and operator. The new tablet for use with its LD Series materials www.ametek.com testing machines incorporates an intuitive interface as well as quick test functionalities such as the defining Continued... of specific tests as favorites on the startup screen. The setting up of a test, selecting test runs and ex- Spring 2020/Wire Forming Technology International 75 porting results can be quickly accomplished only a few key strokes. The 13\" tablet features an easy-to-read, color touch- screen and is ideal for routine applications requiring the measurement of peak loads and breaking loads.

PRODUCT SHOWCASE Belt Conveyor Oven ' culating blowers provide verti- comprise a 42\" wide, 1\" x 1/2\" Two-zone, gas-fired system cal downward airflow over the flat wire conveyor belt with 1/3 The No. 791 is a gas-heated, workload. HP motor drive, variable speed two-zone belt conveyor oven, from 5.8 to 16.1 ipm, 7\" insulated that is currently being utilized All safety devices required by walls throughout, a Type 304, 2B to stress relieve heavy-duty steel IRI, FM and NFPA Standard 86 finish stainless steel interior and springs. This belt conveyor oven for gas-heated equipment are in- an exhaust hood over each end unit provides a maximum operat- cluded on this Grieve Corporaton of the oven, equipped with a 12\" ing temperature of 850°F as well as oven, which also features a two- diameter tube-axial fan driven workspace dimensions of 48\" W x pen, 10\" diameter circular chart by a 1/2 HP motor. The Grieve 360\" L x 15\" H. recorder. Corporation, Round Lake, IL USA. The conveyor portion of the Other construction features www.grievecorp.com No. 791 oven system includes a 4' on No. 791 belt conveyor oven long open belt loading zone, a 2' long insulated unheated entrance The No. 791 is vestibule, two 15' long insulated a gas-heated, heating zones with independent two-zone belt recirculated airflow and tem- conveyor oven, perature controls and a 2' long that is currently insulated unheated exit vestibule being utilized along with a 3 1/2' long open un- to stress relieve loading zone. heavy-duty steel Heat is provided at a rate of springs. 1,600,000 BTU/HR installed in two modulating natural gas burners. Two 10,000 CFM, 7 1/2 HP recir- Automatic Stirrup To simplify the unloading of stirrups and shapes, the Bender-Shaping Machine Bar Wiser 32 can be equipped with the new C-Loop unloading system (patented), the innovative automatic The automatic stirrup bender-shaping machine, the system that moves on tracks with two unloading car- Bar Wiser 32, available from Schnell SpA of Italy, riages for the collection of shapes. produces stirrups and shapes up to 32 mm diameter, and the machine is the perfect union of a cutting bench While the operator ties the elements on the full car- and a bending robot, with consequent savings in labor riage, the machine continues to work autonomously and space in the factory. unloading the products on the second trolley, with a consequent production increase. The Bar Wiser 32 is the ideal machine for rebar shops www.schnellgroup.com because it allows working all the necessary diameters up to 32 mm with one machine. It is the ideal machine to support the cutting lists for big rebar shops where you don’t have to stop the production of the Shear Line cutting line to produce a few different pieces. Additionally, it is of importance to have a powerful machine such as the Bar Wiser 32 automatic stirrup bender-shaping machine for small quantities of bars having different diameters. Renewed in its design and with modern electronics, the Bar Wiser 32 has got a PC with 15.6\" LCD moni- tor equipped with Windows that allows the transfer of the working lists to the machine, the acquisition of production data via USB memory and the Remote Assistance service. And thanks to the internet connec- tion, Schnell is able to assist its machines remotely, guaranteeing the customer great advantages in terms of time and costs. 76 Wire Forming Technology International/Spring 2020

PRODUCT SHOWCASE New Parts Collector And auto bin stack-up combination HSI Machinery along with FSI have recently announced the addition of the new SPC-100 parts collector and auto bin stack-up combination. Important features of the SPC- 100 parts collector system include the following: • Automatic bin stacking system for space savings. include springs, stamping, • A maximum of 20 bins that screws, plastic parts and more. For details, visit the website of are suitable for large quanti- Forming Systems, Inc., School- ties as well as longer collect- craft, MI, USA. ing times. • Product applications that www.formingsystemsinc.com New Multi-Bending, T. Butler Engineering Limited (TBE) is a Rockwell Au- Multi-Forming Machine tomation machine builder partner and has delivered industry leading solutions across the globe, partner- T. Butler Engineering Limited (TBE), located in ing with its customers to deliver innovative concepts Kilkenny, Republic of Ireland, is currently introducing and aligned with its commitment to “Competitiveness the TBE Rapidform X Series machine that provides Through Innovation”. its users with advanced technology including multi- forming, multi-bending, rapid-forming and sinu- Additional information and technical specifications on bending capabilities. the new TBE Rapidform X Series machine are avail- The features of the new TBE Rapidform X Series able at the TBE website: www.tbe.ie multi-bending, multi-forming machine include the following technologies: • Servo-driven form tools and press stations. • Wire diameter range of 0.5 to 6.5 mm. • High-speed decoiler. • Capability for up to 12 servo axes. • Integrated secondary operations and parts col- lection system. • New 5700 Series high-speed Allen Bradley automation controls. • Modular tooling solution with accurate ultra-high- speed forming of products. Continued... Spring 2020/Wire Forming Technology International 77

PRODUCT SHOWCASE Rotor Straightening justments are not needed. ductivity requirements and di- • Mechanical simplicity as ameter ranges to be processed. Machines • Different rotor sizes, cover 5th generation introduced simultaneous feeding and diameters from 2 to 50 mm, Inventor of the hyperbolic roll- straightening guarantees a of regular wire, deformed, ers rotor straightening method is constant, efficient and reliable recessed or rebar of any grade introducing its fifth generation operation. (high tensile, stainless steel). of rotor straightening machines. • Flying shear cutter, cuts the • Scrap elimination by using These machines offer patented wire and rebar while feeding: even last length of each coil. maintenance-free hyperbolic roll- no compromises in speed. For more, contact EUROBEND ers rotor straightening for opti- • Design simplicity allows GmbH, Nürnberg, Germany. mum straightening capability that construction of multi-line outperform other methods. machines depending on pro- www.eurobend.com These machines can process up to 50 mm low-carbon wire, 36 mm stainless steel and 28 mm rebar. There is no material surface damage and no material waste. No straightening adjustments are needed and labor is minimal. The machines are capable of au- tomatic coil opening, wire feeding and coil-end extraction. There is zero operator involvement. Additional features include the following: • Minimal machine downtime: continuous straightening ad- Decades of Wire Double-barrel rotary straightener (above) and Straightening Experience example of parts (below). Baudrand New Tech, Lyon, France, provides the wire Additionally, while providing machines processing two forming industry with integrate home-made designed wires to multiple parts production, the company has and manufactured rotary straightening systems for also designed multi-barrel units. wires ranging from 1 to 16 mm. Raw materials are of www.baudrand-new-tech.com diverse types including low-carbon wires, stainless, spring wire, copper, etc. The wire surfaces may also be corrugated. The rotary barrel principle is used in many cases, regardless of whether the contact to the wire is dry (pins) or curved (hyperbolic bearings), allowing to maintain raw material’s surface in an excellent shape. A good feature is the set-up of the straightening dies. Baudrand New Tech has developed a system that sets the finger ‘on the fly’, meaning that the position of the dies is moved by an electric motor, while the wire goes through the system, and thus, during the straightening operation itself. This permits the comple- tion of a production changeover set up in minutes. It also allows the ability to register the parameters of the straightening setup in the parts’ programs. Since Baudrand New Tech machines sometimes include welding operations, the company offers equip- ment to feed and straighten up to four wires of 12 to 14 mm at same time. 78 Wire Forming Technology International/Spring 2020

ADVERTISERS’ INDEX Company Page Website A&D Trading LLC 13 www.adtradingllc.com AIM Inc. Back www.aimmachines.com • www.aimeuropesa.com Cover Alloy Wire International www.alloywire.com BB Spring Technology 1 www.bbspringtechnology.com CASMI/SpringWorld 2020 Cometo 63 www.casmi-springworld.org Dongguan Jinding Machine Limited www.cometo.ws Eurobend GmbH 65 FENN LLC www.0769jdm.com 9 www.eurobend.com Forming Systems Inc / HTC. www.fenn-torin.com 15 Golden Spot Industry Inc. www.formingsystemsinc.com Larson Systems Inc. 51 Metal Finishing News (MFN) www.goldspot.com.tw OMD - Officina Meccanica Domaso SpA 2 www.larsonsystems.com RK Trading Inside www.mfn.li Back www.omdspa.it Rockford Manufacturing Group Cover Simplex Rapid www.rktradingusa.com SMI Metal Engineering eXpo (MEE) 4 SpringWorld 2020 www.rmgfelm.com Ultimate Automation Ltd. 55 www.simplexrapid.it Vinston US Corp. www.metalengineeringexpo.org • www.smihq.org WAFIOS Machinery Corporation 21 www.casmi-springworld.org 11 www.ultimat.com www.vinstonus.com Inside Front www.wafios.us Cover, 23 49 5 19 65 43 17 7 CLASSIFIED Wire Forming Technology International: Summer 2020 Issue Send editorial files to Mike McNulty, Editor, at [email protected] SSUUMMMMEERR 22001199 SPRING WORLD 2020 Preview • International Conference on SSUUMMMMEERR 22001188 Spring Technologies (ICST) Preview • wire China 2020 Preview Wire Forming & Bending Roundup • Heat Treatment Spotlight Editorial deadline: August 10 • Ad closing: August 18 Serving Manufacturers of Springs, Wire WWW.WIREFORMINGTECH.COM Formed Parts, Wire Mesh and Rebar Products WWW.WIREFORMINGTECH.COM Serving Manufacturers of Springs, Wire Formed Parts, Wire Mesh and Rebar Products MC 50 Ø 0.039” - 0.197” Trade Show MX 15 Ø 0.010” - 0.067” Trade Show MC 80 Ø 0.069” - 0.315” Coverage: MX 30 Ø 0.016” - 0.118” Coverage...pages pages 42, 50, 66 & 72 ...13-14 ...20-21 350 Poplar Avenue Booth #1005 ...34-50 Elmhurst, IL 60126 Phone: 630.359.4273 and Fax: 630.359.4274 ...54-58 Web: www.casmi-springworld.org FORMING & E-mail: [email protected] Spring World® Will Take Place October 3-5 in Rosemont, Illinois Spring 2020/Wire Forming Technology International 79 Contact: Michael Bandy, Co-Executive Director, (630) 359-4273 or [email protected]

EDITORIAL INDEX Events and organizations or companies on page 10 and in any preview articles are not indexed here; additional omissions are made at the editor’s discretion. A&D Trading LLC.............................................. 59 Gibbs................................................................. 14 Raajratna........................................................... 71 AIM, Inc................................................. 34, 35, 56 Gibraltar Corp.................................................... 60 Radyne........................................................ 62, 64 Allen Bradley..................................................... 77 Grieve Corporation, The.................................... 76 Rebar Trade Action Coalition............................... 8 Alloy Wire International (AWI)..................... 44, 45 RichardsApex.................................................... 47 Amada Orii America, Inc.................................... 14 HanHwa Chemical............................................... 8 RK Trading Company........................................ 60 AMETEK Sensors, Test & Herdon............................................................... 60 Rockford Manufacturing Group (RMG)............. 51   Calibration (STC)....................................... 74, 75 Hickory Springs Manufacturing Company......... 18 Rockwell Automation......................................... 77 Amstek Metal..................................................... 14 HSI Machinery................................................... 77 Anchor Abrasives.............................................. 14 HS Manufacturing, LLC............................... 14, 18 Safety and Health Achievement Recognition ASM International.............................................. 69 HTC Spring Machinery...................................... 59   Program (SHARP)........................................... 43 Associazione Nazionale dei Mollifici Italiani...... 70 Huddersfield University..................................... 29 SCHERDEL GmbH............................................ 71 ASTM................................................................. 69 Schlatter Deutschland GmbH & Co KG............. 18 Atlanta Attachment Company............................ 18 Illinois Institute of Technology............................ 69 Schnell SpA....................................................... 76 Automated Industrial Machinery, Inc................. 14 India Essen Welding & Cutting............................ 8 Schwarze-Robitec GmbH............................ 10, 40 Automated Industrial Motion Inc........................ 57 Inductotherm Heating & Welding Ltd........... 62, 64 SDI LaFarga, LLC............................................. 47 Industrial Steel & Wire....................................... 14 SGS MSi............................................................ 14 Banyard............................................................. 64 Insteel Industries, Inc........................................ 16 Shanghai New International Expo Center........... 8 Baoan International Investment Co. Ltd............ 69 Insteel Wire Products Company........................ 16 SHINKO............................................................. 59 Baudrand New Tech.................................... 54, 78 Institute for Materials Technology (IfW)............. 70 Sikora International Inc...................................... 47 Baum’s Castorine.............................................. 47 Institute of Spring Simco Spring Machinery Co. Ltd....................... 60 BB Spring Technology Srl...................... 36, 37, 59   Technology (IST)...................... 21, 28, 29, 52, 70 Simplex-Rapid Srl.............................................. 60 Bekaert.............................................................. 29 InterContinental Düsseldorf............................... 70 Sleeper & Hartley.............................................. 58 Bobbio............................................................... 59 International Conference on Spring Technologies smi metal engineering eXpo.............................. 71 Borouge............................................................... 8  (ICST).............................................................. 70 Sonoco Reels.................................................... 47 BusinessEurope................................................ 25 Interwire 2021........................................ 14, 16, 46 Southwire Company, LLC............................ 46, 47 Byer Steel Group, Inc.......................................... 8 InterWire Group................................................. 14 SpringCon 2020...................................... 6, 21, 28 IRI...................................................................... 76 Spring Manufacturers Institute, Carris Reels nc.................................................. 47   The (SMI)....................................... 22, 69, 70, 71 Cascade Steel Rolling Mills, Inc.......................... 8 James Monroe Wire & Cable Co. (JMWC).. 46, 47 Springs.............................................................. 69 C.D. Wälzholz GmbH & Co. KG........................ 70 JB Springs......................................................... 18 SpringWorld® 2020................................. 10, 22, 69 CE...................................................................... 34 JYF.................................................................... 57 State Materials Testing Institute Darmstadt Champlain Cable............................................... 47  (MPA)............................................................... 70 Chicago Association of Spring KINECOIL Division, Kinefac® Corporation......... 58 Steel Dynamics, Inc............................................. 8   Manufacturers, Inc. (CASMI)... 10, 12, 14, 22, 69 K & S Wire Products, Inc............................. 42, 43 Strand-Tech Manufacturing, Inc. (STM)............ 16 China (Guangzhou) Int’l. Spring Industry Stresstech......................................................... 71  Exhibition..................................................... 6, 21 Lake Michigan Metals Inc.................................. 14 Suzuki Garphyttan............................................. 14 China Import and Export Fair Pazhou Landrum Performance....................................... 33  Complex........................................................... 21 Lee Spring Limited............................................ 75 T. Butler Engineering Limited (TBE).................. 77 China Productivity Center for Machinery........... 70 Lloyd & Bouvier, Inc........................................... 47 Technische Universität Ilmenau......................... 70 China Spring Corporation Limited..................... 70 Lloyd Instruments........................................ 74, 75 Thermatool........................................................ 64 Clifford......................................................... 38, 39 L.S. Starrett Company....................................... 74 TMS................................................................... 69 Commercial Metals Company............................. 8 Torin................................................................... 59 Confident Instruments, Inc................................ 46 Make UK............................................................ 29 Tri Star Metals................................................... 16 CSA................................................................... 34 Messe Düsseldorf............................................ 8, 9 Messe Düsseldorf North Amerioca UL................................................................ 34, 36 Daewon Kang Up Co., Ltd................................. 70  (MDNA).......................................................... 8, 9 UPM................................................................... 20 Deacero S.A.P.I. de C.V...................................... 8 Messe Düsseldorf India....................................... 8 U.S. Customs and Border Protection.................. 8 Donald E. Stephens Convention METEC India....................................................... 8 U.S. Department of Commerce (DOC)................ 8  Center.................................................. 10, 22, 69 MicroStudio....................................................... 18 US Steel Corporation........................................ 69 Dörken/MKS...................................................... 71 Mid-West Spring & Stamping,........................... 33 DOW.................................................................... 8 Millennium Galleries.......................................... 28 VDFI e.V...................................................... 70, 71 Drahtwerk Wagener........................................... 71 Mohegan Sun Resort Casino...................... 14, 46 VentilatorChallengeUK Consortium................... 44 Duer/Carolina Coil, Inc...................................... 70 MIT Sloan School of Management.................... 46 VINSTON US CORP.................................... 14, 57 Muhr und Bender KG........................................ 71 Easydur............................................................. 56 WAFIOS.................. 14, 21, 28, 29, 48, 60, 66, 68 ELB-Form.......................................................... 10 National Association of Manufacturers WAI Operations Summit & Wire Encore Wire....................................................... 47  (NAM).............................................................. 43   Expo 2020............................................. 6, 14, 46 Enkotec Co. Inc................................................. 47 National Standard Company............................. 47 Weiler................................................................ 71 Erre Inox............................................................ 71 New Departure Company.................................. 26 West Coast Spring Manufacturers Association EUROBEND GmbH..................................... 20, 78 Newelco............................................................. 64  (WCSMA)......................................................... 69 European Automobile Manufacturers’ NFL.................................................................... 47 Westfälische Drahtindustrie GmbH................... 71   Association (ACEA)................................... 24, 25 NFPA................................................................. 76 Winoa Group..................................................... 28 European Springs & Pressings Ltd................... 12 NHK Spring Co. Ltd........................................... 70 wire 2020................................................... 6, 9, 10 European Union (EU)........................................ 24 Niehoff Gruppe.................................................. 47 Wire Association International Nightingale Hospital.......................................... 44   (WAI), Inc............................................. 14, 46, 69 Fabricators & Manufacturers Association, NUC..................................................................... 8 Wire & Cable Industry Supplier Association®  International® (FMA)........................................ 18 Nucor Corporation............................................... 8  (WCISA®)......................................................... 47 FENN..................................................... 14, 30, 59 wire China........................................................... 8 FM..................................................................... 76 OSHA (Occupational Safety and Health Wire Expo 2020........................................... 14, 46 Forming Systems, Inc.................................. 59, 77  Administration)............................... 31, 34, 35, 43 Wire Fabricators Association (WFA).................. 20 Fort Wayne Wire Die, Inc.................................. 47 Outokumpu........................................................ 20 wire India............................................................. 8 FSI..................................................................... 77 Wire Machine Systems...................................... 37 PLUSPRINGS CO............................................. 56 Wire & Plastic Machinery Corporation............... 47 Gem Gravure Co. Inc........................................ 47 Posti Group Corporation.................................... 20 WITELS-ALBERT GmbH................................... 50 Georgia World Congress Center................. 16, 46 Pöyry PLC......................................................... 20 Worth Steel & Machinery................................... 14 Gerdau Ameristeel U.S., Inc................................ 8 Precision Payoff Systems.................................. 47 Wright, Roger N................................................. 61 Gerdau Long Steel North America.................... 69 Primera Precision Taiwan CNC German Automotive Industry   Spring Machinery............................................. 59 ZwickRoell......................................................... 27   Association VDA.............................................. 24 ZwickRoell Limited............................................ 26 80 Wire FormingTechnology International/Spring 2020