WFTI Spring 2019 Flip Book Digital Edition

SSPPRRIINNGG 22001199 Serving Manufacturers of Springs, Wire WWW.WIREFORMINGTECH.COM Formed Parts, Wire Mesh and Rebar Products MATERIALS...P. 30 STRAIGHTENING & CUTTING...P. 54 Wire Forming & Tube Bending..P. 62 Preview Articles ...48 & 66

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TablTeabolefoCf Coonntteenntsts FSalpl 2ri0n0g7 2019 Vol. 2V2o,l.N1o0,. N2o. 4 www.wireformingtech.com WFTI EMPHASIS: FeatuFreeaAturrteic Alertsicles eDmhebyardliitrntolge3gmwe0neithnt Lo1o4 kiWSnegcFoTntdIo ATnBencuuahlinlWdiicreoaFlno ArmRcinhegicTeeovcehrndmoloeBgnyrtIe nAtaewrknaaintirodgnaslF T–ei crChsnltiacasQlsAucohaiferv2tee0mr0e7nt Awards, given out Materials 30-31 in spring Successafnunl u‘Calelyrtaoisnptyrining manakUinngcoerrtwaiirne fWoromrilndg’ cinadmusptaryiginndhivigdhualilgshfotsr m‘maajokretetcohonircdael rd’evelopments steel....20 ability toredlaetleivdetroheiqguhi-pqmueanltit,ymnaitcekrieallsaollroaycsc.essories for making springs or wire formed parts. 32 Hi1g6h -“EHnodwS Roel-uEtniogninseeforirngth MeyW Wiirree &FoTrmubinegI ndust ry Equ ipmeBnut ssuipnpelesrst oShaovsteadn nitu afrl oInm-H oEuxsetinExchtiiboitnio”n with more exhibitors in m ore Dspreawc eG,reheignhbllaigtth -t iAn gmualdti-dpitrioonngaeldi nstnraotveagtyio renssu.lted in growth and return to profitability. New hairpin production 36 A 2B0r ieHRficyhGdarrudoiDgd.eSenists Eoonm,SJbrp. r-riAtitnrleevgimewDeonef ttsh oeigfp hnSyspicrailnmge taSlltuergeylof hydrogen embrittlement of process ...33 ChristopshperirngPesttetsel-aWlonhgewthitehrasedilseccutsinsgionaocfamtaitliogagtisopnrminegthoordas.custom item, 38 it’s2a3lw aCysowmorpthocsointisoidne rEinfgfealcl tdse siingn Cfaacrtboros.n Steel Drum washer for springs and wire formed parts...30 InfluemDnre.ctRaelolugroegryfNoM.fWsparrigicnhght -miPnaakerint g6Laoonf dtohwepimrseuflotoir-mpnaerdttshpearerietssB,mTeahnheufSaatcrvetuinrogintrhg.oof SfteEexl, dteednicasteiod tno thSeprings 54 Manuel Paredes, Hervé Orcière, Thomas Stephan - New Method enables transitional load eva2l4ua tioCnofaortiqnugicsk pfoitcrh tchaelc u2l1atsito Cn teonotbutaryin expected initial tension on load-deflecting curve. Kirtan R. Dhami - A look at high-performance and corrosion-resistant fluoropolymer/PTFE Straigchoattiengnsifnorgspr&ingCs aundttwiinregforRmeodupanrtds.up Compact Ed2ito6r ialSSttraeffs-sT hPeesetantein-ogf- t–h eA-a Prt rinacsttriacigahlt eAnpinpglaicnadtciuotnting technology and equipment. mBeeanswcuiehnrldtmedoemienpr.sge.ph.3ncl6ayt lt.-i.n.3g5 Dr. Eckehard Müller - Stress (shot) peening can be used in making auto suspension coil springs 60 The Ffaorsbte,tteQr muaiteertialauntilidzatiSonavfiaehiWghearyhatrdoneTssrraesvueltinlgTinhrerdouucegd hmattehrieal uRseud/hrerduVceadlwleeigyht. Ra3lf0J aeHnieckaet -&A SCausrefaSctued yTroenathtme sepnritn gRsouusenddinupthe RRX fleet of commuter trains. 62 SpotliEagnddihtosrtuiarOflaScnteaftfrWe- aStiumrpeepnliteFersqouhriapmvmeeirnnets.gpon&deTd utobouer cBallefonr tdheinstgate-of-the-art in heat Influence of Mik3e6M cMNuoltrye- FAlleoxokibaitlithtye manacdh iVneesr,sinantiolvitayti ofnosra tnhdeim Wpriorvee Wmeonrtsk.er loops on extension ColumnsDorothee Jungeblodt - A range of mesh welding machines is being offered to wire workers, and when set up by a well-trained worker, the downtime can be less than 30 minutes. springs ...40 22 CA38S MMSoIanGicahVoiitlnafreiO-sV uefortsiran tiPlegrwoiirndeuhJacnuignnegref oWr2mi0irne1g 9aHn,daCnotghAeerSrwsMireIpIroncdesusincgtmsachines offered New Ogloffibalclyewritsh a&fterB-saoleas rsudp,poSrtpanrdinenggiWneeorinrgld. ® 2020 Update Mi3ch9a elCBAanSdMy -I CSAcShMoIlNareswhsi&p EAvwenatsrdUsp dRateeach Total of US$463,000 in 2007 24 CompECrxAceSesMrpsIt e(iCdohfrinocmagStohp eArCsisAnoScgMiaItCCioOnlaN osNf ESsCpirTfiiInOcgN aM,taainopuunfbalscictautrioenrso, fInc.), Naperville, IL, USA. Ra4n4d y DWeFiroerd R-oAdll T&hi nCgos aStpirningg sSupplier Consolidates 26Versatile system for producing Wi re aItns dAcRtiovditiTees nins iVlenTeezsuteinlag &– CPoalurmt 2bia wire hangers....38 Dr. RogJearcNqu. eWs rAignhckt a-eTrth-eCSomtrepnangythinotefnSdtseteol tap the developing growth market in Latin America. 28 Se4l5e cCItnifonormmgapttioahnneoyfO vPaplruoetiftmoilethuseminteMrnaatitoenarlisaplrisngTanedswtiirne fgormMedapcahrtsinindeustry. Alan Thomas - Wire Product Testing Automated CNC jig welder ...46 Tec h BInrdieufsstry Events 37 Straight From The Show Compression 35 BenchImtaogeps aXndRfaFctsPfrloamtiwnirge SMouteheaasstuArSeIAm20e07n, hteSld yOsctotbeemr 16-18, 2007, in Bangkok, Thailand. springs can take high DepaInrtdmuesnttrsy Events stress ...60 Next Issue: Winter 2008 Wire Forming Events ..................................................4 ENdeiwtosriWal.i.r.e......................................4....2............EP......rx..e..v..h..i..e..iw..b......io..tf..i..I..on....tn..e....r,..w....Ci..r..e..o..2....n0....1f....9e..,..r..M..e..68anyc1e3 ,toC16o,n20v1e9n, intiATotolnwapn,i traPFe,roG2orA0du,0uUm8cS tPAsa.r neovdf i2eM0w0o7re in Atlanta Product Showcase......6..6......S...t..a..n...d...-.A....l.o...n..e....W....i..r.e...4T0rade Show in MRoosucnoduwp: Materials Advertisers’ Index ...............P...r.e.v..i.e.w....o.f..w...ir.e...R..u..s..s.i.a...2.0..1.69,3June 18 to 20, 201S9p, iontMliogshcot:w M, Reussshia W. elding Editorial Index...........................................................64 Next Issue: Summer 2019Fall 2007/Wire Forming Technology International 3 Departments SMI Metal Engineering eXpo 2019 Preview wire Southeast Asia 2019 Preview Wire Forming Events ............................................................4 wire South America 2019 Preview Editorial.................................................................................6 News Wire ............................................................................8 Roundups: Surface Treatment • Packaging Product Showcase..............................................................68 Advertisers’ Index ...............................................................71 • Fence Making & Wire Weaving Editorial Company Index ....................................................72 Spotlight: Rebuild & Upgrade Spring 2019/Wire Forming Technology International 3

WIRE FORMING EVENTS Table of Contents October 1Fa–ll 230,027019 Vol. 10, No. 4 May 13 – 16, 2019 Interwire 2019, Atlanta, GA, USA SMI Metal Engineering eXpo 2019 Feature Articles 1741 Akron Peninsula Rd, www.interwire19.com Pittsburg, PA, USA Dealing with hydrogen May 13 – 16, 2019 14 WFTI Technical Achievement AwaArdksr o–n C,laOssHo4f 24030173 USA WFA Spring Meeting, embrittlement Atlanta, GA, USA www.metalengineeringexpo.orgin spring Tel: +1 330 864 2122 • Fax: +1 330 864 5298Second Annual Wire Forming Technology International Technical Achievement Awards, given out annually to spring making or wire forming industry individuals for major technical developments October 16 – 17, 2019 steel....20 www.wireformingtech.comrelated to equipment, materials or accessories for making springs or wire formed parts. 16 “How Re-Engineering My Wire Forming WFA Fall Meeting DBruews iGnreeesnsbl aStt a- Av emdul tii-tp rfornogmed sEtrxatteignyc retsioulnted” in gCrowhthi pandL reipturpn itno pcrooftitatbility. www.wirefabricators.org 20 Hydrogen Embrittlement of SpringP Srteeseildent and Publisher June 13 – 15, 2019 Rockford, IL, USA [email protected] D. Sisson, Jr. - A review of the physical metallurgy of hydrogen embrittlement of China (Guangzhou) Int’l. Spring spring steel along with a discussion of mitigation methods. Industry Expo, Guangzhou, Chin www.wirefabricators.org www.julang.com.cn 23 Composition Effects in Carbon Steel SMtreinkgteh oMf StceNel,udeldtiycated to the September 17 – 19, 2019 Dr. Roger N. Wright - Part 6 of the multi-part series, The wire Southeast Asia 2019 metallurgy of spring making and wire formed partsVmiacneufPacrtuerisnigd. ent and Editor Bangkok, Thailand March 30, 2020 – April 3, 2020 Drum washer for springs and www.wire-southeastasia.com wire 2020 wire formed parts...30 24 Coatings for the 21st Century [email protected] www.mdna.com Kirtan R. Dhami - A look at high-performance and corrosion-resistant fluoropolymer/PTFE September 26, 2019 10th International Congress of coatings for springs and wire formed parts. Tom Hutchinson Spring Wire wDüwswse.lwdiorref-,tGraedrmefaainry.c o m Compact Hamburg, Germany 26 SDrt.rEecskesh aPrdeMeünllienr -gS –tre Ass P(shroatc) pteicenainl gAcpanpbliecuGastelidooibnnmalakSinaglaeusto Msusapennasigonecroil springs www.esf-springs.com for better material utilization via higher hardness trlehsu@ltinwg inirreedfuocremd miantegritael cushe.dc/roedmuced weight. October 1 – 3, 2019 www.mdna.commesh 30 Heat & Surface Treatment Roundup for the sJtaitme-ofM-thea-asrat inrheat wire South America 2019 welding cyl- Sào Paulo, Brazil inder...36 Editorial Staff - Suppliers have responded to our call www.wire-south-america.com www.mdna.com and surface treatment equipment. Senior Editor June 2 – 4, 2020 36 MDoororthee eFJleunxgiebbilolidtty- Aarnandg eVoef rmseashtiwlietyld infgojmra amtchh@ein eWws iisirrbeee iWfnogoromfrfekrieendrgtotewcirehw.corokemrs, and when set up by a well-trained worker, the downtime can be less than 30 minutes. WAI Operations Summit & 38 Machines for Producing Wire Hianntgeersrnational Sales Wire Expo 2020 globally with after-sales support and engineering. Sonia Vitari - Versatile wire hanger forming and other wire processing machines offered CHINA Uncasville, CT, USA 39 CASMI Scholarship Awards ReachR Tinogtaiel roTf UraSd$e4M63e,0d0i0a iLnt d20. 07 CExAcSeMrpIt e(Cdhfriocmagtoh eACssAoScMiaIEtCioaOnsN otNf CESCphrTiiInOngNa M,:aaVnpuuifbvalciictaautnrioenrSso,h fInacn.),gNa+p8er6vi-lle2,1IL,6U2S8A.9-5533, EXT 169 Swewpwte.mwbireern2e3t.o–r2g6, 2020 Versatile system for producing 4 4 IWtsi rAec Rtiovdit i&es C iona VtiennNge ozSurutephlpa& l&ie SrC oCouolutnhmsvCoibvlhiiaidiananat@e:sMr inaggigeiret rLadiue.+c8o 6m-20 8 732-3 316, wire hangers....38 Jacques Anckaert - Company intendsEtoXtapTth9e 3de3v2elopmingaggrogwitehlmiuar@ket rininLagtiineArmtrearicdae. .com wire China 2020, Shanghai, China 45 Company Profiles interHnaotionnagl sKpriongnagn:d MwireikfoermHedapyart+s i8nd5u2stry2. 369 8788, ext 11 Information of value to the www.wirechina.net Industry Events [email protected] www.mdna.com 37 Straight From The SSohuothweastTASoImA 20H07u, htcelhd iOncstGoobenEr,1R6G-M1l8o,A2b0aN0l7Y,SinaBlaensgkMok,aTnhaailganedr. Images and facts from wire October 7 – 9, 2020 Dep artments SPRING WORLD 2020, ® [email protected] Next Issue: WINinDtIeAr 2008 Wire Forming Events ..................................................4 Strategise.inToPpv Pt.rLodtdu.c,tAs bohf i2j0at07Sanghvi, Co-Founder Rosemont, IL, USA Editorial.......................................................................6 Tel : +91-22-w6i5re262300186 5P/r6e6v,ieCwell : +91-98211 27628 www.casmi-springworld.orgNews Wire ..................................................................8 REoumnadiul p: :a [email protected] Product Showcase....................................................40 Advertisers’ Index .....................................................63 Spotlight: MeIsThA WLeYlding Editorial Index...........................................................64 Casiraghi Pubblicatá Internazionale DFailel 2g00o7/WCirae FsoirrmaingghTeic,hnOololgiyvIneterrnCatioansail ra3ghi Tel: +39 031 261407 • Fax: +39 031 261380 [email protected] JAPAN Sakura International, Ken Myohdai Tel: +81 6 6264 3900 or +81 3 5646 1160 Fax: +81 6 6264 3901 or +81 3 5646 1161 [email protected] TAIWAN Worldwide Services Co. Ltd. Robert Yu Tel: +886 4 23251784 • Fax: +886 4 23252967 [email protected] Publisher's Notice: We assume no responsibility for the validity of claims in connection with items appearing in Wire Forming Technology International magazine. Ad- dresses are given to facilitate further inquiry. Wire Forming Technology International is published in the months of February, May, August and November by Initial Publications Inc., Chip Lippincott, Pres., 1741 Akron Peninsula Rd, Akron, OH 44313 USA. For subscription info write: Circulation Dept., Wire Forming Technology International, 1741 Akron Peninsula Rd, Akron, OH 44313 USA. For changes of address, visit www.wireformingtech.com. Wire Forming Technology International is distributed with- out charge to people employed by a company or division of a company engaged in the manufacture of springs, wire formed parts, wire mesh and rebar products and the materials, tooling, machinery and control systems for making those parts. Others may subscribe at US$35/yr in the USA and Canada or US$65/yr elsewhere. Single copy price is US$20 plus shipping. Editorial reprint prices will be furnished upon request.CanadaPostInternationalPublicationsMailProduct (Canadian Distribution) Sales Agreement No. 40025486. Canadian return address: BleuChip International, PO Box 25542, London, Ontario N6C 6B2 Canada. Postmaster: Send address changes to Wire Forming Technology International, 1741 Akron Peninsula Rd, Akron, OH 44313 USA. 4 Wire Forming Technology International/Spring 2019

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EDITORIAL Atlanta Highlights depression, not a recession, is coming to the USA in 2030. The root causes will be demographics, entitlements, infla- There will be a sizable contingent of equipment and ma- tion and debt. We can blame the baby boom generation terials suppliers in Atlanta this May exhibiting their latest for this dooms-day business cycle, and in 10 years, nearly products and services for making springs, wire forms, three-quarters of USA federal government spending will wire mesh and rebar products as well as associated educa- be consumed by interest, healthcare and social security tion, networking and information sessions. Everything is payments. The numbers don’t lie, so be prepared. centered around the Wire Association International’s bi- ennial Interwire exhibition and annual convention, which Reagan’s Warnings is previewed in this issue on pages 42 through 53 as well as online at www.interwire19.com. In addition to the wire After witnessing the repression, carnage and collapse forming related exhibits, here are some highlights that I of many communist and socialist states from the 20th think are important for wire product makers: century, it is not only a huge disappointment, but actual comedy bordering on the absurd that it is necessary for • Tariffs & Trade - Steel Wire Impact, by Howard Osler the president of the United States to denounce socialism Woltz, III, CEO of Insteel Industries. in a state-of-the-union speech while in the same week, left-wing politicians release, endorse and defend the lu- • State of Manufacturing, by Karl G. Glassman, President dicrous, incoherent and destructive “Green New Deal”. and CEO of Leggett & Platt. This nonsense is simply the latest and most ridiculous utopian plan of total government control disguised • AWPA's Breakfast at Interwire, by the American Wire as environmentalism and phony concern for common Producers Association (AWPA), www.awpa.org. people. This brings to mind the joke about rabid climate activists being called watermelons: green on the outside, • Interwire Welcome Reception at the Chick-fil-A College but red on the inside. Football Hall of Fame. For these activists, it is always about control and de- Business Cycles ception, which brings me a 30-year-old warning from Ronald Reagan. In his farewell address to the country, Earlier this year, consumer confidence in the USA rose to he spoke about the resurgence of national pride during its highest level in nearly 20 years following the end of the his time in office, and he said that going forward that we federal government shutdown, which is a red flag in my needed informed patriotism grounded in thoughtfulness book. Excitement about the federal bureaucrats restarting and knowledge. He then asked if we were doing a good their reckless spending habits is no cause for celebration enough job teaching our children what America is and in my view, so hopefully the improved consumer outlook what she represents in the long history of the world. He was buoyed by potential trade deal resolutions and tariff said that we have to teach history based not on what is in relaxations. In any case, I am more inclined to put my fashionable, but what’s important, and if we forget what stock in forecasts prepared by professional economists, we did, we won’t know who we are. especially ones that are looking carefully at industrial production levels and business cycles. In 1988, Ronald Reagan warned us that the eradication of the American memory would result in an erosion of A good example of this type of forecasting was contained the American spirit. Well, based on the historically and in an excellent economic presentation given by economic economically illiterate things we are hearing not only analyst Taylor St. Germain of ITR Economics™. His pre- from people born since then, but from their powerful and sentation was based on factual data and business cycles, famous parents and grandparents, we have obviously and ITR boasts impressive accuracy rates north of 90%, failed in the education department. Even though the so there was not much hyperbole in his presentation even American story isn’t being told properly, I say that it is not though it had a room quieting prediction at the end. Here too late to fan the flames of the informed patriotism fires are some key takeaways: that are still burning all over the USA. And if you want to join the fight, then teach responsible love of country to • 2019 will be a year of slowing growth in the USA. anyone right in front of you, because as another famous Ronald Reagan warn- • Overall USA GDP growth for 2019, 2020 and 2021 is ing says, “freedom is never more than forecasted to be 0.5%, 2.7% and 1.1%. one generation away from extinction”. • Overall USA industrial production growth for 2019, Mike McNulty, Editor 2020 and 2121 is expected to be 0.5%, 0.7% and 2.0%. [email protected] • The next USA recession will be in 2023, but it will not be as severe as the one we experienced in 2008-2009. • Growing sectors in 2019 include aircraft at +5.1%, medical at +3.3% and electrical equipment at +0.4%, while declining areas include automotive at -4.3% and computers at -1.2%. And now for the alarming prediction: ITR says that a great 6 Wire Forming Technology International/Spring 2019

“You’re Invited.” IN-HOUSE WAFIOS is proud to announce the 12th • World premiere of the FMU 20 EXHIBITION edition of its popular In-House exhibition in • World premiere of the F2 Ultra and F30 MAY 8-10 Wuppertal, Germany, where we will present • World premiere of the RE 50 WUPPERTAL numerous world premieres on more than • World premiere of the BM 36 GERMANY 15,000 square feet of exhibition space.* • Also on demonstration: B 36, BM 60, BMS 36 • WAFIOS proprietary technologies, including solutions and • Separate halls for our wire and tube solutions automation possibilities • Detailed information and registration at • Specialist lectures on E-Mobility, Smart Factory, and New Spring wwwwww.h.haauussmmeessssee.w.waafifiooss.c.coomm Technologies (Eng./Ger. versions) • Numerous co-exhibitors and partner companies antechnologies Engineered for What’s Next Spring Coiling & Forming Wire Bending & Forming Wire Straightening, Cutting Tube Bending & Forming Nail, Fastener & Chain Machines Machines & End Working Machines Machines Machines WAFIOS Machinery Corporation 27 NE Industrial Road, Branford, CT 06405 WAFIOS Midwest Technical Center 9830 W. 190th Street, Mokena, IL 60448 USA www.wafios.us / 203 481 5555 / sales@wafios.us Canada www.wafios.ca / sales@wafios.ca WAFIOS Machinery Corporation is a subsidiary of WAFIOS AG *Exhibition program subject to alterations. Please, refer to web site for current information.

NEWS WIRE Sjogren Releases smi metal engineering Track: Business Trends & Best 2019 Catalog eXpo Events Program Practices. • 8:00 AM – 8:50 AM: Evalua- Sjogren Industries has released The smi metal engineering eXpo, tion of Stress Concentrators an updated catalog for 2019 that sponsored by the Spring Manu- and Their Effect on Fatigue showcases new and improved facturers Institute (SMI), will be Life, Presenter: Jason Sicotte, additions to its product line. A held October 1 to 3, 2019, at the NPD Engineering Manager manufacturing innovator since David L. Lawrence Convention at Associated Spring, Track: 1927, Sjogren Industries provides Center in Pittsburgh, PA, USA. Materials & Testing. the highest quality machinery, • 8:50 AM: Coffee Break. tooling and accessories for the wire The events program has been • 9:00 AM – 9:50 AM: Breaking and cable industry. announced as follows: Boundaries for Operating • Monday, September 30, 9:00 Excellence…A Quest for a Sjogren continues to introduce Higher Performance Orga- enhancements in wire straighten- AM: Executive Committee nization, Presenter: Vince ing assemblies and components Meeting (Invitation Only), Bovino of Bovino Consult- that deliver major efficiencies Room TBA ing Group, Track: Business and increased productivity for its • 1:30 PM: Board Meeting (Invi- Trends & Best Practices. customers. These enhancements tation Only), Room TBA. • 9:00 AM – 9:50 AM: Crawl- are highlighted in the 60-page, • Tuesday, October 1, 3:00 PM – Walk-Run Your Way Into full-color catalog. 6:30 PM: Exhibit Hall Hours. Additive Manufacturing, Pre- • 5:00 PM – 6:30 PM: Opening senters: Dr. Timothy Simp- The catalog outlines the new Reception in the Exhibit Hall. son, Ph.D; Paul Morrow, Pro- SH and V Series Thumb Release • Tuesday, October 2, 8:00 AM fessor of Engineering Design pullers, the new Swivel multi – 8:50 AM: Tax Reform and & Manufacturing; Director, side hook and RC side hooks and Its Impact on Manufacturing, Additive Manufacturing & improved machinery from the Mo- Presenter: Michael Devereux Design Graduate Program of torized Die Stringer to Die Room II, Partner and Director of Penn State CIMP-3D at The Pullers and the Hand Pointer that Manufacturing, Distribution Pennsylvania State Univer- provides a simple solution to the & Plastics Industry Services sity, Track: Manufacturing, wire pointing process. at Mueller Prost, Track: Busi- Technology & Innovation. ness Trends & Best Practices. • 9:00 AM – 9:50 AM: Accelerate The Sjogren Industries catalog • 8:00 AM – 8:50 AM: Servo Success With Business Align- also provides information in the Technology Goes Show Floor, ment, Presenter: Vanessa company’s all-new line of Testing Presenter: Max Linder, Tech- Dodds, President & Founder and Handling equipment from the nical Sales Director at Bi- of Connections 4 Success, Bench Top Wrap Tester designed hler of America Inc., Track: Track: Business Trends & Best to test spring wire for ductility, Manufacturing, Technology Practices. or to test the adhesion of metal- & Innovation. • 9:00 AM – 9:50 AM; New De- lic coatings to the Torsion Twist • 8:00 AM – 8:50 AM: Session velopments for the Enhance- Tester, which identifies brittleness, TBA, Presenter: Bill Strauss, ment of Spring Production, inclusions, hidden seams and Senior Economist & Economic Presenter: Dr. Peter Weig- other flaws. Advisor at Federal Reserve mann of WAFIOS Machinery Bank of Chicago, Track: Busi- Corp., Track: Manufacturing, Sjogren Industries’ belief that, ness Trends & Best Practices. Technology & Innovation. “Simple ideas make better solu- • 8:00 AM – 8:50 AM: Study on • 9:00 AM – 9:50 AM: The Role tions,” has been at the core of the Fatigue Diagrams of Helical of Human Resources in Busi- company’s innovative product Compression Springs, Pre- ness Planning: Metrics, Mea- designs since its inception, and senter: TBA, Company: Japan surements and Linking HR this belief is reflected in Sjogren’s Society of Spring Engineers, to Financial Objectives, Pre- 2019 product line. Track: Manufacturing, Tech- senter: Bob Floreak, President www.sjogren.com nology & Innovation. of Acuity Human Resources, • 8:00 AM – 8:50 AM: The Track: Business Trends & Best 30-Minute Marketing Plan, Practices. Presenter: Eric Keiles of • 9:00 AM – 9:50 AM: Body- Square 2 Marketing Inc., cote Kolsterising, Presenter: Derek Dandy, Marketing 8 Wire Forming Technology International/Spring 2019



NEWS WIRE Development Engineer of Presenter: Max Linder, Tech- tion of innovation including sto- Kolsterising, Track: Materials nical Sales Director at Bi- ries of global contributions from & Testing. hler of America Inc., Track: local Pittsburghers like Carnegie • 10:00 AM – 05:00 PM: Exhibit Manufacturing, Technology Steel and Mister Rogers’ Neighbor- Hall Hours. & Innovation. hood. Several of the biggest fea- • 5:30 PM – 7:30 PM: Offsite • 9:00 AM – 9:50 AM: The New tures of the museum are dedicated Networking Event Location: Age of Local Digital Market- to the businesses and sports teams Senator John Heinz History ing: User Experience and Digi- of Pittsburgh. Center. tal Knowledge Management, • Thursday, October 3, 8:00 Presented by: Dan Harmon, Tickets are US$85 per person for AM – 8:50 AM: Session TBA, VP at Higher Images Inc., this event and must be purchased Presenter: Laura Rhodes, Track: Business Trends & Best as part of your event registration. SMI Technical Committee at Practices. www.metalengineeringexpo.org Spring Manufacturers Insti- • 9:00 AM – 9:50 AM: New tute, Track: Business Trends Developments for the En- William Hughes & Best Practices. hancement of Producing Wire Adds Salt Spray • 8:00 AM – 8:50 AM: The New Forms, Presenter: Dr. Peter Testing Equipment Dawn of Manufacturing in Weigmann at WAFIOS Ma- America, Presenter: Rosemary chinery Corp., Track: Manu- Hot on the heels of its fatigue Coates, Track: Manufacturing, facturing, Technology & In- testing facility, William Hughes Technology & Innovation. novation. has added salt spray testing to its • 8:00 AM – 8:50 AM: Research • 9:00 AM – 9:50 AM: Glob- cannon of quality control proce- into the Limitations of Nitrid- al Cost Drivers in the Wire dures. Salt spray or salt fog testing ed Spring Design and Future Industry, Presenters: SMI exposes springs and other compo- Research at IST, Presented Technical Committee Chairs, nents to a saline fog environment by: Dr. Conor McCaughey, Track: Business Trends & Best in order to ascertain the corrosion Track: Business Trends & Best Practices. resistance of the material of which Practices. • 9:00 AM – 9:50 AM: Niti- they’re made or the surface coat- • 8:00 AM – 8:50 AM: Report nol Shape Memory Alloy, ing thereof. A controlled saline of Research Committee on Presenter: Dave Plumley, situation will show how long it Height Reduction of Com- Nithinol Technology Develop- takes for a component to accede pressive Coil Spring, Pre- ment Manager at Fort Wayne to rust or other oxides, if indeed it senter: TBA at Japan Society Metals, Track: Materials & succumbs at all. of Spring Engineers, Track: Testing. Manufacturing, Technology • 10:00 AM – 2:00 PM: Exhibit Equipment required for the & Innovation. Hall Hours. salt spray chamber comprises the • 8:00 AM – 8:50 AM: Exit/ The Opening Reception on Oc- holding tank with its salt solution Succession Planning for Baby tober 1, from 5:00 PM to 6:30 PM of between 4% to 6% pH and the Boomer Business Owners, in the Exhibit Hall at the David L. salt spray cabinet itself where the Presenter: John “Jack” Ells- Lawrence Convention Center is salt water solution is atomized worth, Shareholder at Cottrill the perfect time to get a glimpse using pressurised air. The samples Arbutina, Track: Business of what’s in store on the exhibit to be tested are then exposed to Trends & Best Practices. hall floor. Plus, you’ll enjoy the this extremely corrosive saline • 8:00 AM – 8:50 AM: Theory opportunity to make introductions fog for the requisite amount of of Stress Relaxation Behavior and building relationships that are time, which can be days or weeks in Compression Springs, Pre- important to the success of your depending on the standard to senter: Dan Sebastian, Track: business. be achieved. Regular daily tests Materials & Testing. The Heinz Museum Party on • 8:50 AM: Coffee Break October 2, from 5:30 to 7:30 PM is • 9:00 AM – 9:50 AM: Accelerate a very special networking event Success With Business Align- at the Senator John Heinz His- ment, Presenter: Vanessa tory Center, an iconic Pittsburgh Dodds of Connections 4 Suc- venue that houses Pennsylvania’s cess, Track: Business Trends largest history museum and is a & Best Practices. proud affiliate of the Smithsonian • 9:00 AM – 9:50 AM: Servo Institution. Technology Goes Show Floor, Explore Pittsburgh’s rich tradi- 10 Wire Forming Technology International/Spring 2019

VISIT US AT: BOOTH 317

NEWS WIRE ensure that temperature and the with his technical ability, makes Hyperco engineers and manu- specific gravity of the salt solution him the ideal fit for this role. factures precision, high-perfor- are maintained at a level consistent www.ipsenusa.com mance suspension coil springs, with ASTM B117, an international- kits and related components ly recognized salt spray standard. Hyperco Expands supporting original equipment Line in Response manufacturers and aftermarket The salt spray test is generally to 2019 IMCA Rules customers in motorsports, street applied to items coated in, for ex- performance, off-road, power- ample, Delta-tone® or KTL-Black. Hyperco, Chicago, IL, USA, sports and automotive markets. These coatings, used in the aero- an MW Industries company, Hyperco’s catalog and custom space and automotive industries, announces an all new line of per- products are designed to improve typically are required to meet formance springs designed specifi- the total performance, aesthetics specifications, which include a cally to meet the 2019 IMCA Modi- and durability of vehicles. number of hours of salt spray test- fied Series regulations. The new www.hypercoils.com ing. The requirements that William Hypercoil 9.9\" free length by 5\" OD Hughes meet range from 48 hours front springs, available in 350, 400 New Fortuna Federn to over 600 hours of salt spray test- and 450 lb rates, were developed Machines Installed ing. www.wmhughes.co.uk based on extensive research from lead- Fortuna Federn of Austria has Ipsen USA Promotes ing IMCA modi- installed a new WIM-14 CNC WCS Matt Clinite to Service fied competitors, 5AX in New Zealand. This ma- Sales Manager chassis builders chine can handle wire diameters and shock partners. from 6 up to 18 mm (0.197\" up to Ipsen USA, Cherry Valley, IL, These new products 708\") and can coil with a speed of USA, is pleased to announce the factor in the high up to 150 rpm. promotion of Matt Clinite from stress levels of vary- Midwest Regional Sales Owner ing track conditions seen on the Fortuna Federn has also re- to Ipsen Customer Service Sales IMCA circuit, and are designed ported the successful installation Manager, effective immediately. to withstand repeated abuse in the of a brand new COM-20 CNC S. harshest of environments, while The new COM-20 CNC S is an In this newly created position, maintaining Hyperco’s legendary advanced machine version. It is Clinite will be respon- tolerance for installed height and designed for 24/7 application in sible for building the load consistency. Ipsen Customer Service sales team to provide In addition, Hyperco has added best-in-industry after- additional rates of 50 and 85 lb market support for parts, engi- to its 16\" by 5\" OD conventional neered solutions and service. Clin- line of SNU series springs. With ite joined the company in 2014 as a a limitation of a 16\" free length on Sales Engineer and most recently the rear of the IMCA Modified, has served as the Regional Sales the Hyperco line now offers more Owner for the Midwest Region. incremental rates ranging from 50 He earned his Bachelors Degree to 250 lb to suit the needs of any in business administration from competitive racer. Illinois State University in 2011. “Hyperco supports the new “Since day one, Matt has in- IMCA rules that specify maxi- fluenced Ipsen in a positive di- mum and minimum spring free rection,” said Pete Kerbel, Vice length and outside diameter for President of Sales, Ipsen USA. both front and rear suspension,” “Matt has excelled because of his stated Kelly Falls, Vice President work ethic and determination to of Hyperco. “By using the newly solve problems for customers.” optimized Hypercoil 9.9\" free length front spring line, racers Ipsen’s customer service team is will gain a performance advantage responsible for providing custom- with additional usable deflection ers with comprehensive aftermar- while remaining in compliance ket support and services. Matt’s with the 2019 rules.” experience and proven approach to customer service, combined 12 Wire Forming Technology International/Spring 2019

OFAGCROINMDPINLEGTME ARCAHNIGNEES M1 H50 H100-1 H110-1 M3-S M4D H150 MA6-1E MA6-2E HA100-2 MA6-D HA100-2-2 MA9-1E MA9-2E MA10-1E MA16-1E MA16-2E MA10-2E OMD OFFICINA MECCANICA DOMASO SPA 22013 Domaso (CO) • Italia • Via Case Sparse, 205 • Tel. +39 0344 97496 • Fax + 39 0344 96093 http://www.o-m-d.it • E-mail: [email protected]

NEWS WIRE the production line. at the University of Michigan. Dr. The company says it is now The COM-20 CNC S is capable Hart’s areas of expertise include easier to contact BB Spring Tech- additive manufacturing, advanced nology as well as to find the near- of coiling 18 mm EN 10270-2 OT materials, machine design, au- est agent. Customers can stay CrSi wire, making it a leading tomation and nanocomposites. tuned about any on-sale machine machine on the market. He has worked extensively with or any work possibility thanks to www.fortunafedern.com industry in these areas and has the news page. co-founded three start-up com- Carpenter Technology panies including Desktop Metal. The company says the new Adds Two to Its Board Dr. Hart earned his Master’s and website makes BB Spring Technol- Ph.D. degrees from MIT, and his ogy more accessible and efficient. Carpenter Technology Cor- undergraduate degree from the www.bbspringtechnology.com poration, Philadelphia, PA, USA, University of Michigan. recently announced that Dr. Viola BASF Expands Scope in L. Acoff and Dr. John Hart have “We welcome both Viola and Asia Pacific with New been appointed to the company’s John to Carpenter Technology’s Facilities & Solutions Board of Directors, effective im- Board of Directors. Their exper- mediately. The Carpenter Board tise in the materials, engineer- BASF is enhancing its regional now consists of 12 members, 11 of ing and additive manufacturing innovation capabilities with new whom are independent directors. space further supports Carpenter facilities at the Innovation Cam- Technology’s strategic objective pus Shanghai, Shanghai, China, Dr. Acoff is currently the As- to be a leading solutions provider to further strengthen collaboration sociate Dean for Undergraduate across all the markets we serve,” with the automotive industry and and Graduate Programs at The said Gregory A. Pratt, Chairman to offer new process catalysts to University of Alabama College of the Board. the chemical industry. of Engineering, a position she has held since 2014. For the last Carpenter Technology Cor- With an investment of around 15 years, she has been a professor poration is a leading producer €34 million, the new 5000 m2 facili- in the University’s Department of and distributor of premium spe- ties includes the Automotive Ap- Metallurgical and Materials En- cialty alloys including titanium plication Center and the Process gineering, where she also served alloys, nickel and cobalt-based Catalysis Research & Develop- as Department Head from 2009 to superalloys, stainless steels, alloy ment (R&D) Center. 2014. Dr. Acoff also led the Depart- steels and tool steels. Carpenter’s ment of Chemical and Biological high-performance materials and At the recent inauguration, the Engineering. Her areas of exper- advanced process solutions are company also presented a range tise include additive manufactur- an integral part of critical applica- ing, welding metallurgy, physical tions used within the aerospace, metallurgy, titanium and nickel transportation, medical, energy alloys, and materials characteriza- and other markets. Building on its tion using electron microscopy. history of innovation, Carpenter’s She is a Doctor of Philosophy in metal powder technology capabili- Materials Engineering and holds ties support a range of next-gener- graduate and undergraduate de- ation products and manufacturing grees in the same field. All degrees techniques including Additive were earned at the University of Manufacturing and 3D Printing. Alabama at Birmingham. www.cartech.com Dr. Hart is an Associate Profes- BB Spring’s New sor of Mechanical Engineering at Website Now On-Line the Massachusetts Institute of Technology (MIT). He is also the BB Spring Technology reports Director of the MIT Laboratory for that thanks to its new website, Manufacturing and Productivity, it is now possible for custom- and the Center for Additive and ers to view all of the company’s Digital Advanced Production products. Every spring coiling Technologies. Prior to joining machine or wire payoff has its own the MIT faculty in 2013, Dr. Hart dedicated page. The website also was Assistant Professor of Me- present a dedicated page for all chanical Engineering, Chemical services offered to the customers. Engineering and Art and Design 14 Wire Forming Technology International/Spring 2019

TOO GOOD. Precision. Performance. Introducing the newest line from Simco. Ultra High Simco YM-80 Speed • 7-axis CNC coiler with up to 16 axes (Up to 40% faster • 3.50-8.0mm (.138-.312\") wire range • Available options include: than EM-80) – IT-axes (2) for better controlling and improving initial tension – Optical camera gage with three-way sorter (Now with single point checking and OD compensation.) – Arbor retraction (in/out) by servo (up and down by servo is std.) Simco SFX-20 & SFX-40 • 11 axes standard and upgradeable to 18 axes max • SFX-20 0.50-2.60mm (.020-.102\") wire range • SFX-40 1.80-4.20mm (.071-.165\") wire range • 21\" touchscreen display • Beckoff Controls with reliable EtherCAT network • Modular design with four sliding tables with 2-dimensional movement • Large work zone for complicated parts • Scaled sides that can hold multiple tools for maximum flexibility and ease of setup • Easy-to-use Windows OS software features a patented, timeline-based program so multiple motions can be synchronized Michael Shapiro [email protected] | 847-383-5442 708 Anthony Trail, Northbrook, IL 600062 www.gibraltar8.com

NEWS WIRE of locally-developed innovations ville, NC, USA. The company’s company’s mission to provide which support customers in indus- core business includes designing, tries like automotive, construction building, machining and test- winning engines through demon- and consumer goods, and which ing purpose-built race engines. address important market trends Ford Performance in partnership strated power and performance. to reduce emissions, increase with Roush Yates Engines is the energy efficiency and enhance exclusive engine builder of the “Starrett is glad to work with a performance. BASF launched an NASCAR FR9 Ford V8 engine innovative waterborne coating and twin-turbo EcoBoost Ford V6 high demanding customer such as system on the same occasion. race engine that powers the Ford GT super car. Roush Yates Engines, as they use “China’s most important growth industries can benefit “Starrett’s brand is iconic and precision with everything they enormously from innovations in known worldwide, while its sup- chemistry. Thanks to continuous port to our racing programs has do,” said Emerson Leme, Head investment in research and de- provided competitive advantages velopment over the past several to win races,” said Todd English, of Starrett Metrology Division. years, we are able to support our VP Business Development, Roush customers in China and the entire Yates Engines. “We rely on their “Starrett has been a long-standing Asia Pacific region as they strive to employee’s workmanship in their improve consumers’ quality of life, manufacturing facilities in Athol premier supplier to Roush Yates address the challenges of rapid de- and across the globe. We look velopment and meet their sustain- forward to expanding our valued Engines for many years and ex- ability goals,” said Dr. Stephan partnership and leveraging Star- Kothrade, President Functions rett’s force and vision measure- tending this partnership is a win Asia Pacific, President and Chair- ment systems.” man Greater China, BASF. for all of us.” “We utilize Starrett’s inspection “At the Innovation Campus equipment for accuracy, reliability www.starrett.com Shanghai, we are continuously and repeatability,” said Jennifer enhancing our R&D capabilities LaFever, NASCAR QA Manager, www.roushyates.com in advanced materials, chemical Roush Yates Engines. “We must process engineering and catalysts have 100% confidence that our www.roushyatesmfg.com by integrating new technologies parts are accurate and correct and building our teams,” said every single time. Starrett tools AWPA Breakfast Dr. Harald Lauke, President, provide us that confidence, when at Interwire 2019 Advanced Materials & Systems there is no room for error.” Research and Research Represen- The American Wire Producers tative Asia Pacific, BASF. “We have With an unparalleled culture of Association (AWPA) Breakfast at invested nearly €180 million here winning and steeped in rich rac- Interwire 2019 will be held May since 2012. More importantly, our ing history, Roush Yates Engines 15, 2019, from 7 AM to 10 AM, R&D experts work closely with continues to follow the company’s in room 404/405 of the Georgia our business teams and customers, vision to lead performance engine World Congress Center in Atlanta, so as to shorten the time-to-market innovation and staying true to the GA, USA. of innovative products.” www.basf-coatings.com More information on this event will soon be available from the Starrett Renews AWPA. www.awpa.org Partnership with Roush Yates NESMA Events in 2019 L.S. Starrett Company, Athol, The New England Spring MA, USA, and Roush Yates En- & Metalstamping Association gines have announced a multi- (NESMA) will hold its Annual year partnership extension agree- Golf Outing on September 16, ment. Roush Yates Engines is a 2019, from 10:30 AM to 7:00 PM cutting-edge engine development at the Chippanee Golf Club, Inc., company, with three state-of-the- Bristol, CT, USA. art facilities based in Moores- The NESMA Annual Holiday Party takes place on December 5, 2019, from 6:00 PM to 10:00 PM at 16 Wire Forming Technology International/Spring 2019

the Farmington Club, Farming- NEWS WIRE (SVT) is an important addition to ton, CT, USA. the global organization, offering ensure we continue to offer world- solutions for both the heat treat- NESMA will also hold its An- class manufacturing performance ment of metals in controlled atmo- nual Meeting on December 6, 2019 across all of the industries we spheres and vacuum technologies from 9:00 AM to 10:00 AM at the serve.” www.alloywire.com in the North American market. DoubleTree by Hilton in Bristol, CT, USA. www.nesma-usa.com SECO/VACUUM “The purpose of creating the Delivers 50 Solutions SVT company was to provide Strong Sales Recorded current and future customers with at Alloy Wire The youngest company in the products as well as maintenance SECO/WARWICK Group, SECO/ services that would meet the As featured recently in Insider VACUUM Technologies LLC Media, Alloy Wire International (AWI) has recorded its best-ever GQ wire guide month in its 73-year history. AL6 AL12 feeder Alloy Wire, which supplies more than 60 different high-per- ASM-ADM AS-AD formance nickel alloys, has se- wire straightener wire straightener cured more than £1.2 million of sales in January 2019, shipping 339 complete range of equipments for the individual orders to customers in processing of wire 27 different countries. Via Cabella Lattuada 41 23841 Managing Director Mark Ven- Annone Brianza Lc Italy ables, said, “2018 was our best- +39-0341-263090 ever year, with about £11 million [email protected] of orders secured and delivered. www.cometo.ws “We thought this was good, but 2019 has got off to a flying Spring 2019/Wire Forming Technology International 17 start, culminating in our first-ever month where we have enjoyed sales of more than £1 million. “We’ve just continued doing what we do best, providing more than 60 high-performance alloys in just three weeks, with repeated reliability.” Alloy Wire has also signed off a £250,000 investment that will see the arrival of three new machines to boost speed, repeatable quality and capacity. Sales Director Angus Hogarth, added: “There’s no point basking in what we achieved in 2018, we need to focus on where the market is going and make sure we are at the forefront of any changes. “The spend for this year will go towards automating part of the process and bringing in new tech- nology that will help us continue the production of high-quality wire—in varying sizes and vol- umes—even quicker. “Finally, there is also the small matter of going for three major quality re-accreditations that will

NEWS WIRE standards and expectations of the Homeland Security, turers is securing its position as a North American market. So far, will greet NASF at- key international supplier for the SECO/VACUUM, which began its tendees and deliver automotive and industrial sector. operations at the start of 2017, has remarks at NASF’s delivered 50 complete solutions in annual Washington Over the last 12 months, Eu- such a short time,” said Managing Forum, April 15, 2019. ropean Springs & Pressings, Director, Piotr Zawistowski. has invested over £2 million in Creation of the USA’s 15th Cabi- its two Cornish factories with The most popular solution is the net Department marked the larg- an addiional £1 million invested SECO/WARWICK Vector vacuum est reorganization of government more recently in a number of new furnace line. As much as 50% of since the Truman administration. advanced technologies. A new the equipment provided by SECO/ During his tenure at Homeland powder-coating line has been in- VACUUM constitutes a universal Security, Secretary Ridge worked stalled in a 700 m2 extension, a new single-chamber vacuum furnace with over 180,000 employees from heat treatment oven acquired and used for annealing, brazing, hard- 22 government agencies to cre- two high-performance spring-end ening and tempering as well as ate an entity that facilitated flow grinding machines complete the low-pressure carburizing. This is of people and goods, instituted recent purchases. because every year various indus- layered air/land/seaport security, try sector customers expect higher developed a unified national re- The new equipment, spread reliability, efficiency and better sponse and recovery plan, pro- across the Penryn and Redruth results in their heat treatment tected critical infrastructure and factories, has doubled the grind- operations. The wide range of improved information sharing ing capabilities in the company’s possibilities offered by the Vector worldwide. Prior to September industrial sector and expanded technology are utilized in tool and 11, 2001, Ridge was twice elected the automotive sector grinding die manufacturing, aviation, en- Governor of Pennsylvania as well facilities by 400%. The new heat ergy, automotive and commercial as served six terms as a member of treatment oven and powder coat- heat treatment. The commercial the US House of Representatives. ing line increases automotive pro- heat treatment industry accounts duction infrastructure by 200%. for 30% of SVT customers. Ridge serves on the boards of the Institute for Defense Analy- Michael Gibbs, Managing According to Zawistowski, or- ses and the Center for the Study Director of the Cornwall op- ders for new, high-efficiency vacu- of the Presidency and Congress. erations, concludes, “Develop- um furnaces, “Come from the most He is Chairman of Ridge Global, ing enhanced manufacturing demanding industries—aero- LLC and the Ridge Global Cyber- capabilities through investment space, military and automotive. security Institute and a Partner of in high-tech infrastructure and These are most likely to choose Ridge Policy Group, LLC, which education, enables us to sustain ZeroFlow® nitriding furnaces and offers solutions to cybersecurity, manufacturing competitiveness. CaseMaster Evolution® (CMe) international security and risk With a global market place across multi-chamber vacuum furnaces management. multiple industries, it is essential equipped with PreNitLPC® and that we maintain our reputation FineCarb® LPC technology.” NASF’s Washington Forum for innovation and manufacturing provides valuable insights on excellence. The recognition of ZeroFlow developments and challenges and CaseMaster Evolution tech- impacting the surface finishing “We’re accelerating our indus- nologies is due to the huge poten- industry. Participants gain insight trial and automotive sector exper- tial of both solutions and applica- from industry experts during for- tise, through operational focus, in tion capabilities. Both products mal sessions, and share their views direct response to customer de- are included in the catalog of the directly with Senators, Represen- mand. Our program of machinery SECO/WARWICK Group's flag- tatives and Congressional Staff. financing is strategic, reflecting a ship products due to their quality, The Forum assists the finishing in- number of years of record growth efficiency and reliability of the dustry in fostering positive work- and our parent company’s, Lesjo- results of heat treatment processes. ing relationships with regulatory fors, global position as an investor www.secowarwick.com officials. www.nasf.org Governor Tom Ridge to Record Investments Speak at NASF Forum by European Springs & Pressings Tom Ridge, former Governor of Pennsylvania and America’s first Ongoing investment in one of Secretary of the Department of the UK’s leading spring manufac- 18 Wire Forming Technology International/Spring 2019

in manufacturing.” NEWS WIRE for the first time. Fasteners and European Springs & Pressings springs will be presented in Halls multi-purpose Hall 1, which can 16 and 17. Ltd. has sites in Cornwall, London accommodate up to 10,000 people and Yorkshire. It is part of the with its 129,200 ft2, will offer Tube In 2020, wire will be presented Lesjofors parent company with 28 exhibitors new display options. in Halls 9 to 12 and 14 to 17. On spring manufacturing companies More space also means more show will be machinery and across Europe, America and Asia. growth potential. Exhibitors can equipment for wire manufactur- www.europeansprings.com book larger, versatile and digi- ing and wire processing, process tally equipped stands to present engineering tools and auxiliaries, William Hughes Named their product portfolio optimally. materials, fiber optic technologies, “Company of the Year” In addition, end products will be special wires and cable as well as included in the wire 2020 portfolio William Hughes reports that it has been selected by Industrial Process News as the publication’s Company of the Year. The selection as Company of the Year is in recognition of Hughes’ achievements in the de- sign and manufacturer of springs, wire parts and assemblies for a variety of industrial applications. OCTOBER 1–3, 2019 • PITTSBURGH SMI is the community and Metal Engineering eXpo is the networking event. Dan Sceli, CEO, Peterson American Corporation The award also takes into ac- EDUCATION AND EXPERTISE count the success of William FOR THE ENGINEERED SPRING Hughes’s newly installed 80 m² AND PRECISION METAL class 7 clean room. COMPONENTS INDUSTRIES. www.wmhughes.co.uk Presented by Become an exhibitor or register to attend at wire 2020 & Tube 2020: Larger and With an metalengineeringexpo.org Extended Concept Spring 2019/Wire Forming Technology International 19 From March 30, 2020 to April 3, 2020, wire 2020 and Tube 2020, will again be held at the fairgrounds in Düs- seldorf, Germany. On-line exhibitor registration is now open at the websites below. Messe Düs- seldorf, expects some 2600 exhibi- tors on 1.2 million ft2 of net exhibit space in 15 halls and over 70,000 visitors from some 130 countries to participate in 2020. For the first time, the new

NEWS WIRE measuring, control and automa- In addition to wire and Tube forming technology, spring mak- tion technology. in Düsseldorf, there are now ing technology, cable and strand- also eleven international satellite ing machines, process engineering In addition to wire and cable events for the wire, cable, tube and tools and auxiliaries as well as machinery manufacturers, wire pipe industries. In their regions, measuring, control and automa- and cable products, fiber optic these trade fairs are market leaders tion technology. Also, all types of technologies and dealers in Halls with high growth potential. Trade wire such as wire rod, bare wire, 9 to 12 and 14 to 17, and mesh fairs in Russia, Brazil, China, railings, special wire, cable and welding machinery will be seen in Thailand, India and the USA form sheet metal will be shown. Hall 15. They present logistics with part of the portfolio of the Metals demanding challenges since heavy and Flow Technologies trade fairs Despite cautious growth pros- machinery requires particularly organized by Messe Düsseldorf. pects for 2019, investment by thick cables to be installed in the Contact Messe Düsseldorf North private business and digitization supply shafts to generate power. America (MDNA), Chicago, IL, projects are predicted to provide In Hall 13, Chinese exhibitors will USA to learn more. significant impetus for the Russian again showcase their wire and www.wire-tradefair.com economy, with increased demand cable solutions under the heading www.tube-tradefair.com for wire and cable machinery. “meet China´s expertise”. www.mdna.com Contact Messe Düsseldorf A premiere in Halls 16 and wire Russia 2019 North America (MDNA), Chi- 17—for the first time the complete On-Line Exhibitor cago, IL, USA. value chain for fasteners and Registration www.wire-russia.com springs will be presented in these www.mdna.com halls. In addition to raw materi- On-line exhibitor registration als, machines and equipment, for wire Russia 2019 is now open Blue Blade Steels the finished products—fasteners, at the website below. The leading Invests in Strip Steel connectors and industrial springs Russian trade fair for the wire will also be on display. For manu- and cable industries takes place New in 2019, Blue Blade Steel facturers, distributors and buyers in Moscow, June 18 is joining the new Flex-Flat tech- of screws, fasteners, construction to 20, 2019. In order nology from Ebner with Blue and fitting components as well as to facilitate further Blade Steel’s lead-free process as springs of all kinds and bent wire growth at the Kras- part one of a multi-phase invest- parts, wire in Düsseldorf will be a naya Presnya exhi- ment strategy designed to expand new information and order plat- bition center, wire upon existing capabilities and form in 2020. Russia will be held target new markets and further as a stand-alone event this year. growth. This multi-million dollar The entire process chain of the At the last staging in 2017, wire investment by Blue Blade Steel tube industry will be presented at Russia was held together with the will ultimately have laser sensing Tube 2020, in Halls 1, 3, 4, 5, 6, 7.0 Tube Russia, Metallurgy Russia and technology designed to automati- and 7a. Litmash Russia trade fairs. cally affect the flatness once fully operational. The extensive ranges will in- Jointly organized by Messe clude machinery and equipment Düsseldorf, its subsidiary, Messe This Flex-Flat system is de- for tube manufacturing and tube Düsseldorf Moscow and its local signed to improve flatness beyond processing as well as raw materi- partner, VNIIKP, more than 200 the industry standard tolerance als, tubes and accessories, used exhibitors from some 25 countries of 0.003 PIW max. concavity. Blue machinery, process engineering are expected to present their latest Blade Steel welcomes the opportu- tools, auxiliaries, measurement, products and technologies at wire nity to review any flatness critical control and testing technology. Russia 2019. In addition to many specifications you have, please These exhibits will be comple- exhibitors from Russia and its send your specifications and quote mented by tube and pipeline neighboring countries, there will requests for prompt review by our trading, OCTG- technology as well again be companies from Ger- expert sales team. as profiles, machines and plastic many, Belgium, the Netherlands, www.bluebladesteel.com tubes. France, Great Britain, Austria, Switzerland and Italy. Bekaert Makes Tube makers and distributors Organizational & will be in Halls 1, 3 and 4 with The exhibitors will display ma- Leadership Changes ample space to exhibit machinery, chinery and equipment for wire equipment and products. Tube production and wire processing, A new organizational structure processors will be in Halls 5, 6 and has become effective at Belgium- 7a, while Hall 7.0 will feature the “meet China’s expertise” exhibits. 20 Wire Forming Technology International/Spring 2019

based Bekaert. The new organi- NEWS WIRE to be the preferred supplier for zational structure consists of four its steel wire products and solu- Business Units and four Global main in the position of Chief tions by continuously delivering Functional Domains. Human Resources Officer for the superior value to its customers on company. a worldwide basis. The new Bekaert Group Ex- ecutive, which is being led by And Curd Vandekerckhove Bekaert is a global company Matthew Taylor, Chief Executive has been appointed Chief Opera- having approximately 30,000 Officer (CEO), will be focused on tions Officer. employees on a worldwide basis, value growth and higher-level and the company has €5 billion in performance. Bekaert is a world market and combined revenue. technology leader involved in steel www.bekaert.com The newly established Business wire transformation and coating Units that are currently being an- technologies. nounced at Bekaert include the following. The company makes it its goal The Business Unit Rubber Re- OCTOBER 1–3, 2019 • PITTSBURGH inforcement (serving industries that make use of tire cord, bead We frequently purchase large pieces wire, hose reinforcement wire and of equipment right off the show floor transportation belt reinforcement) because we can compare manufacturers’ will be led ad interim by Lieven Larmuseau, until the appoint- offerings in real time and engage ment of a Divisional CEO Rubber our production staff in the Reinforcement. decision-making process. The Business Unit Steel Wire Steve Kempf, President, SMI Solutions (serving industrial, agri- CEO, Lee Spring cultural, consumer and construc- tion markets with a broad range EDUCATION AND EXPERTISE of steel wire products) will be FOR THE ENGINEERED SPRING led by Stijn Vanneste, Divisional AND PRECISION METAL Chief Executive Officer, Steel Wire COMPONENTS INDUSTRIES. Solutions. Presented by Become an exhibitor or register to attend at The Business Unit Specialty Businesses (including building metalengineeringexpo.org products, fiber technologies, com- bustion technology and sawing Spring 2019/Wire Forming Technology International 21 wire) will be led by Jun Liao, Divisional Chief Executive Officer, Specialty Businesses. The Business Unit Bridon- Bekaert Ropes Group (ropes and advanced cords businesses) will continue to be led by Brett Simp- son, who is the Chief Executive Officer of BBRG. These new Business Units will all have global P&L accountability for strategy and delivery in their distinct areas. Additionally, they will have dedicated production facilities and commercial and technology teams. Additionally, Frank Vromant will continue as Chief Financial Officer ad interim, until a new, permanent Chief Financial Officer is appointed. And Rajita D’Souza will re-

CASMI News & Events Update by: Chicago Association of Spring Manufacturers, Inc. Michael Bandy Chicago Association of Spring Manufacturers, Inc. (CASMI) 350 S. Poplar Avenue Elmhurst, IL 60126 USA www.casmi-springworld.org CASMI Golf Outing CASMI Board Directors: Will Take Place This June  Anthony “Tony” Iuliano  Rapid Wire Forms, Inc. The Chicago Association of Spring Manufacturers, Inc. (CASMI) will host its Annual Golf Tournament  Chris Kozka at the competitive Bloomingdale Golf Club located  Mohawk Spring Corp. in Bloomingdale, IL, USA, on June 18, 2019. The course will welcome the average player and will  Daniel Schneider challenge everyone.  O’Hare Spring Co., Inc. The day’s activities include lunch, shotgun start golf tournament, cocktail hour and dinner. Also, various prizes will be presented throughout the evening. All CASMI members, SpringWorld® 2020 exhibitors, and suppliers who are interested in exhibiting at SpringWorld are encouraged to attend this great in- dustry event. Start putting together your foursomes today to join the competition and for a relaxed net- working atmosphere with your industry colleagues. Details will be posted on the CASMI web site: www.casmi-springworld.org CASMI Inducts New Officers & Board at Biennial Dinner Dance & Spring Fling CASMI formally inducted its new Officers and Di- rectors who will serve on the organization’s Board of Directors during 2019 and 2020. The ceremony took place during CASMI’s Biennial Spring Fling & Dinner Dance on February 23, 2019 (see accompa- nying photographs). The inductees are as follows. President:  Tony Pesaresi  Winamac Coil Spring, Inc. Vice President:  Joe Wesner  Sterling Spring Corp. Secretary-Treasurer:  Sandy Lidman  Mohawk Spring Corp. Immediate Past President:  Joshua Kahn  Perfection Spring & Stamping Corp. 22 Wire Forming Technology International/Spring 2019

SpringWorld® 2020 Update More About CASMI: SpringWorld 2020 will take place from October 7 CASMI was founded in 1944 as an independent, not-for-profit to 9, 2020, at the Donald E. Stephens Convention trade association dedicated to development of good business Center in Rosemont, IL, USA. With nearly 70% of practices and sharing of technical information through ongoing available space sold on the trade show floor, com- communications among the job-shop spring manufacturers in panies that are interested in exhibiting at the 2020 the greater Chicago, IL, USA area. While membership is mainly SpringWorld event should contact CASMI to secure located in Illinois, Indiana and Wisconsin, CASMI provides sup- their participation. port to spring manufacturer and supplier members throughout the USA. Although CASMI works closely on several issues with the Call +1 630 359 4273, or contact by sending an e-mail Spring Manufacturers Institute (SMI), a national organization, to [email protected]. both organizations are independent of one another, with unique missions, programs, services and members. CASMI sponsors Exhibiting information is also available on the or- SpringWorld® every two years. www.casmi-springworld.org ganization’s website at: www.casmi-springworld.org/?page=SWExhibiting SpringWorld, which is presented by the Chicago Association of Spring Manufacturers, Inc. (CASMI) every other year, provides a unique opportunity for spring manufacturers, wire formers, OEMs and their suppliers to network including one-on-one discus- sions with colleagues to share challenges, discuss solutions and provide new insights for business. www.casmi-springworld.org WFTI FOYER REGISTRATION Escalators RCC FH 1 6' 6' 6' 6' 6' xxxxxxxxxxxx GREETER 2 ph KIOSK 3EE EE 4 5 FILL IN 6 Payphones COUNTERS SPRINGWORLD ENTRANCE STAR Elevators BUCKS Stairs FH Mech. Fire Exit Fire Exit Freight Door Sprinkler 1100 Show Office FE Equip. FOOD 601 20' Concession FOOD STATION #1 800 40' STATION #4 20' CASMI 20' 20' 700 20' 703 502 60' 504 501 905 20' 1005 1105 1205 1405 30' 1605 506 30' 20' 30' 30' 30' 40' 40' 508 50' 807 909 1008 50' 50' 510 FE FH 20' FH FE 20' 50' FH 1014 514 20' 20' 516 30' 513 613 1013 1112 20' 1213 20' 40' 1015 1114 1115 1214 20' 20' 30' 20' 1117 1216 50' 1415 1513 617 1017 1217 1219 1311 1313 1315 20' 20' 30' 30' 20' 20' 20' 20' 20' 20' EDUCATION 40' SESSIONS 522 521 621 721 821 920 921 1018 1021 1120 1121 1220 1221 1321 1421 1520 152120' 823 20' 1020 142320' 40' 20' 30' 20' 30' 20' 20' 20' 30' 20' 20' C 20' 20' 526 1027 1126 20' HALL F 528 529 628 627 530 825 924 925 1022 20' 1125 1224 20' 532 20' 927 1026 534 20' FH 929 1030 1031 1128 20' FE FE 536 FH FH 827 926 20' 727 824 1226 1325 1427 1526 20' 20' 1130. 1429 20' 20' 30' 1129 1230 1227 1326 30' 1431 30' 829 Women 1229 1330 20' 20' 20' 933 1032 1131 533 733 833 50' 20' 30' 20' FOOD STATION #3 835 BAR Men Electrical Concession STATION FE Fire Exit Fire Exit Freight Door FOOD CASMI'S SPRING WORLD 2020 STATION #2 Freight Door CHICAGO ASSOCIATION OF SPRING MANUFACTURERS, INC. DONALD E. STEPHENS CONVENTION CENTER Spring 2019/Wire Forming Technology International 23

All Things by: Randy DeFord, Engineering Manager Springs Mid-West Spring & Stamping 105 Etna St. Compression Spring Mentone, IN 46539  USA Classifications E-mail: [email protected] www.mwspring.com I had the fortune, early in my career, to be mentored by a meticulous German engineer named Horst Pimmler. nominal. Coils are locked in. Mr. Pimmler was the founder of Monticello Spring Corporation and had a way to classify everything. His TYPE FOUR: This design has both a single load at a way of classifying compression springs made it possible height and a rate requirement—a single load is toler- to group just about any compression spring into one of anced and the rate is toleranced. This type is a combina- five categories, based on their requirements. tion of both Type Two and Type Three. Therefore, both coils and free length should be referenced (or generously This method was predicated on the notion that certain toleranced) to allow adjustment to nominal of both load callouts defined a definite tolerancing scheme. This and rate. This type allows a tolerance on the wire size made it easy to relate to what should be toleranced and and OD, but not the coils or free length. Free length is what should be referenced. Since spring engineering is allowed to vary to adjust load to nominal, and coils are rooted in time-tested physics and mathematics, fitting allowed the vary to adjust rate to nominal. a given design into a “type” was a natural flow. Any parameter requiring tolerancing would follow the SMI TYPE FIVE: This design has two load requirements industry guidelines, while the referenced parameters at two designated heights—two loads are toleranced. were allowed to vary as needed to meet the critical A two load requirement demands a given rate so this toleranced requirements. essentially requires the same tolerancing as a Type Four. This type allows a tolerance on the wire size and TYPE ONE: This is a dimensional only design. This OD, but not the coils or free length. A two load spring means there are no load or rate requirements. This is design does, however, require a sequence of events in the simplest of types and only requires conformance the proper order. The rate must first be obtained because at the dimensional level—wire diameter, OD, coils and the two loads depend on the proper rate. Then, the free free length. All the parameters are toleranced, except length can be adjusted shorter or longer as needed to the number of coils, which is locked in with no variation bring both loads to nominal. The rate must always be required. This means any load or rate will vary somewhat adjusted first, then the free height since the two loads with the inherent variation of material and coiling, but cannot be realized unless the rate is correct. inspection is simplified and any load requirements are not critical to function. In Summary: TYPE TWO: This is a design with only a spring rate re- Dimensional only—tolerance all parameters, lock in quirement—the rate is toleranced. Spring rate is largely a function of active material—this is the most expedient the number of coils parameter to adjust for conformance. This type allows a tolerance on every dimensional parameter except the Rate only—tolerance all parameters except coils coils. Coils are allowed to vary to adjust rate to nominal. Load only—tolerance all parameters except free length TYPE THREE: This is a design with only a single load requirement at a height—a single load is toleranced. Load and Rate—tolerance all parameters except coils Single loads are largely a function of free length—this parameter is easily adjusted and can obtain a nominal and free length load by tweaking the free length. This type allows a tolerance on every dimensional parameter except free Two loads—tolerance all parameters except coils and length. Free length is allowed to vary to adjust load to free length One last comment: these are guidelines, not laws. The customer still defines what is critical to its needs. But this is the science of it all and if these guidelines can be followed, the requirements on all five types are more easily obtained, which reduces set up times, production time and reduces overall shop hours. And hats off to Mr. Pimmler. www.mwspring.com WFTI Randy DeFord is the Engineering Manager at Mid-West Spring & Stamping, a custom spring manufacturer that offers custom spring design, stock springs and metal stamping services. The company is multi-plant spring manufacturer and leading supplier of auger springs and metal stampings. For more information, call +1 574 353 7611, Ext. 231, fax to +1 574 353 7388, email to [email protected] or visit www.mwspring.com. The company is also the home of Landrum Performance coil and leaf springs for racing applications, call +1 866 703 3154 or visit www.landrumspring.com. 24 Wire Forming Technology International/Spring 2019



The Strength by: of Steel Dr. Roger N. Wright Roger N. Wright, LLC Wire and Rod Tensile Testing – Part 2 600 State Street Lawrenceville, IL 62439 USA E-mail: [email protected] www.rnwinc.com Last time, In Part 1 of this series, we considered a trated within the neck. The force-bearing capability typical pattern of force-elongation data from a tensile of the specimen steadily diminishes, and fracture en- test, as presented in Figure 1. The tensile specimen sues within the neck at point D. The neck, and the is generally extended until it breaks at point D in Fig- concentration of elongation therein, are illustrated in ure 1. The test begins at point A, and between points Figure 2. A and B, the force is very nearly proportional to the elongation. If the test is stopped in this region, the specimen will “spring back” to its original dimensions. (/ /o, etc.). The region, A to B, where the elongation is recoverable and proportional to the force, is the elastic region. Fig. 2 — Schematic drawing of a necked tensile specimen and the variation of elongation along the gage length. The data in Figure 1 are dependent on specimen size. To generalize the behavior, the size factor is eliminated by converting the force, F, to a stress and the elongation, (/ - /o) to a strain. Stress is simply force divided by the cross-sectional area upon which the force is acting, whereas strain is the elongation referred to the starting gage length. Fig. 1 — Typical pattern of force-elongation There are two common systems used for defin- data from a tensile test. ing stress and strain in the tensile test: engineering stress and strain and true stress and strain. It is im- At point B, the specimen begins to undergo perma- portant to know each system, and to use the system nent elongation. If the tensile test is stopped beyond most appropriate to a given technical situation. In our point B, a certain part of the elongation is recovered, next column of this series, we will examine these sys- with the specimen unloading along a line parallel to tems in detail. the slope of the line from A to B. The recovered elon- gation is again, elastic deformation. The nonrecover- If you sense that this is material you have seen in a able, or permanent, elongation is described as plastic deformation. previous life, as a pre-engineering student, etc., you Beyond point B, the load-bearing capability of the might want to get out those old books and notes and specimen is generally seen to rise gradually to the point C, at which point a neck or local thinning is ob- do a quick review. Nothing has really changed. How- served. All further elongation, beyond C, is concen- ever, modern quality control and specification prac- tice is much tighter than in the good old days, and as one of my old professors once said: “you can get a thesis out of a tensile test”. Good luck!!!! WFTI The WireDrawing 101® short course, presented and developed by Roger N. Wright, LLC., and Wire & Cable Technology International magazine, is the comprehensive two-day course that teaches the fundamentals of wire drawing to manufacturers of ferrous and nonferrous wire. WireDrawing 101 features a unique handbook, with practical process design and trouble-shooting exercises suitable for work-a-day formats and continuing study. WireDrawing 102™ will be offered in the future. www.wiretech.com / www.rnwinc.com 26 Wire Forming Technology International/Spring 2019



Wire by: Alan Thomas, Marketing Department Product ZwickRoell Limited Southern Avenue Testing Leominster Herefordshire HR6 0QH Selecting the Optimum United Kingdom Materials Testing Machine www.zwickroell.com Mechanical testing plays a major role in research and education, product development and design and quality control. In the mechanical testing of steel, a sample of the steel is subjected to a tension test in order to measure various properties including ten- sile strength, yield strength, ductility and reduction in area. The tensile test is one of the most common me- chanical tests for steel and the results of such tests are used for two primary purposes, namely, engi- neering design and quality control either by the steel producer to verify the manufacturing process or by the end user to confirm the material specifications. Typical ZwickRoell electro-mechanical ZwickRoell High-Force capacity EM tensile testing tensile testing machine. machine with hydraulic specimen grips. From a testing machine manufacturer viewpoint, Electro-Mechanical Systems tensile testing systems must be robust and flexible, capable of determining the mechanical properties of Electro-mechanical (EM) testing systems are often a broad range of materials and components ranging utilized for static testing applications in tensile or from metals to composites and from plastics to natu- compressive mode. Two types of load frames are ral, bio-based materials. available for EM testing systems, single-column for lower force testing applications and dual-column Mechanical testing incorporates a wide range of frames, which are normally available in benchtop techniques, from common tensile and compression and floor-standing models. Additional elements of tests to flexural or torsional characterization. Test- EM systems include a load cell, moving crosshead ing may also be done under ambient or non-ambient and a means of measuring extension, also common- conditions, with widely varied temperatures and en- ly referred to as elongation. A load cell is a transduc- vironmental conditions. er that creates an electrical signal whose magnitude is directly proportional to the force being measured. A moveable crosshead moves up or down at a given rate of speed specified by the standard to which the test procedure is being conducted. Some applica- tions require a constant rate of extension while oth- ers require a variable ramp rate. ZwickRoell EM testing systems incorporate mod- ern design elements to deliver the most reliable test results possible. In these systems, AC drive tech- nology couples virtually maintenance-free operation with digital control advantages. Also, an innovative motor feedback system ensures excellent constant velocity properties, even at very low speeds. 28 Wire Forming Technology International/Spring 2019

EM testing systems are particularly beneficial for ap- to the test specimen; a servo valve and controller for plications that call for high levels of precision, and adjusting actuator position, velocity and force; a load applications that require support for measuring com- frame with close-coupled hydraulic power source; plex strain may be addressed through the use of an and an electrical feedback loop enabling the test extensometer. The requirements to be met by an variables to be controlled utilizing position and load extensometer are determined primarily by the char- transducers. Although they require infrastructure for acteristics of the material to be tested. This includes both electrical and hydraulic connections, servo- its shape and dimensions, test requirements and the hydraulic testing machines can be a cost-effective formal test standards that must be satisfied. These static testing choice at very high forces or if a high define the gauge length, accuracy, test sequence testing speed is required. and environmental conditions, such as the test tem- perature. During the tensile test, the elongation of Strain measurement primarily applies when servo- the gauge section is recorded against the applied hydraulic systems are used for static tests, although force and typically, elongation is measured between identical instrumentation can be employed on elec- two fixed points on the specimen. tro-mechanical machines. Typically in these cases, a sensor arm extensometer will accommodate the The primary scope of tests addressed by EM sys- need for a high precision form of strain measure- tems is classic static materials tests such as tensile, ment. With such an extensometer, deformations on flexure or bending tests. EM machines offer a highly the specimen are acquired in the elastic and plastic suitable technology because for these kinds of tests, deformation ranges during the entire tensile test up especially tensile tests, a high degree of control and to specimen break. precision in strain rate measurement is relevant. In addition to conventional materials tests, EM sys- tems are also applicable to component testing when high precision is necessary. Servo-Hydraulic Systems Servo-hydraulic testing machines may be used in static, dynamic or fatigue materials testing applica- tions. They operate through a closed-loop system consisting of a bi-directional hydraulic actuator linked ZwickRoell High-Force capacity servo-hydraulic ZwickRoell Sensor Arm Extensometer. tensile testing machine. To learn more,visit: www.zwickroell.com WFTI ZwickRoell is one of the world’s leading suppliers of materials and component testing systems. The company supplies both standard and tailor-made so- lutions to satisfy the most demanding requirements, in research and development, production and quality assurance, across more than 20 industry sectors. Privately held, the company’s consistent focus on innovation and commitment to outstanding quality has supported its growth in markets worldwide. Ad- ditional information about ZwickRoell may be found at: www.zwickroell.com For further information regarding this article, please contact: Alan Thomas, Marketing Department E: [email protected] T: +44 (0) 7710 196684 Spring 2019/Wire Forming Technology International 29

Looking to Build on Record Breaking First Quarter by: ‘Certainty in an Uncertain World’ cam- Alloy Wire International (AWI) paign has been a major success, and Narrowboat Way, Hurst Business Park, it highlights ‘make to order’ ability to Brierley Hill, West Midlands DY5 1UF, UK www.alloywire.com deliver high quality nickel alloys. Alloy Wire International (AWI) is extending its grip Angus Hogarth, Sales Director at AWI, commented: on the world’s manufacturers by targeting them with “2019 has started fantastically well for us. Our abil- its largest ever range of Exotic nickel alloys, including ity to react quickly to customer needs has helped us Nimonics®, Monel 400®, Incoloy A-286® and Stainless grow our existing accounts, as well as pick up new Steels. clients – this is right from the initial quoting stage and offering technical support to responding to queries in The company, which secured a record-breaking start a timely fashion.” to the year, is looking to showcase its products to customers looking for high quality nickel alloys with He continued: “We understand exactly what they reliable delivery for use in the aerospace, motorsport, need and supply exactly how they want it, whether nuclear and oil and gas sectors. that is wire in coils, on spools or as straight/centerless ground bars. AWI’s campaign – ‘Certainty in an Uncertain World’ – has been an overwhelming success and highlights its “What we do really well is that we can supply bar or ability to ‘make to order’ in just three weeks and its wire to very tight tolerances, for example h8 or h9 on huge stock range that now exceeds 200 tonnes. diameter.” Desire for the firm’s friendly technical support service Bars, which can be used to produce precision turned also continues to grow at pace. Recent recruitment has components for aerospace and oil and gas industries, seen it strengthen its technical team and quality depart- have been in significant demand from customers, with ment to ensure it is well placed to discuss material AWI supplying them in a wide range of materials, application and to help solve potential manufacturing including Inconels, Nimonics, Hastelloys, Phynox situations around the need for material to work in cor- and Monels. rosive environments and high temperatures. The longest length AWI offers is 9' (2.8 m) and the shortest is just ½\" (12.50 mm), with the latter often used as shear pins. Additionally, the company can offer bars with a center- less ground finish to its cus- tomer’s requested diameter, saving the client valuable manufacturing time. Operating across 55 coun- tries worldwide, Alloy Wire makes round, flat and profile wire in a range of mate- rial that is growing by the month, with more than 60 currently available to choose from, each offering superior corrosion resistance and/or excellent performance at high temperatures. (l-r) Gary Whitehouse, Kevin Guest and Andrew Du Plessis with three recent quality In order to build on the year- accreditations secured by Alloy Wire International. on-year growth, the company has also signed off a £250,000 investment that will see the 30 Wire Forming Technology International/Spring 2019

WFTI EMPHASIS: Materials Kevin Guest (left) in the quality control lab and Andrew Du Plessis (right) in the technical department. arrival of three new machines to boost speed, repeat- wire – in varying sizes and volumes – even quicker. able quality and capacity. “All of our 60 different Exotic alloys are DFARS com- Angus concluded: “There’s no point basking in what we achieved in 2018; we need to focus on where the pliant, of EU origin and can be supplied from as small market is going and make sure we are at the forefront of any changes. as 0.025 mm to as large as 21 mm in diameter.” For “The spend for this year will go towards automating further information, please visit www.alloywire.com part of the process and bringing in new technology that will help us continue the production of high quality or follow @alloywire on twitter. WFTI ® Trade name of Special Metals Group of Companies VISIT US AT: BOOTH 970 Spring 2019/Wire Forming Technology International 31

High-End Solutions for the Wire & Tube Industry by: Equipment supplier to host this year’s WAFIOS AG In-House Exhibition featuring more Public Relations exhibitors with increased exhibition Silberburgstraße 5 space and additional innovations. D - 72764 Reutlingen Germany www.wafios.com The twelfth In-House Exhibition of WAFIOS AG will set new records with more exhibitors, more exhibition space and more innovations. As usual, the event for experts from within the wire and tube forming industry will take place in Wuppertal, Germany, this year from May 8 through 11, 2019. A particular focus at this year’s event is on tube forming technology. Besides WAFIOS AG and WAFIOS Umformtechnik, three more com- panies of the WAFIOS Group will present their products and services at this year’s In-House Exhibition. These include WAFIOS Tube Automation The WAFIOS AG’s In-House Exhibition in Wuppertal is among the GmbH, Witels-Albert GmbH and E. most important events for any wire and tube forming expert. This W. Menn GmbH & Co. KG. In addi- tion, more co-exhibitors from the wire year the exhibition is bigger than ever before. and tube forming industry have been invited than World-Class Innovations ever before. There are several world-first features among the exhib- With an area of 1400 m², about two soccer pitches, this ited machines at this year’s WAFIOS In-House Exhibi- year’s fair breaks all previous records. This also applies tion. These world-class innovations include the flexible to the number of exhibition machines. About 20 exhibi- wire bending machine, BM 36, for producing large tion machines can be seen live. What is completely new quantities and meeting the highest quality standards; about this year’s In-House Exhibition is the division the spring end grinding machine, G660, for large wire of wire and tube processing machines into two halls. diameters up to 12 mm, along with automatic feeding This underlines the increasing importance of WAFIOS’ of springs during the grinding process; and the F 30 tube processing machinery. compression spring coiler, which has been designed Lecture Presentations A particular focus this year is on tube forming technology. Wire and tube forming are therefore Since the lectures held at previous In-House Exhibi- tions have been very well received by visitors, the exhibited in two separate halls. range of topics has been extended. The block of lectures on new spring, wire and tube forming technologies will be complemented by presentations on current topics such as the WAFIOS Smart Factory (Industry 4.0) or E-Mobility. E-Mobility demands new formed parts like hairpins for electric motors or busbars (see related side bar). The specialists from Reutlingen have already developed new production solutions for both. Also, a guest speaker from the Metal Forming Fac- ulty of the University of Siegen will hold a lecture on “Cyber Set-Up 4.0 - Expert to Go” to complete the range of lectures. 32 Wire Forming Technology International/Spring 2019

New & Revolutionary Process for Hairpin Production Hairpins are challenging bent wire components Hairpin production tooling area. made of copper wire as the core element, clad in a layer of insulation. These electrically conductive parts are used in the new generation of hairpin motors. These components are subject to very de- manding requirements in terms of their geometry and surface properties. Existing manufacturing pro- cesses such as those involving the use of automatic multi-slide units or transfer systems usually entail a high level of overhead in terms of tool set up and programming work as well as substantial tool costs. With the wealth of experience that comes from 125 years spent forming wires and tube components of all kinds, WAFIOS elected to shoulder the challenge of hairpin production. The result? Quite simply, the most flexible machine currently available on the market. Flexible Production Stator with Without Changing Tools hairpins. This flexible new process means that the majority Hairpin samples. of hairpin geometries for a stator including the con- nection assemblies required, can be manufactured files. And after the 3D geometric co-ordinates have in any sequence without the need to change tools. been imported, the requisite bending program can be produced automatically. A patent for this bending process has been applied Additionally, there is the option of integrating and for. This is a process that enables the bending work making use of the simulation tool to run through to be accurate and free of physical damage. This the complete production sequence of the bending is a field in which WAFIOS has many years of ex- component. The entire process is simulated using perience. The measurement and feedback control a digital twin, which includes machines, tools and algorithms that this new process employ ensure workpieces in order to create a dependable collision that the machine is able to monitor and control itself check in advance. during production operations. Even in situations The entire production planning process including the where the paint gets stripped inadvertently from the programming of parts, the simulation, definition of contact points, WAFIOS is a competent partner, and cycle time and the collision check, can be performed one able to offer various solutions to suit customer in a parallel manner and at an external programming wishes. station. In addition, simulation is utilized to establish the optimum tool arrangement for the specific bend- Efficient Programming Capability ing component. www.wafios.com Geometric programming dispenses with the require- ment for the system user to program individual CNC axes. And this capability speeds up the definition of hairpin geometry. Flexibility depends on the geometric programming of bending parts and/or hairpins. The WAFIOS control- ler, the WPS 3.2 EasyWay, also permits the importa- tion of 3D geometries automatically with STEP/IGES Continued... Spring 2019/Wire Forming Technology International 33

High-End Solutions for the Wire & Tube Industry ...continued and engineered for additional flexibility and, which This year, WAFIOS presents once more the is an enhancement of the reliable Eco Coiler series, latest wire and tube forming technologies now equipped with the WPS 3 Easy Way program- ming system. at its biennial In-House Exhibition. As a special highlight among the tube bending machin- ery, there will be several TWISTER² production cells Customer Support Capabilities on display. What makes these solutions so special is the integration of a robot. The enhanced efficiency of the Customer Service and The tube bending machine and the robot share one and the Tool Center are further important topics to be high- the same user interface of the programming system, the lighted at this year’s WAFIOS In-House Exhibition. WPS Easy Way, which enables an intelligent interac- tion of bending and handling tasks. And there is no The Customer Service program now has new retrofit special robot software needed anymore. This concept packages to offer customers as well as a superior spare allows the flexible production of three-dimensional parts program and an extensive range of training geometries while ensuring high process reliability, program options. easy operation and high productivity. Also, the Tool Center has included new solutions A highlight of this year's In-House Exhibition is the TWISTER² production concept for bending tubes. The meant for the reconditioning of tools in their portfolios. WAFIOS programming system WPS 3 Easy Way enables The webshop ensures the shortest delivery periods for the control of the robot for handling tasks. tools and spare parts. www.wafios.com WFTI Company Profile: And based on this production concept, WAFIOS WAFIOS AG, located in Reutlingen, Ger- Tube Automation will exhibit an automated solution many, is a globally leading company for the designed for the production of hydraulic lines. This manufacture of wire and tube working ma- equipment solution is comprised of the automatic chines, along with significant activities in the feeding in of components, the end forming machine, cold forming industry. The WAFIOS Group RU 18-8 and the TWISTER² 16-20-R. thinks and functions internationally. Every- where in the world, the name of WAFIOS is The iQ functions developed by WAFIOS software ex- known as a reliable partner in the wire and perts for optimizing processes are also very important tube processing industries. The many subsidi- in the tube forming area. Visitors of the In-House Ex- aries, which are a part of the WAFIOS Group, hibition have the chance to see how iQtube+ can help along with the company’s many sales agen- the machine fitter to avoid collisions when bending cies are based in different countries on almost complex tube shapes. all continents. The tight network of WAFIOS agents and more than 70 commercial agen- The software enables the graphical simulation of the cies cover more than 100 countries. entire forming process before actually starting pro- www.wafios.com duction. If iQtube+ detects a collision, alternatives are automatically calculated. Based on these solutions, the opening travels of clamping jaws and backstops can also be optimized in order to minimize unproductive times. The system also calculates the maximum pos- sible output of each solution suggested. The operator quickly sees which solution is without doubt the most economical one. 34 Wire Forming Technology International/Spring 2019

TECH BRIEF Benchtop XRF Plating Measurement System Bowman, Schaumburg, IL, XRF has been developed for both is provided by the company for USA, the producer of XRF quality quality laboratories and produc- users of all Bowman instruments control instruments, has recently tion environments. It is highly and systems as well as for other introduced an important addition advantageous for users having major XRF brands. to its suite of benchtop XRF plating limited benchtop space or budget measurement systems. limitations. Bowman’s G Series www.bowmanxrf.com WFTI XRFs are ideal for both coating The new Bowman G Series XRF thickness and solution analysis. Bowman G Series XRF. is a robust plating measurement system that is ideally suited for Bowman is a leading producer jewelry, connectors and other pre- of precision XRF coating meas- cious metal analysis. Because the G urement systems, with a robust Series quantifies zinc, zinc-nickel local service network that pro- and other anti-corrosion coatings, vides same-day response for it is also ideal for components such every benchtop XRF requirement as springs and wire formed parts. worldwide. Equipment evalua- tion, selection, commissioning, The two most distinctive fea- maintenance and modernization tures of the new G Series are “bottom-up” measurement using a motorized Z-axis with laser-based auto-focus, and precision video imaging. An available manual XY stage having 1.5\" x 1.5\" travel facilitates easy positioning of small and large parts. The standard G Series configu- ration includes a single fixed col- limator, solid-state PIN detector and long-life micro-focus X-ray tube. Like all Bowman models, components can be upgraded to include multiple collimators, a variable focal camera or an SDD detector. And like the other sys- tems in the Bowman XRF product portfolio, the G Series instruments simultaneously measure up to five coating layers and 10 elements in each layer for 25 elements in all. Element range is Al (13) through U (92.) To quantify coating thickness from detected photons, the sys- tems run advanced Xralizer soft- ware. Xralizer software combines intuitive controls with time-saving shortcuts, extensive search capa- bility and “one-click” reporting. Additionally, this software allows easy creation of new applications by the user. Equally important, the G Series XRFs are full-access instruments from the day of in- stall—there are no dongles or lock-outs to complicate, delay or add cost. Bowman’s G Series desktop Spring 2019/Wire Forming Technology International 35

A Brief Guide to Spring Design by: Whether selecting a catalog spring or Christopher Petts, M.D. specifying a custom item, it is always Lee Spring Limited worth considering the factors that are Latimer Road expressed in this article. Wokingham, Berkshire, RG41 2WA, UK www.leespring.co.uk Principles of Spring Design Hooke’s Law is a principle of spring design relating to Load and Deflection. It states that a restoring force due to a spring is proportional to the distance the spring is deflected and acts in the opposite direction. Another principle of spring design is Spring Rate (R), which is the ratio of force per unit of deflection. Spring Design Elements Spring Index— The spring index is the ratio between the mean diam- Direction of Wind— eter and the diameter of the wire. A high index spring A coil spring can be wound in a left-hand has a smaller wire and a larger spring diameter such as or right-hand direction, in the same way a Lite Spring, whereas a low index spring has a larger as a screw thread. The direction of wind, wire diameter and a smaller spring diameter such as therefore, is a primary element of spring a Die Spring. design. This can be particularly important depending on how the spring will be used. Load (P)— For instance, when one spring is required to operate Load refers to the force that is required to compress within another spring, the springs should be designed the spring to a specific height. This force is different to wind in opposite directions to avoid them becom- than spring rate, which is the amount of force that ing wound together. Or if the spring is to be screwed required to compress or extend the spring a standard onto a threaded component, it must follow the same deflection unit. thread direction. Solid Height— Spring ‘Squareness’— The solid height of a spring refers to dimension of the The ‘squareness’ of a spring relates to the angular spring when the coils are closed. This may be impor- difference between the outside of the spring diameter tant in some applications and if so, should be specified and the straight edge of the spring when it is stood as a maximum allowable. on its end. Number of Coils— Spring Parallelism— The number of coils required in a spring should be Spring parallelism relates to how parallel the ends of specified as a reference figure. It is important to distin- the spring are to one another. guish between whether the number of coils relates to active coils, which are free to deflect under a load, or Spring Diameter— total coils which also includes the outer coils forming Spring diameter can either refer to the outside diam- the ends that will not deflect under load. eter (the OD), which is important when the spring is to be used in a cavity, or the inside diameter (the ID), Pitch— which is important for springs that are required to Spring pitch is a dimension that relates to the distance work over a rod or shaft. However, the mean diameter between the centers of adjacent coils. is more commonly used when calculating for stress or deflection. Free Length— The free length is the overall spring length when the spring is in an unloaded or in a ‘free’ position. Where definite loads are specified, the free length of the spring should be an approximate dimension that can be varied to meet the load requirements. 36 Wire Forming Technology International/Spring 2019

Spring Set— at the website: Before its first compression, the spring’s free height www.leespring.com/uk_whitepaper-compression-design- might be longer than is required, which is a com- general-considerations.asp. mon manufacturing occurrence. This free height length situation can be corrected in one of two Or to obtain further information and technical speci- ways. First, the spring can be designed and then manufactured with a free length that includes al- fications on the products available from Lee Spring, lowance for set, allowing for length loss when the spring is compressed for the first time. Or second, visit the website listed below. an additional manufacturing step, which is known as ‘removing the set’ or ‘presetting’ can be imple- www.leespring.co.uk WFTI mented. Also known as a ‘set spring’, this involves compressing the spring to the solid height. Then Company Profile: the set spring will have a new free length that will remain consistent through future compression cycles. Lee Spring Limited is a global manufacturer of mechanical springs and related products. Conclusion Lee Spring Limited maintains a product line of more than 25,000 stock springs, and is capa- In the final analysis, if you do not find a suitable stock ble of manufacturing custom spring products spring for your purpose—and approximately 50% of made to customer specifications. Established applications still require something extra special—then more than a century ago in 1918, Lee Spring the engineering team in place at Lee Spring Limited Limited is an ISO 9001-certified company with in the UK is experienced at quick response specifica- multiple locations in the United States as well tion and fulfilment. And you can contact the team for as locations in Mexico, Europe, China and In- assistance. dia. www.leespring.co.uk You can see more at “A guide to spring design”, which is available form Lee Spring Limited, and can be found INDUSTRY 4.0 READY MACCHINE AVVOLGITRICI ASPI BB-8MM phone SPRING COILING MACHINES PAYOFFS +39 031 536584 3.00 – 8.00 mm .120 – .310 inches fax +39 031 2170001 REVISIONI sales department UPGRADES [email protected] service department [email protected] BB Spring Technology SRL Via Socrate, 27 22070 Casnate con Bernate (CO) ITALY bbspringtechnology.com Spring 2019/Wire Forming Technology International 37

Influence of Machine Loops on the Behavior of Extension Springs by: New analytical method enables transi- Manuel Paredes, Professor at INSA and tion load to be evaluated, with benefit to Head of the Mechanical Engineering manufacturers who can quickly calcu- Department. Head of STRAIN Institute late pitch to obtain the expected initial [email protected] tension on the load-deflecting curve. Hervé Orcière, Engineer Manager for ize the different parameters of the force/displacement 20 Years in CGR Group. CGR Training law that governs the behavior of the spring. In addi- Manager for the Wire Spring Division, Flat tion, an analytical study was carried out to express Spring Division and Aerospace Division. in the form of usable formulas the different stiffness Deputy Head of STRAIN institute. identified during the experimental tests. [email protected] Experimental Study of Extension Springs Thomas Stephan, FEM Calculation Engineer for four years in CGR Experimental Test Bench. The implementation of ex- Aerospace Division. perimental tests was used to accurately observe the [email protected] spring behavior. In this study, four extension springs made of steel have been tested (see Figure 1). The www.insa-toulouse.fr • www.cgr.fr main design characteristics of the springs are detailed in Table 1. Spring #1 and #2 have standard machine The presence of tension springs in many mechanical loops while spring #3 and #4 have nonstandard ma- systems is due to their ability to store and restore chine loops. energy under a large number of external stresses. To design the springs as close as possible to the required requirements, manufacturers can rely on numerous software packages that have generalized the main formulas expressed by Wahl1. However, the specificity of tension springs concerns the presence of loops at their ends, whose role in the overall performance of the spring is still poorly ex- ploited. The designers commonly exploit extension springs that work in a range between 20% and 80% of the maximum length of the spring. This condition, which is relatively restrictive to ensure linear stiffness, is due to the hypothesis made on the stiffness of the loops to consider as negligible and only characterized by the initial tension P0 : P2 = k (L0 – L2) + P0, with L2 the working length and P2 the resulting force and k the global stiffness. Fig. 1 — Tested springs. Table 1. Main Design Characteristics of the Tested Springs. Load-length relation for extension springs, For each spring, four specimens were tested on a a: from European standards2, b: from IST3. Spring Test 1 test bench from Andilog4 (Figure 2). The This article focuses on the influence of machine loops force gauge had a capacity of 500 N with 0.1% accuracy on the initial and overall stiffness of an extension and 0.04 N resolution. The handle enabled a 2 mm per spring. Initially, the tests were carried out to character- revolution stroke. The displacement transducer with digital display had a resolution of 0.01 mm. The axial 38 Wire Forming Technology International/Spring 2019 stiffness of the test bench has been taken into account in the results.

Fig. 5 — Results for spring #3. Fig. 2 — Test bench. Fig. 6 — Results for spring #4. Table 2. Average Values of Experimental Results. Results. The test results are presented in Figure 3, dinate with no deflection of the line fitting the Figure 4, Figure 5 and Figure 6. For each spring, two common linear part of the curve when the spring curves are presented, the overall one (left) and a focus deflects fully. at a beginning of deflection (right). • Initial rate ki at the beginning of deflection when the coils are still in contact. • Transition load PT between the two linear parts. The obtained values are detailed in Table 2. Fig. 3 — Results for spring #1. Analytical Study Fig. 4 — Results for spring #2. Analytical formulae are useful for designers as they All the springs exhibit an overall bilinear load-de- enable obtaining of quick results and are of key inter- flection curve. When looking at the beginning of the est for standard geometries. When complex designs curves, we can also note that the transition between are involved, it is more convenient to exploit Finite the two linear parts is very short except for spring #4. Element Analysis. In our case, springs #1 and #2 have It is thus possible to extract for each spring type an standard machine loops while springs #3 and #4 have average value of: more complex loop geometries. We thus present an • Global rate k when the spring deflects fully (it is analytical study for machine loop and the results are compared with experimental data of springs #1 and #2. the common rate). • Initial tension P0, which is calculated as the or- Stiffness of an Extended Machine Loop. In a previous study, Dym5 exploited the Castigliano’s second theo- rem6 to determine the rate of compression springs with accuracy. We have exploited the same approach to find the flexibility of a machine loop. It is first necessary to precisely describe its geometry (see Figure 7). This geometry can be split into three parts: 1. Circular part linking loop with body, with radius R1. 2. Linear part of length L1 that links two circular parts. 3. Circular part equal to the diameter D at the end. Spring 2019/Wire Forming Technology International 39

Influence of Machine Loops on the Behavior of Extension Springs ...continued (3) Fig. 7 — Detailed geometry of an extended machine loop. (4) Each part is first studied separately to identify its flex- Global Stiffness. It can be seen in Figure 7 that the cir- ibility, and the flexibility of the loop FL is obtained by cular part with radius R1 decreases the number of coils adding the flexibilities of the three parts. of the body (that has the common helix shape). This decrease can be estimated by the following formula: In part 1, radius R1 is assumed to be small, and the geometry can be considered as contained in a plane (5) parallel to the axis of the spring. Thus an axial load P on the spring induces in Part 1: Thus the common formula for an extension spring can be adapted to define the flexibility of the remain- ing body: (6) Eq. 4 and Eq. 6 can be combined to calculate the global rate of the spring, k: (7) Initial Stiffness. At the beginning of deflection, a Finite Element Analysis highlighted that the stiffness was due to the deflection of the loops and the deflection of half a coil of the body. Thus, Eq. 2 and Eq. 4 are combined to define the initial rate of the spring ki: (8) Comparison With Experimental Data. Springs #1 and #2 are made of steel7 with G =81500 MPa and E = 210600 MPa. The springs have standard machine loops thus our analytical approach can be exploited. The parameters defining the geometry of the loops and the obtained stiffness are detailed in Table 3. k and ki are the stiffness calculated with Eq. 7 and Eq. 8 while kW is the basic stiffness commonly calculated with the Wahl formula. Table 3. Parameter of the Loops and Analytical Stiffness. (1) Those results are compared with the experimental one. For more readability, the experimental results are presented with one curve having the mean values (see Figure 8 and Figure 9). (2) For the two springs, the advanced curves are closer to the experimental results than the basic ones (left fig- ures). It shows that the advanced analytical approach increases the accuracy of the overall stiffness. Moreover, the focuses on the beginning of the behavior (right figures) show that the initial behavior has been 40 Wire Forming Technology International/Spring 2019

standards: the initial tension induces the extension spring to show a bilinear load-deflection curve with high stiffness at the beginning of deflection. Then, an analytical approach was developed using Castigliano’s second theorem and a bilinear behavior was modeled. This new model gives a more accurate evaluation of the global stiffness of the extension spring than the one commonly used that is also used for compression springs. Fig. 8 — Comparison of analytical and Also, the proposed analytical approach enables the experimental results for spring #1. transition load to be evaluated (transition from initial Fig. 9 — Comparison of analytical and experimental results for spring #2. stiffness to the global stiffness). This transition load can analytically defined with accuracy. This is a key issue. opportunely be exploited by manufacturers to quickly Indeed, the proposed bilinear approach enables the transition load to be estimated using Eq. 9. and PT can calculate the pitch to be set on the coiling machine in be exploited to improve the manufacturing process of extension springs. order to obtain the expected initial tension on the load- (9) deflection curve, saving time on the manufacturing On a coiling machine, the initial tension of extension process. www.insa-toulouse.fr / www.cgr.fr WFTI springs is introduced by manufacturing a body having an axial pitch smaller than the wire diameter. Until References: now, manufacturers had to define the axial pitch of the body of extension springs with a trial and error process 1 Wahl, A. M., 1963, Mechanical Springs, McGraw-Hill Book but now the pitch value can be determined depending Company, New York. on the required transition load PT and the deflection of one coil using the following formula: 2 European standards related to extension springs, 2002, EN 13906, ISSN 0335-3931. (10) 3 IST, 1980–2005, “Essential Spring Design Training Course,” Handbook, As far as we are aware, Eq.10 is defined for the very The Institute of Spring Technology, Sheffield, United Kingdom. first time and is thus of key interest for saving time in the manufacturing process of extension springs. 4 http://www.andilog.com/springtest-manual-spring-tester. html?category_id=14 Conclusions 5 Dym, C., 2009, “Consistent Derivations of Spring Rates for Helical To analyze the behavior of extension springs in greater Springs”, ASME J. Mech. Des., 131. Available online at: depth, a finite-element study was then developed. As http://dx.doi.org/10.1115/1.3125888. far as we are aware, this modeled the initial load of extension springs for the first time. This was done us- 6 Dym, C. L., and Shames, I. H., 1973, Solid Mechanics: A ing beams for the spring and connectors to introduce Variational Approach, McGraw-Hill, New York. the pretension. Simulations highlighted that the initial rate of the spring was due to the deflection of the loops 7 Steel for mechanical springs, 2001, NF EN 10270-1, ISSN 0335-3931. and about half a coil of the body. This study focuses on the influence of the loops on the load-deflection curve Company Profiles: of extension springs. The experimental study performed on four extension STRAIN is the Spring Technology ReseArch INstitute. It is springs clearly exhibits what is only suggested by the first research institute in France fully dedicated to spring technology and a 2018 partnership of ICA/INSA and CGR. Founded in 1963, CGR is a spring manufacturer and world- wide supplier for the automotive and aerospace industry. CGR has developed complementary tech- nologies such as cold forming of tubes and wires, mechatronics, EDM (electro-erosion) and additive manufacturing. CGR employs 1550 people in 20 production sites in Europe, North and South America and Asia. www.cgr.fr With some 14,000 alumni present in all economic sectors, the Institut National des Sciences Appliquées of Toulouse, an international, pluridisciplinary, state engineering school, is recognized for the excellence of its five- year education which attracts students of a high academic level and who have obtained excellent results at the Baccalaureat. Institut Clement Ader is a research laboratory that focuses on the study of structures, systems and mechanical processes. With about 80 researchers and 90 PHD students, our activ- ity sectors are in the mechanical industries with particular focus on aerospace, space, transportation and energy. Our work usually focuses on be- havior modeling, instrumentation and study of durability of the structures or products considered. Spring 2019/Wire Forming Technology International 41

Exhibition, Conference, Convention, Forum and More in Atlanta submitted by: municate and live. As we usher in a digitized, datafied Wire Association International, Inc. (WAI) 71 Bradley Road, Ste. 9, Madison, CT 06443, USA world, the next industrial revolution is unfolding www.wirenet.org • www.interwire19.com before us and forever changing our businesses. The Wire Association International (WAI), Inc., Madi- son, CT, USA, presents Interwire 2019, the 89th WAI Also, VIPs from Prysmian Group, Leggett & Platt, Annual Convention and the third Global Continuous Casting Forum. All three events are being staged con- Insteel Industries, Nexans Energy and Southwire Co. currently at the Georgia World Congress Center in Atlanta, GA, USA. The WAI Annual Convention and LLC are among luminaries to address “Next Genera- Global Continuous Casting Forum will run from May 13 to 16, 2019, and the exhibits for Interwire and the co- tion of Wire and Cable” at the Interwire Conference, May located International Fastener Manufacturing Exposition (IFME) will run from May 14 to 16, 2019, at the Georgia 14 and 15, 2019. World Congress Center in Hall A. Conference highlights on May 14 include: The Exhibition •  “State of Manufacturing,” by Karl G. Glassman, Spring making and wire forming machinery is intro- duced, reviewed and sold at Interwire. This biennial President & CEO, Leggett & Platt; and Director, trade show—the largest of its kind in the Americas— features an ever-changing landscape of new and National Association of Manufacturers. returning exhibiting companies, which draws the attention of leaders throughout the industry. •  “Global Wire & Cable Market Outlook,” by Over 400 exhibiting companies are expected to show- case the latest products, developed technologies and Philip Radbourne, Director, Integer Research services available in the world for the wire manufac- turing and wire forming industry. At Interwire 2017, (An Argus Media Company). WAI welcomed visitors from 45 states and 50 countries; similar attendance is expected in 2019. • “Sector Insights/Forecasts” Panel, with Bill If you are involved with the purchase or recommenda- tion of capital equipment and want to know about the Reichert, President, Champlain Cable; next generation of products, Interwire 2019 is for you. Brian Parsons, President, Dekoron Wire & Cable, The Conference Marmon Specialty Group; and Paul Wagner, With a “Next Generation” theme, and a new conference format that features a remarkable lineup of speakers President & CEO of Minnesota Wire. from the industry’s most influential companies, you can expect change and a multitude of choices at Inter- Conference highlights on May 15 include: wire. You will come face-to-face with the people, topics and technology that affect what you do and how you •  “Positioning for Future Challenges and do it within the industry’s global market. Dr. Shawn G. DuBravac, best-selling Opportunities,” by Giacomo Sofia, Head of author, global futurist and trendcaster is the keynote speaker at the new Interwire Operations for Prysmian Group North America. Conference. DuBravac’s presentation, titled, “The Future of Wires and Cables •  “Operations Innovation” Panel, with Andy in a Connected World,” is open to all Interwire Conference registrants, and takes Talbot, Mid-South Wire; Dave Hawker, Nexans place from 9:05 AM to 9:45 AM, on May 14, 2019. According to DuBravac, the number of “things” con- Energy; Richard Wagner, Insteel Wire Products; nected to the Internet surpassed the number of people on the planet over 10 years ago. This colossal change Tom Heberling, Southwire Co. LLC; and Ali is creating tremendous challenges and unheralded opportunities. Massive experimentation today will Shehab, Cimteq Ltd. redefine our future and influence how we work, com- •  “Tariffs & Trade – Steel Wire Impact,” by H.O. Woltz III, CEO Insteel Industries, Inc. Commenting on the lineup, WAI Executive Director, Steven Fetteroll, said, “These leaders have a tremen- dous amount of insight to share with the Interwire audience, specifically tomorrow’s key decision mak- ers. This conference is one of several components that makes the Interwire experience stronger and more valuable than ever.” Complete Interwire Conference and Exposition de- tails, and info on the Global Continuous Casting Forum, technical sessions, “nextworking” activities and col- located International Fastener Manufacturing Exposition, are available at: www.interwire19.com. WFTI The Wire Association International, Inc. (WAI), founded in 1930, is a worldwide technical society for wire and cable industry profession- als dedicated to the promotion, collection and dissemination of techni- cal, manufacturing and general business information and trends in the industry. Throughout the year, WAI organizes events such as Interwire and the WAI Operations Summit and Wire Expo trade shows, technical workshops and symposiums, an on-line trade show and annual Interna- tional Technical Conference. www.wirenet.org See pages 44-53 for select wire forming exhibits in Atlanta. 42 Wire Forming Technology International/Spring 2019

DESIGNED & BUILT All-In-One Solution. Shape wire and coil springs with a single line from FENN. Torin FZ-11 Spring Coiler >>> FENN 3U-HP Power Driven Turks Head >>> Payoff designed for your specifications Maintain complete control of your product by eliminating reliance on outside vendors Increase productivity by eliminating secondary processes with this complete in-house solution Fully automated line — set it and forget it! See it at Interwire 2019 Booth #711 Metal Forming Solutions since 1900 www.fenn-torin.com FENN LLC | 80 Clark Drive, Unit 5D | East Berlin, CT 06023 | [email protected] | 860.259.6600

COMPANY Interwire 2019 PREVIEW BOOTH A. Appiani Srl/AITMAC  1719 A leading manufacturer of reels since 1962, A. Ap- piani will demonstrate their engineering capabilities by exhibiting a selection of structural and corrugated flanged reels for cable, rope and strands; single and double-flange pressed steel reels; composite reels; solid flange and double-flange processing reels, ma- chined and dynamically balanced; spools for steel cord and saw wire applications; and steel storage pal- lets. Also available is a complementary line of take- apart reels (hydraulic, mechanic, pneumatic), tilting units, steel baskets and machinery for B-type spool reconditioning. Appiani, represented in North Amer- ica by AITMAC, Inc., has a worldwide presence in the manufacture of standard and custom build steel reels according to DIN specifications or to customer AFM 3D8 S machine from AIM. requirements. AITMAC Inc.  1719 See how our best in class equipment and accessories from world leader manufacturers will keep you at the leading edge of technology and maximize your productivity, with wire straightening, guiding and feeding equipment by COMETO; wire and cable cut- ters/shears, rod straighteners and flat bar cutters by TRAMEV; a display of steel reels for shipping and processing and reel handling equipment by APPIA- NI. Aitmac Inc., is also the official supplier of Lesmo and Eurodraw Energy machine spare parts and ser- vice requirements. Reels from A. Appiani/AITMAC. AIM Inc.  1111 At Interwire 2019, AIM Inc. will present automated work cell solutions: Input wire from straight and cut or coil and form, weld and systematically arrange the finished parts. During the past few years, AIM Inc. has developed new benders and accessories that the company will unveil at Interwire. Stop by our 2500 ft2 booth 1011 to witness these innovations first-hand. From the company’s patented hybrid forming solu- tion, the Synchro AFM line, capable of unmatched versatility, fast output and low-cost maintenance B & Z Galvanized Wire Ind.   242 to the company’s newest innovation in wire bend- Wires, galvanized wires, fine wires, black annealed ing, upgraded and updated 2D and 3D CNC wire wires and bright wires. bending solutions, single and double bending head machines with robotics integration and complete Bekaert   133 automated systems. In all instances, wire can be fed Whatever industry you’re active in, no matter what directly from a coil, straightened, bent and cut using your application is, we can offer you a customized a software package that provides flexibility and sim- wire solution by combining various basic materials, plicity in programming and is offered in all “univer- coatings, shapes and added value services. At Inter- sal languages.” wire 2019, we showcase a fine selection of innovative 44 Wire Forming Technology International/Spring 2019

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

Interwire 2019 PREVIEW wire products including coated spring wire, tailor- machine and a wire butt welder. There will have sales made flat and shaped wire, ACSR strands, utility and technical personal on hand to answer booth visi- strands, barrier cable and PC strand. Would you like tors’ questions. to know how our customized steel wire solutions can move your business forward? Cometo Srl/AITMAC  1719 AITMAC will exhibit Cometo’s range of wire straight- Bergandi Machinery Co.   800 ening, guiding and feeding equipment including ma- Bergandi Machinery is a world-class leader with chinery offering a simple solution for material straight- over 90-years of manufacturing history in developing ening, feeding and cutting requirements. Visit us and equipment for the wire industry. Bergandi has over see Cometo’s new rotating die holder, PFR43, engi- 2000 machines in more than 65 countries. Bergandi’s neered for use on dry drawing machines. Also on dis- knowledge and experience, serves as a testament to play: feeder units for wire, flat strip, tube and shaped its customers of the quality, performance, and ef- wire; traversing units; wire straighteners in single ficiency that is necessary to be successful in a com- plane, dual plane and multi-plane models; various petitive world. Come and see our newest Chain Link wire guides for a diverse selection of applications; re- Weaving Machines WVR-A6 and WVR-L7 models. placement wire straightener rollers; wire guide rollers; rotating die holders; special wire straighteners for tire Bühler Redex GmbH   841 cord and welding wire with roller positioning/adjust- Bühler Redex is a special machinery manufacturer ing indicators. who is specialized in cold rolling mills for wire and strip. Steel applications can be covered as well as non-ferrous alloys. We are specialist for special ap- plications as the precious metal industry, e.g., mints, PV ribbon for the solar industry, magnet wire for mo- tors and transformers and fine flat wire for medical applications. Chemetall   310 Chemicals and coatings, cleaning and plating materi- als and lubricants. Clifford North America   431 Clifford Machines & Technology and AWT Machin- ery will co-exhibit in booth 431, with booth personal, Wire straightening system from Cometo/AITMAC. Scott Liebenberg, Clive White, Pieter Vorster and Iain Ambler. Together the companies offer a wide DEM SpA  1159 range of machinery for the wire industry including DEM SpA makes a step further! With many lines sold reinforcing mesh welders, industrial mesh welders, in the last years in the USA, DEM confirms its commit- jig welders, wire straightening machinery, grating ment to the American market by presenting its new welders and wire butt welders. This year the firms advanced engineering technologies at the exhibition will be exhibiting an automated CNC jig welder from Interwire, Atlanta, GA, USA. As an Italian company Clifford, along with a wire straightening and cutting specialized in the design, manufacture and commis- sioning of competitive plants for the wire industry, DEM delivers worldwide solutions for cold material transformation in the reinforcing wire industry. The company is highly appreciated all over the world for its standard products: Flat and Profile wire rolling lines, High speed reinforcing wire rolling, Stretch- ing lines, Cold rolling and micro rolling cassettes and Customized engineered Machines. Moreover, DEM team will be glad to introduce new and long- standing customers to the latest developments in the Company product portfolio: DDP (DEM DIGITAL PLATFORM) and DWR (DIRECT WIRE ROLLING), shown at booth 1159. The future technologies sur- round us everywhere: DDP is DEM’s answer to the Automated CNC jig welder from Clifford. digitalization requirements in the ERA of Industry 46 Wire Forming Technology International/Spring 2019



Interwire 2019 PREVIEW 4.0. By allowing advanced analytics and artificial in- proach to new everyday challenges! telligence to increase production outputs, monitoring line efficiency in real time, suggesting predictive and Die Quip Corp.  1101 scheduled maintenance of wear parts and compo- nents with this new visionary platform we can en- On display will be die grinding and finishing equip- sure strong reduction of time to market, increase of repeatability and enhance plant efficiency and safety. ment, dies and die compounds and measuring and The DWR has set a new standard in reinforcing wire cold rolling line. This new revolutionary product has testing equipment. been developed merging DEM know-how of profile rolling and reinforcing wire rolling. It’s the DEM’s an- Drawing Technology Inc.   217 swer to the market flexibility demand with small and many productions lots per day. The concept is based Drawing equipment incuding straightening and cut- on the initial idea of removing pulling capstans from the cold rolling technology by using driven rolls and off macines. therefore allowing a new flexibility on the machine output. All this results in shorter footprint, less com- ERA Wire Inc.   301 ponents, faster production change over, less mainte- nance, less operational costs, more production output Wire straightening and cutting, centerless grinding as and better efficiency. Moreover, a new patented quick locking system, combined with a fast roll positioning, well as used machinery, parts, tooling and material allows roll changing time to be reduced in less than a coffee break. With more than 20 years of activity, warehousing. DEM has a proven track record of successfully deliv- ered lines. A team of qualified and well-trained field Eurobend GmbH  1173 service technicians provides support for the operat- ing machines all over the world. Furthermore, where Fabrication and bending machines and equipment, possible, online service could be a smart way to solve problems without an intervention on site thus saving welders and wire straighteners and cut-off machines time and money. For further information, please visit booth 1159 at Interwire exhibition in Atlanta or visit and equipment. the website: demgroup.com. DEM team look forward to meeting you to share an enthusiastic way to ap- EVG Inc.  1159 EVG Inc. provides automation equipment for fabrica- tion and bending equipment, straightening and cut- off machinery and technology for construction wire manufacturing. Fenn LLC   711 FENN provides an “all-in-one” solution to in-house wire processing. In business since 1900, FENN’s latest product offering enables users to shape wire and coil springs with a single line. The line integrates an FZ Series single point, six-axis Torin spring coiler with a FENN 3U-HP Power Driven Turks Head, and will produce clutch springs with square wire at Interwire 2019. The complete line eliminates reliance on outside DDP (DEM Digital Platform) above, and DWR Wire processing equipment from FENN. (Direct Wire Rolling) below from DEM SpA. vendors for either piece of the process and increases 48 Wire Forming Technology International/Spring 2019 productivity by removing secondary operations. FENN is proud to offer a variety of customized metal forming equipment designed to meet customers’ spe- cific requirements. Available in four, five, or six axes, Torin’s FZ Series includes simplified, state-of-the-art controls with Torin’s “Spring Shortcut” spring gen- erator program to produce a variety of springs and wire forms. Setting the standard for precision and versatility, FENN wire lines are not limited to the rolling of natural edge flat wire. Square, trapezoid, half round, and many other specialty shapes can be