WFTI WINTER 2019 DIGITAL

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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

TablTeabolefoCf Coonntteenntsts FWalli2n0te07r 2019 Vol. 2V2o,l.N1o0,. N1o. 4 www.wireformingtech.com Feature Articles DheyadlirnoggwenitFh e a1t4u rWe FATrIt Ticelcehsnical Achievement Awards – Class of 2007 embrittlement Second Annual Wire Forming Technology International Technical Achievement Awards, given out sitneespl.r.3.in.24g0 AheadraenlanotuefadlltytohtoeeqsupGirpinmagemmnta,ekminafgtoeorrriawl1siroe0rf0oarcmYceinesgsaoinrridesussftoryr individuals for major technical developments making springs or wire formed parts. Daniel Kromberg - Cohesive company positioned for stable development announces expansion. 36 Tw1 i6n -TB“Huuorsrwine etR,seTs-w ESniangv-ienHdee eiatr idfnrogWm Mi rEye xWBtiinercent Fidooinnr”mgiMnga chine Twin-turret wire bender ...36 Jenn iferDTraeywl oGrr-eeIdneblaalttf o- Ar mmeuldtii-upmro-ntgoe-ldo sntgrapteagryt srewsuitlhtemd iunl tgiprolewtbhe anndds r.eturn to profitability. 38 To2p0 PHRriocyhddarrudoDcg.teSsnisso Eofnm,2Jbr0. r-1iAt8trleevimeweonf tth oe fp hSyspicrailnmge taSlltuergeylof hydrogen embrittlement of Drum washer for springs 4an6d The winsnperrinsginstoeeulra1lo9nthgawnitnhuaaldaisrctuicslseioonnotfhmeittigoaptiopnromdeutchtosdcs.overed editorially in the past year. wire formed parts...30 Re2su3l ts Caroembapsoedsiotniosnel eEcftifoencbtys thine WCiarerbFoornm SingteTeelchnology International Editorial Staff. 51 IntricaDmrce.tRiaelolugsregryoNof.fWsIpnrrigidnhgtu-mcPatakirintog6naonf Hdthweeimraeutflotiinr-mpagerdt ospeafrrietWss,mTiarhneeufsSatc,retuRnrginothg.dofsS,teRel,odepdeicsate&d toCthae bles Easy-to-learn 4-slide machine ...40 54 Compact bJuesc2to 4inm MinCKogirrottianiamnct reRiern.,a DgDshisrna.g mVflyoai -lrp eA ort ylphouoRelkau a2rdtnf1 ohesirgtv hh,C-eDpeaeatnrvifnoetgrumCfraelyonrrwcoeeu assn, &dB conoborrnSofsheioarrnwo-ur-essEiwsletiarcnettr- otfylmupoearogppnroeolytdimcuecinrt/sdPuTcFtEio n is mesh MeshcWoatienglds fionr sgpriRngos aunnd wdiruepformed parts. welding cyl- inder...36 Ed2ito6r ialSDSrt.traEeffcsk-esTh ahPredesMetüanltleienr-o-gfS- t–thre eAs-sa Pr(st hrinoatcm) pteeiscehnainwl gAecldpainpngblietceuacshteidnooinnlomgaykainngdaeutqousipusmpeennst.ion coil springs Indusftorr ibaetlteIrnmtaeterrinaleuttilizoaftioTn hviainhigghser:hIatrdAnelslsSretsaultrintgsinwreidtuhcedamSatiegrianl uasled/reduced weight. Mic3h0a elHEGderitooalrltia- &lTSh tSaeffuI-nrSdfuaupscptreliiea rTlsIrnhetaeavretnmreetseopnfonTt dhReindogtuos noreudrliuecaspllofonrcthoemsmtauten-iocfa-tthioe-na,rtainndheinatindustrial applicatiaonndss,uarfsacime ptrleeaetmveenntteinqucirpemaesnets. in advantage as it goes wireless. 58 Sp3o6 tliMgohrteO FnlexSibpirlitnyg anCdo Vileinrsgatility for the Wire Worker Mike McDaNnoudrolwttyhhe-eenInJsnueontgvueapbtiblooydnats-waAevrlala-itnlraagbienleeodf, mowreosirnkhetwrh,eethldpeinldagonmwnaninctighminesetcasaginsebsbe,eitlnhegsasot ftafherareendr3et0loamwteiinrdeuttweoso.rkers, improved productivity, performance, setup and quality. 38 Machines for Producing Wire Hangers Sonia Vitari - Versatile wire hanger forming and other wire processing machines offered globally with after-sales support and engineering. Compact 3D bender ...41 C ol3u9m CnAsSMI Scholarship Awards Reach Total of US$463,000 in 2007 Excerpted from the CASMI CONNECTION, a publication of 24 SucceCAsSsMfIu (Cl hCicAagSo AMssIoHciaotiloind oaf ySpErinvge Mnant,ufMactaurrecrsh, InMc.)e, Nmapbeervrillse,hILi,pUSA. MMi4ce h4ea etilWIJntBascgaiq rnA,uedecC ysRt-AAiovnCcdSiAkt iaSM&eeMrs ItCI -SiNoCnecoa wVmhtsiepnoan&ngleyaE zSirvnuetsuenenhptdlspaispU lt&iopePtd arCa prCtooetholgeundrmseavobmellioia,dpinaCgtAegrsoS w Mth ImGarkoet lifn OLatuintAi mnegrica. Versatile system for producing wire hangers....38 26 Th4e5 QCuoimckp-aFniyx PSrporfiilnegs Rate Compensation FormIunfloarmfaotiorn Cof voailuleetrosthOe inntelrynational spring and wire formed parts industry. Bright annealing wire system Ra nd yInDdeFuosrdtr-yA lEl TvheinngstsSprings with modular design ...48 28 W3ir7e aSntrdaiRghotdFrToemnsTihlee TSehsotwing – Part I Dr. RogIemraNg.esWarnigdhftac-tTs hfreomStwreirnegStohuothfeSatseteAlSIA 2007, held October 16-18, 2007, in Bangkok, Thailand. Wire Forming EventsD..e.3.p.0..a..r..tHE.m..U.a.e.r.n.Ad..t.us.B..t.ro..e.m.x...io.t..t.Ci.v..o.e..n..Ss...ue..pq4puleienrcse’sO, NuWtelhoxaottkiI,fsVasellunCeica:erWstowinCetrheearrE g2lee0cE0trn8ictr?y Fee Editorial................................K..o..n..r.a..d...D..e..n..g..le..r..-..E..u..r.o..p..e..a.n. 6Perspectives Top Products of 2007 News Wire ...................3..2......T...h...e...I..m...p...o...r..t.a..n...c...e...o...f..M8 aterials Test Mwaicrhe i2n0e08A Pligrenvmieewnt Product Showcase...............A..l.a..n...T..h.o..m...a..s..-..W...i.r.e...P..r.o..d..u4c0t Testing Roundup: Materials Mesh weldAindgvteecrthisneorlosg’ yIn.d..e53x .....................................................63 Spotlight: Mesh Welding Editorial Index...........................................................64 Next Issue: Spring 2019Fall 2007/Wire Forming Technology International 3 Departments Wire Forming Events ............................................................4 Interwire 2019 Preview Editorial.................................................................................6 wire Russia 2019 Preview News Wire ............................................................................8 Emphasis: Materials (Wire, Strip & Bar) Product Showcase..............................................................61 Roundups: Straightening & Cutting Advertisers’ Index ...............................................................63 Spotlight: Wire Forming & Tube Bending Editorial Company Index ....................................................64 Winter 2019/Wire Forming Technology International 3

WIRE FORMING EVENTS Table of Contents October 1F–al3l ,20200719 Vol. 10, No. 4 March 13 – 16, 2019 FENCETECH ‘19, Indianapolis, IN, USA SMI Metal Engineering eXpo 2019 www.americanfenceassociation.com Feature Articles 1741 Akron Peninsula Rd, Pittsburg, PA, USA Dealing with March 14, 2019 hydrogen USA NESMA Casino Night & Table Top Show 14 WFTI Technical Achievement AwaArdksr o–n C,laOssHo4f 24030173 Birstol, CT, USA www.metalengineeringexpo.orgembrittlement Tel: +1 330 864 2122 • Fax: +1 330 864 5298Second Annual Wire Forming Technology International Technical Achievement Awards, given out www.nesma-usa.com in spring 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 BDruews iGnreeesnsbl aStt a- Av emdul tii-tp rfornogmed sEtrxatteignyc retsioulnted” in gCrowhthi pandL reipturpn itno pcrooftitatbility. Rockfrd, IL, USA 20 Hydrogen Embrittlement of SpringP Srteeseildent and Publisher [email protected] D. Sisson, Jr. - A review of the physical metallurgy of hydrogen embrittlement of May 13 – 16, 2019 www.wirefabricators.org spring steel along with a discussion of mitigation methods. Interwire 2019, Atlanta, GA, USA 23 Composition Effects in Carbon Steel SMtreinkgteh oMf StceNel,udeldtiycated www.interwire19.com Dr. Roger N. Wright - Part 6 of the multi-part series, The March 30, 2020 – April 3, 2020 Drum washer for springs and to the wire 2020 wire formed parts...30 metallurgy of spring making and wire formed partsVmiacneufPacrtuerisnigd. ent and Editor 24 Coatings for the 21st Century [email protected] Düsseldorf, Germany Kirtan R. Dhami - A look at high-performance and corrosion-resistant fluoropolymer/PTFE May 13 – 16, 2019 coatings for springs and wire formed parts. Tom Hutchinson WFA Spring Meeting, Atlanta, GA, USA www.wirefabricators.org www.wire-tradefair.com 26 SDrt.rEecskesh aPrdeMeünllienr -gS –tre Ass P(shroatc) pteicenainl gAcpanpbliecuGastelidooibnnmalakSinaglaeusto Msusapennasigonecroil springs for better material utilization via higher hardness trlehsu@ltinwg inirreedfuocremd miantegritael cushe.dc/roedmuced weight. June 13 – 15, 2019 www.mdna.comCompact China (Guangzhou) Int’l. Spring mesh Industry Expo, Guangzhou, Chin welding cyl- www.julang.com.cn June 2 – 4, 2020 inder...36 30 Heat & Surface Treatment Roundup for the sJtaitme-ofM-thea-asrat inrheat Editorial Staff - Suppliers have responded to our call and surface treatment equipment. Senior Editor WAI Operations Summit & 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. Wire Expo 2020 38 Machines for Producing Wire Hianntgeersrnational Sales Uncasville, CT, USA globally with after-sales support and engineering. Sonia Vitari - Versatile wire hanger forming and other wire processing machines offered CHINA www.wirenet.org 39 CASMI Scholarship Awards ReachR Tinogtaiel roTf UraSd$e4M63e,0d0i0a iLnt d20. 07 September 17 – 19, 2019 CExAcSeMrpIt e(Cdhfriocmagtoh eACssAoScMiaIEtCioaOnsN otNf CESCphrTiiInOngNa M,:aaVnpuuifbvalciictaautnrioenrSso,h fInacn.),gNa+p8er6vi-lle2,1IL,6U2S8A.9-5533, EXT 169 wire Southeast Asia 2019 Bangkok, Thailand SweirpetCemhibnaer220320–, 2S6h,a2n0g2h0a i, C hina 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, www.wire-southeastasia.com wwwwww..wmidrneach.cionma.net wire hangers....38 Jacques Anckaert - Company intendsEtoXtapTth9e 3de3v2elopmingaggrogwitehlmiuar@ket rininLagtiineArmtrearicdae. .com www.mdna.com 45 Company Profiles interHnaotionnagl sKpriongnagn:d MwireikfoermHedapyart+s i8nd5u2stry2. 369 8788, ext 11 Information of value to the [email protected] Industry Events October 7 – 9, 2020 37 Straight From The SSohuothweastTASoImA 20H07u, htcelhd iOncstGoobenEr,1R6G-M1l8o,A2b0aN0l7Y,SinaBlaensgkMok,aTnhaailganedr. September 26, 2019 SPRING WORLD® 2020, Images and facts from wire [email protected] 10th International Congress of Spring Wire Rosemont, IL, USA De partments Hamburg, Germany www.casmWiire-sFoprmriinng gEvwenots.r..l..d......o....r..g..................................4 Next Issue: WINinDtIeAr 2008 www.esf-springs.com Editorial....................................................................... 6 Strategise.inToPpv Pt.rLodtdu.c,tAs bohf i2j0at07Sanghvi, Co-Founder News Wire ..................................................................8 Tel : +91-22-w6i5re262300186 5P/r6e6v,ieCwell : +91-98211 27628 Product Showcase....................................................40 REoumnadiul p: :a [email protected] 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. 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EDITORIAL Manufacturing Jobs THE INDUSTRY 4.0 MATURITY MODEL As a long-time fan of companies and processes that Transformative technologies have entered the manufacturing sector and have started doing what they do best: Transform it. Technologies such as are involved in making things, I was pleased to see the additive manufacturing, IIoT, edge and cloud computing, machine learning and artificial intelligence, advanced robotics, augmented reality, production reports that the USA manufacturing industry posted a simulation and wireless connectivity have and will continue to impact manufacturing, automate it and augment the work and abilities of humans on the net job gain of 284,000 in 2018, capping its best calendar shop floor. Incremental changes, such as improving the performance of legacy machines with new component systems (sensors, motors, actuators, and year since 1997. In 2017, the net increase was also pretty drive belts, for example), will also continue, but transformative technologies will reshape the way manufacturers build products and do business. ABI good—207,000. These numbers would probably be Research delineates this transformation as follows: higher if it was not so difficult to find quality workers. Dr. Chad Moutray, Chief Economist at the National As- Level 0: Human Level 1: Early Level 2: The Level 3: IT/OT Level 4: Digitally Level 5: Lights Out sociation of Manufacturers (NAM), www.nam.org, says, Controlled Automation “Modern” Factory Integrated Transformed “Our industry currently faces a workforce crisis with more than half a million open jobs today, and 2.4 million Description Momipnodaeaatstneaorfhnttvdaasatautlerttitbtaslhtfelefilmeeiieltroloaoimcatlocaigsdupclhhnolwhosel-tpletsen.pttenrlualtdiaayohvesomrbscbulteyimccltuonkaoeatelosot.gogergisuvuecrTythmiinifneacleeqhsidatosrsdltuaieavbnrmmo.tstiyuetieipTuiielthmosothshimryhsotinrtciaeneyuemneaeervstkalrnufsateeaniteahntntowtdfceaigsitorinotmnhrtyshepSctsrtuictolhsdrultdotiubtensstuaiifgrvtennoTorcleotgepscettgthrtramlclohevrgiaeeocoekaedenanlsiepdntldovzlnoeisqowegeneoshilfqudfezoednwogoaaiuai,grrtrdapvtpnnitmfsmikocjnemieiaesuroktsos.artwamahsenl.htTntyttlwensaAaihset.vlmtlecabeeaeldkcrauaytehficstfrrhnnktoeoaeorcmovesltfoesisogigniehst. The truly cutting-edge jobs are expected to go unfilled over the next decade. manufacturing firms Closing the skills gap continues to be the top challenge At this level, a manufacturing These firms have a real today have reached this This future state will fulfill facing manufacturers in the USA.” If you know young firm has not implemented any strategy for innovation level. They have scaled the idea of lights-out people that are interested in making things, and money, of today’s transformative and transformation manufacturing. point them in this direction including the section below. technologies. Humans manually and have started to multiple transformative control all machinery and implement it. They can technologies and have a Factories at this level can Digital Factories operations. Individual human handle custom orders for team or multiple teams operate without humans productivity limits the scale and customers willing to pay We hear lots of talk these days of disruptive and transfor- efficiency of operations, and extra and can ramp up or dedicated to innovating on site. Many of these mative technologies related to industrial activities like manpower costs reduce decrease plant with newer technologies, factories will work spring making, wire forming, mesh welding and rebar competitiveness. productivity easily but such as AI or blockchain. processing: Industry 4.0, IIoT (industrial internet of cannot reconfigure lines They have started to dynamically with mobile things), AI (artificial intelligence), additive manufactur- without significant costs. master mass work stations instead of ing or 3D printing, robotics and one of my new favorites, customization and can a fixed production line for the digital factory. A new report from ABI Research in rapidly reconfigure Oyster Bay, NY, USA, says, “The Digital Factory market increased flexibility. will grow at a compound annual growth rate of 33% to reach US$673 billion in 2026.” These impressive sales production lines. numbers include robots, PLCs, intelligent industrial battery management systems, electric motors, pumps, Robotics and No industrial robots. Some industrial robots, Scaled industrial robots Scaled industrial robots Transition from The robots will have higher data networks, app platforms and security systems as Automation Human tended machines perhaps for stud welding where applicable in paint in paint shops, for wire-guided AGVs to payloads and mobility and well another favorite of mine, smart glasses. such as lathes. or painting. shops or for heavy stud-welding and for Autonomous Mobile could work collaboratively ABI Research reports that the automotive industry leads Machines controlled by payload jobs and heavy payload jobs, Robots (AMRs). the way in the adoption of most digital factory technol- humans with manual controls. wire-guided AGVs wire-guided AGVs to Scaled industrial robots if desired. ogy technologies and represents the largest opportunity Relatively modern assembly (Automated Guided move materials and and at least one scaled Mobile manipulation for globally with 20% of the total market in digital factory lines. Vehicles) to move PoCs or pilots for cobots, use case for cobots for AMRs through the use of revenues expected in 2030. Potentially some CNC examples include screw driving, welding, Pierce Owen, ABI’s Principal Analyst says, “The auto- machines. materials. screw-driving pick and place, CNC or mounted arms with motive industry has demonstrated a willingness to scale machine tending collaboration between transformative technologies ranging from generative Reductive, casting and other applications. design and additive manufacturing to IIoT connectivity more traditional methods for applications. different vehicles. and robotics of all kinds more than any other industry, production. but other industries will start to catch up over the next Manufacturing Additive manufacturing Experiments beyond Scaled one low-volume Mass customization, some For some industries, additive decade. The companies that follow automotive OEMs’ Process for rapid prototyping. prototyping for additive, additively manufactured spare parts, low volume manufacturing will become lead first and scale technologies with proven value Reductive, casting and e.g., customized parts, part within a product production parts and an integral part of the will gain a competitive advantage.” The ABI Digital other more traditional but reductive, casting and but otherwise reductive, some production production. It will also Factory market data report is part of the company’s methods for production other more traditional casting and other more toolmaking using be used for mass Industrial Solution, which aims to help manufacturers still dominant. methods for production. traditional methods for additive, but 95+% of customization, spare digitize operations to create better quality products at production. production uses more part perpetuity, and lower costs. A visit to www.abiresearch.com turns up traditional methods. production toolmaking. lots of interesting information including details on 18 Reductive and additive Industrial Solution modules that “are composed of the manufacturing will operate most compelling transformative technologies” and the on the same lines. More Industry 4.0 infographic shown on the right of this page. additive will also empower manufacturers to deliver extremely small batch runs for minimal or no extra cost. Software Firms simulate production Engineers use topology operations on production simulation software to optimization for Managers use an ERP verify and validate them light-weighting some Most software has AI tools to system to track materials before physically building parts. Smart An unbroken tool chain assist in managing and production at the new production lines. Manufacturing Platforms used to collaborate and operations. corporate level and MES Engineers and take live data from the Generative design Still directing operations on paper. systems to track management use product factory floor and deliver maintain digital threads software will adopt materials, production, lifecycle management them to apps at the of products from overall equipment (PLM) to manage products edge or in the cloud as generative design and generative adversarial effectiveness (OEE) and themselves from design needed. Apps can include simulation through PLM networks (GANs) to get to product quality on the through production. They predictive maintenance, and IoT connectivity for final product designs faster, plant floor. products and operations. regardless of manufacturing also still use ERP at the productivity control and process. corporate level and MES quality control. on the plant floor. Control Operators manage machinery using a manufacturing operations management (MOM) system that AI controls the MOM Machine operators Machine operators provides live data and Operators use a MOM system and human Manually controlled machines. interface through a SCADA interface through a SCADA information about orders, system tightly integrated computer system. computer system. fulfilment, workers, with a Smart operators only intercede materials, equipment Manufacturing platform. to handle unplanned issues. sensor readings and shipments. They can also get alerts from predictive maintenance apps. Data Management Data processed in lambda AI models used to extract and Analytics hybrid architecture with actionable data, and decide edge-to-cloud closed loop what to process at the edge vs machine learning applications for predictive deliver to the cloud. Siloed industrial PCs and maintenance, quality Some might use Line managers carrying clipboards. operational historians Sensor data delivered to Low level use of cloud control and continuous collect data for process dashboards for computing, either public improvement: some of blockchain for data condition-based or private, on-prem or off protection, secure control or production which leverage machine communications, tracking. These expensive monitoring. for predictive vision or image pieces of equipment Some workload maintenance, recognition. manufacturing requests usually lack the consolidation at the edge. productivity control through smart contracts, networking necessary to and quality control. exchange data. Some of these companies inventory systems or to have started investigating record asset information, blockchain applications such as various adjustments, in cybersecurity, supply updates, and ownership, chain, smart contracts and product lifecycles. throughout the device’s life cycle. Connectivity Wireless is slowly Fiber is being introduced Mostly wired but adapting 5G and edge computing running introduced due to due to large amounts to wireless for use cases AI applications are deployed on mobility requirements, of data collected from where it makes sense the factory floor. Network e.g. AGV on factory floor. factory floor. Equipment and starting trials with slicing and dedicated remains wired with some cellular connectivity such Connectivity remains short-range wireless as private LTE or 5G. Some cellular networks are widely Wired and siloed: largely wired but possibly for asset tracking and deployed, enabling low Wired if existent, mostly independent processes some industrial Wi-Fi inventory management. have started using LPWA latency, high reliability Ethernet or other proprietary use their own mainly limited to Emerging SRW pilot technologies for communications across wired technology. connections, e.g., networking infrastructure deployments in condition-based the factory floor and prototyping, metrology. applications. condition-based on-premise. Location monitoring, initial smart monitoring. Wider technologies widely Wireless deployment only glass deployments, deployment of location when absolutely industrial wearables such technologies for asset and utilized and combined to necessary, e.g., bridging as portable gas detectors. vehicle tracking. enable dynamic production wired networks, HMI, Wider use of RFID for Wired connections mobility applications. inventory management. leverage OPC UA over TSN environments through or other software for low collaborative and mobile latency processing and robotics, AGVs, streamlined communications. intralogistics operations, and personnel tracking. Worker Paper instructions/manuals and Digital traditional PDF Beginnings of improved Started PoCs or pilots Multi-use-case smart Smart glasses come as Enablement limited to no M2M integration. instructions/manuals are digital instructions with for AR applications such glasses implementation standard equipment for Traditional in person training with more common. 3D models/CAD but no as assembly guidance, at moderate scale, mixed shop-floor workers. Mobile little digital training content, no Connected machines augmented application. inspection, service, with mobile AR for mobile or headworn AR usage. more common but no Limited smart glass maintenance, repair, appropriate use cases. device AR declines. digital external control or applications for data remote assistance and Assisted reality Glasses will show specific metrology. Proof of collection, glanceable order picking. applications most concept tests for AR with simple information, and Most of these currently common but extended assembly instructions, very limited scale and remote expertise. run over smartphones or reality/immersive content live IoT data, live reach. tablets, and any smart growing for training, glass usage is single navigation, and metrology and inspection use case. results, repair instructions collaboration. or any other necessary information in context. | www.abiresearch.com | [email protected] | Americas +1 516 624 2500 | Europe +44 203 326 0140 | Asia-Pacific +65 6592 0290 | © 2019 ABI Research Bipartisan Politics While our two major political parties in the USA have just treated us to a partial shutdown of our massive federal government, the bipartisan pattern of spending vastly more money than is collected continues every day. It does not matter who is elected or which party controls the legislative or executive branches of govern- ment. In less than 20 years around the year 2038, total spending on the federal government’s current insurance entitlement trifecta of social security, medicare and medicaid plus the interest payments on the trillions of racked up debt will exceed all federal tax revenue. We often hear about the great political divide, but the truth is that our financial mess is the fruit of a dozen years of modern day bipartisan political madness, and the jig is up. We have a ticking time bomb that needs to be diffused with constitutional republic common sense and not any idiotic, uninformed and divisive iterations of socialism, na- tionalism, communism, populism or any other half-baked isms. Mike McNulty, Editor [email protected] 6 Wire Forming Technology International/Winter 2019

“You’re Invited.” IN-HOUSE WAFIOS is proud to announce the 12th edition of its popular In-House exhibition in Wuppertal, EXHIBITION Germany, where we will present numerous world premieres on more than 15,000 square feet MAY 8-10 of exhibition space.* WUPPERTAL • Separate halls for our wire and tube solutions GERMANY • World premiere of the BM 36 • Also on demonstration: B 36, BM 60, BMS 36 • WAFIOS proprietary technologies, including solutions and automation possibilities • Specialist lectures on E-Mobility, Smart Factory, and New Spring Technologies • Numerous co-exhibitors and partner companies and technologies • Detailed information and registration at www.hausmesse.wafios.com (Eng./Ger. versions) *Exhibition program subject to alterations. Please, refer to web site for current information. B 36 Technical Data 2.0 - 6.5 mm .08 - .26 in 2.0 - 5.0 mm .08 - .20 in Wire dia. 600 N/mm2 (87 KSI) 2.0 - 3.6 mm .08 - .14 in Wire dia. 1200 N/mm2 (174 KSI) Wire dia. 1900 N/mm2 (276 KSI) 2 pairs 2 pairs 120 m/min 134 ft/min Feed rollers ca. 180 Nm 133 ft/lbf Infeed speed 5 ( 6 option ) 5 ( 6 option ) Bending torque CNC axes 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

NEWS WIRE Industry Luminaries Commenting on the lineup, from within the EU. WAI Executive Director, Steven Mark Venables, Managing to Speak at Interwire Fetteroll, said, “These leaders have a tremendous amount of insight Director, said, “2018 was our best Conference Event to share with the Interwire audi- ever year, with about £11 mil- ence, specifically tomorrow’s key lion of orders secured and deliv- The Wire Association Interna- decision makers. This conference ered. We thought this was good, tional (WAI), Inc., Madison, CT, is one of several components that but 2019 has got off to a flying USA, announces that its new In- makes the Interwire experience start, culminating in our first ever terwire Conference features a roster stronger and more valuable than month where we have enjoyed of VIP speakers representing the ever.” sales of over £1 million. We’ve industry’s leading wire and cable just continued doing what we manufacturing companies. All The complete Interwire Confer- do best, providing over 60 high- are set to address the conference’s ence and Exposition details as well performance alloys in just three “Next Generation” theme during as information about the concur- weeks—with repeated reliability.” sessions that run on May 14 and rent Global Continuous Casting 15, 2019, during Interwire. Interwire Forum, technical sessions, “next- He continued, “This is our runs May 13 to 16, 2019, in Atlanta, working” activities and collocated business philosophy—a strategy GA, USA, at the Georgia World International Fastener Manufactur- focused on the combination of a Congress Center. ing Exposition, are available at: significant stockholding, a multi- www.interwire19.com skilled team and major investment Highlights on May 14 include in supporting our sales teams the following: AWI Kicks Off 2019 that are located in more than 50 with Best Ever Month countries. • “State of Manufacturing,” by Karl G. Glassman, President Leading UK manufacturing “Our suppliers and customers & CEO, Leggett & Platt; and specialist, Alloy Wire Interna- have talked to us about Brexit. Director, National Associa- tional (AWI) is casting aside the We’ve been very open and proac- tion of Manufacturers. uncertainty of Brexit by recording tive in these discussions and this its best ever month in its 73-year seems to be working.” • “Global Wire & Cable Market history. AWI, which supplies more Outlook,” by Philip Rad- than 60 different high-perfor- Alloy Wire International makes bourne, Director, Integer mance nickel alloys, has secured round, flat and profile wire in a Research (An Argus Media over £1.2 million of sales in Janu- range of materials that is growing Company). ary 2019, shipping 339 individual by the month, with more than 60 orders to customers in 27 different currently available to choose from, • “Sector Insights/Forecasts” countries. each offering superior corrosion Panel, with Bill Reichert, resistance and/or excellent perfor- President, Champlain Cable Boosted by a new quoting mance at high temperatures. Corp.; Brian Parsons, Presi- system, the company has seen dent, Dekoron Wire & Cable, demand for its wire emanate In order to build on the year-on- Marmon Specialty Group; from clients in the automotive, year growth, the company has also and Paul Wagner, President & aerospace, oil and gas and nuclear CEO of Minnesota Wire. sectors, with many citing AWI’s three-week lead time commitment Highlights on May 15 include as being crucial to their manufac- the following: turing operations. • “Positioning for Future Chal- Despite all of the negativity of lenges and Opportunities,” by Brexit negotiations, a significant Giacomo Sofia, Head of Op- proportion of new work has come erations for Prysmian Group North America. • “Operations Innovation” Pan- el, with Andy Talbot, Mid- South Wire; Dave Hawker, Nexans Energy; Richard Wag- ner, Insteel Wire Products; Tom Heberling, Southwire Co. LLC; and Ali Shehab, Cimteq Ltd. • “Tariffs & Trade – Steel Wire Impact,” by H.O Woltz III, CEO, Insteel Industries, Inc. 8 Wire Forming Technology International/Winter 2019



NEWS WIRE signed off a £250,000 investment ham to talk to manufacturers from roof in Freeport, IL, USA. Tri Star that will see the arrival of three every area of industry imagin- also purchased seven more acres new machines to boost speed, able, with significant interest in of property to support continued repeatable quality and capacity. AWI’s ability to offer straight bar expansion. All material storage below 10 mm diameter. This is and shipping will shift to the new Angus Hogarth, Sales Director, extremely applicable to compa- building, opening up room in the concluded, “There’s no point bask- nies who ‘turn’ bar to make small company’s existing manufactur- ing in what we achieved in 2018, components supplied into units ing facility to install additional we need to focus on where the that have to withstand very high production equipment. market is going and make sure we temperatures and/or corrosive are at the forefront of any changes. environments. Tri Star will continue to invest www.alloywire.com in state-of-the-art production “The spend for this year will technologies to enhance its capa- go towards automating part of the Upcoming WFA Events bilities/product quality, reduce its process and bringing in new tech- lead times and develop a world- nology that will help us continue Wire Fabricators Association class cost structure. In 2019, Tri the production of high quality (WFA), Montgomery, IL, USA, Star is scheduled to install various wire—in varying sizes and vol- holds three meetings per year— new draw lines, shot blasting and umes—even quicker. Spring, Fall and Winter. pickling capabilities. “Finally, there is also the small The Spring and Fall Meetings The company is currently com- matter of going for three major include a social hour and din- missioning its new batch anneal quality re-accreditations that will ner the night before, a half-day furnace. This AMS 2750-certified ensure we continue to offer world- meeting consisting mostly of a furnace will be fully operational class manufacturing performance discussion on current economic by the end of January 2019. across all of the industries we developments and trends in the www.tristarmetals.com serve.” industry, a luncheon and a guest speaker presentation or a member NESMA Casino Night AWI also reported on its atten- plant tour. & Table Top Show dance at two trade shows, Valve World Expo and the Advanced En- The 2019 WFA Spring Meeting The New England Spring gineering Show. at the Interwire trade show, takes and Metal Stamping Associa- place May 13 to 14, 2019, at the tion (NESMA) will hold it Ca- At Valve World Expo, the com- Georgia World Congress Center sino Night & pany made global imp[act when in Atlanta, GA, USA. Table Top Show, it brought its unrivalled speed of March 14, 2019, delivery to an audience featuring The 2019 WFA Fall Meeting from 5 PM to 9 PM, at the Double- industry specialists from 86 coun- and Franklin Wire Products and Tree by Hilton in Bristol, CT, USA. tries. Over the course of the three- siffron Plant Tours, take place Oc- day show, AWI staff met with 70 tober 16 to 17, 2019, in Rockford, Join NESMA for an evening new contacts that could lead to IL, USA. www.wirefabricators.org of Roulette, Crap, Poker and new orders as well as holding 20 Blackjack Tables as well as a Buf- meetings with exhibitors who are Tri Star Expansion fet Dinner and Hors d’oeuvres. already tapping into AWI’s ability in Freeport Raffle prizes will include US$500 to support a wide range of nickel assorted gift card basket, 55\" 4k alloys in unrivalled three-week Tri Star Metals has finalized Smart TV and a Wheelbarrow of lead times. a deal to purchase the 100,000 ft2 Booze. building adjacent to its 200,000 ft2 Alloy Wire International also manufacturing facility, bringing Cost for the event is US$40.00 enjoyed significant interest at the the company to 300,000 ft2 under per person for NESMA members Advanced Engineering Show with potential customers from all over the UK heading to its stand. Staff was on hand in Birming- 10 Wire Forming Technology International/Winter 2019



NEWS WIRE and US$45 per person for non- high-carbon drawn steel wire and “The decision to invest in ad- NESMA members. Every attendee bedding industry machinery. ditional fourslides and power gets one free drink ticket for use www.leggett.com presses was a simple one to make,” during NESMA happy hour from said DiVenere. “As a company, it 5 PM to 6 PM only. Cash bar to GEMCO Reflects on is our job to make ourselves avail- follow after 6 PM. Successful 75th Year able to service our customer’s www.nesma-usa.com needs whether it be short-run In 2018, which was its 75th year or high-volume production. The Leggett & Platt of operations, GEMCO Manufac- technology that we have brought Announces New COO turing Company Inc., Southing- online, such as our state-of-the-art ton, CT, USA, continued to build measuring equipment, means that Diversified manufacturer, upon past successes. GEMCO we are well positioned to meet Leggett & Platt, Carthage, MO, earned its certification to the new those needs.” USA, has announced that Mitch ISO 9001:2015 standard, invested Dolloff assumed the role of Chief in additional production equip- GEMCO is also planning to Operating Officer (COO) effective ment and began to implement new launch a new enterprise resource January 1, 2019, a role last held by CAD software to assist itstooling planning (ERP) software this year. Karl Glassman prior to his becom- engineers with the design of fours- It will play a key role in internal ing CEO in January 2016. Dolloff lide and progressive tools in sup- organization and efficiencies mov- will also maintain his current posi- port of their global customer base. ing forward. tion as President of the Specialized GEMCO’s Quality team and Lead Products and Furniture Products Auditors completed a thorough Looking to the new year, GEM- segments until such time successor updating of its internal systems CO plans to exhibit at numer- segment Presidents are appointed. and procedures, which led to ex- ous trade shows throughout the Perry Davis will remain the Presi- ceptional marks from its registrar. country. The first scheduled event dent of Residential Products and will be the Southern New England Industrial Products segments and And fFor more than 23 years, Design-2-Part Show, April 23 to 25, will report to Dolloff. GEMCO has been registered to 2019, at Mohegan Sun in Uncas- the ISO 9001 standard and GEM- ville, CT, USA. GEMCO will also Dolloff joined Leggett & Platt CO President, Mark DiVenere, be exhibiting at the Schaumburg, in 2000 in the Mergers & Acquisi- believes that attaining this new IL, USA, Design-2-Part Show in tions department and then became certification reaffirms Gemco’s May 2019. President of the Tubular Products commitment to quality and its division in Nashville, TN, USA. He valued customers. “We’ve exhibited at a number of returned to the corporate office in D-2-P shows over the past several 2007 to assume the role of Director “Quality has been a pillar of our years, and this year we are very of Business Development for the company for the past 75 years,” excited to have the opportunity Specialized Products segment. He said DiVenere. “This certification to exhibit at the Mohegan Sun was appointed Vice President of is one of the many goals that we inaugural show,” DiVenere said. the Specialized Products segment work toward to ensure our cus- “This will no doubt be one of the in 2009, President of the Automo- tomers receive the highest quality premier events for the region. tive Asia division in 2011 and Pres- parts and solutions possible.” We look forward to meeting with ident of the Automotive Group in current customers as well as intro- 2014. Dolloff became Senior Vice Registration to the standard ducing GEMCO to future business President and President of the demonstrates GEMCO’s ability to partners.” www.gemcomfg.com Specialized Products segment in consistently provide custom pre- 2016 and was appointed Executive cision metal stampings and wire CNBM & Fives Vice President and President of forms along with support services Seal Their Agreement the Specialized Products and Fur- that meet customer and industry- niture Products segments in 2017. specific requirements. On January 26,, 2019, CNBM and Fives signed a cooperation Leggett & Platt is the leading Also, investing in additional frame agreement to open avenues USA manufacturer of bedding capacity in both its fourslide and of collaboration. Through this components, automotive seat power press departments puts frame agreement, CNBM and support and lumbar systems, GEMCO in a position to better Fives defined areas of collabora- components for home furniture support the diverse industries that tion to benefit from either party’s and work furniture, flooring un- it serves. Focusing on the customer expertise or technologies. The par- derlayment, adjustable beds, and continued investment in ties will explore projects together, equipment and technology helps in plant upgrade, plant expansion keep GEMCO a step ahead of its competition. 12 Wire Forming Technology International/Winter 2019

A COMPLETE RANGE OF GRINDING MACHINES 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 and new plants to implement With full-line services covering “We are excited to expand Fives technologies such as the FCB scientific research, manufacturing our portfolio in the USA with Horomill® grinding system, FCB and logistics, CNBM is the largest Chemetall’s product line and tech- Pyro-line and Pillard burners to building materials manufacturer nical support,” said Jason San- reach the highest level of energy on the globe and a world-leading chez, Business Director of Aero- efficiency, emission controls and comprehensive service supplier. space and Custom Packaging at product quality. The scope of the Nexeo Solutions. “The Chemetall agreement is international. Ex- As an industrial engineering portfolio complements our exist- pertise and key technologies are Group with a heritage of over 200 ing portfolio by adding specialty at the heart of this cooperation years, Fives designs and supplies cleaners, corrosion protectants, agreement. machines, process equipment and surface preparation and sealants, production lines for the world’s supporting our continued focus By partnering with Fives, an largest industrial players in vari- in the aerospace, military and international engineering group, ous sectors such as steel, aerospace defense markets. Together, we CNBM, the largest comprehensive and special machining, aluminum, are expanding and leveraging the building material industry group automotive and manufacturing in- strength of our distribution net- in China with a leading position dustries, cement, energy, logistics work and Chemetall’s technical in cement production and plant and glass. www.fivesgroup.com capability to create real value for construction, acknowledged Fives’ our customers.” ability to develop sustainable Chemetall Names technologies providing unsur- Nexeo Solutions “Chemetall is excited to be passed performances in electrical N.A. Distributor working with Nexeo to bring consumption and CO2 emissions. their expertise to customers in the CNBM and Fives’ complementar- The Surface Treatment global Aerospace market. With Nexeo, ity will create opportunities to business unit of the Coatings di- BASF and its Chemetall brand collaborate, aiming at improving vision of BASF, operating under is well positioned to have effec- plant energy efficiency, reducing the Chemetall brand, and Nexeo tive support, timely deliveries thereof CO2 footprint, preserving Solutions, Inc., announce the ex- and the infrastructure to meet natural resources, while increasing panded distribution relationship, the demands of the commercial cement quality and reducing total in the USA, to include Chemetall’s and military aerospace markets. cost of ownership. surface treatment portfolio devel- Nexeo will be able to offer key oped for the aerospace industry. Chemetall technologies like cor- Fives’ performing technologies rosion inhibiting compounds, are acknowledged by CNBM. Chemetall is a leading global nondestructive testing and surface one-stop supplier for Aerospace treatment to customers who need The ceremony gathered several OEMs and maintenance compa- the high quality and exacting stan- top level representatives from both nies. Chemetall offers its well- dards that Chemetall brings to the companies including Song Zhi known line of products including Aerospace industry,” said Gregg Ping, Chairman of CNBM and Fré- Ardrox® and Naftoseal® brands, Sanko, Director of Aerospace déric Sanchez, President of Fives. offers sealants, nondestructive Technologies for Chemetall North This agreement was the occasion testing (NDT) products, corrosion America. www.chemetall.com to reaffirm their strong commit- inhibitors, cleaners, pretreatments ment to multilateralism, which is and paint strippers for airframe, Construction Has the right direction to develop col- aircraft operation and aero-engine Begun for Advanex laboration between Chinese and applications. Czech Republic European enterprises, meeting both interests. Advanex of the UK has begun construction for the new manufac- turing site in the Czech Republic. The new purpose-built 7300 m2 factory will be located in Horní Počernice. Construction for the new site is well underway and is on track for completion in Spring 2019. The delivery and further management of the building is secured by P3 Logistic Parks. Continued... 14 Wire Forming Technology International/Winter 2019

DESIGNED & BUILT The American Dual Point. A standard offering from Torin! Torin’s REVOLUTION Series is available with the optional Spring Vision camera gauge system. Spring Vision allows the coiler to self-adjust, via closed loop control, for any changes that may have occurred with the material, the tooling or the environment. Standard features include: • Left Hand OR Right Hand Coiling — Save on set up time with multiple programmable axes for diameter allowing quick, 2 screw, changeover from left hand to right hand spring helix. • Movable Wire Lines — Save time and get production up and running faster with our multi wire line tooling. Wire line tooling does not need to be changed with the wire size. • Common Guides and Feed Rolls — Compatible with your existing Torin machines. • Capable of single point & torsion coiling • Retractable arbor • Programmable horizontal pitch & vertical (wedge) pitch • Programmable servo elliptical cutter motion Contact us today to learn more about our Dual Point Coiler! Torin Spring Coilers | Connecticut, USA | 860.259.6600 | [email protected] | www.fenn-torin.com

The construction site was re- NEWS WIRE burg in Hamburg, Germany. cently visited by Advanex Ex- For additional information, ecutive Director, CFO, Toshiya dard, while DIN part 1 makes up Ohno, who travelled from Japan the LCD – Lee Compression DIN visit: www.esf-springs.com to celebrate the early stages of the standard series. construction project. Sjogren Industries Lee Spring’s hundred-year Enters New Year Advanex is working closely history is built on a customer on a Roll with P3 in Prague to ensure that service ethic, which directs prod- the project management of the uct design and supply today. We As Sjogren Industries settles in new factory runs seamlessly. are pleased that they continue to for another year of innovation in The P3 logistics park on which demonstrate this with continued the wire tooling industry in 2019, the new Advanex factory will be introduction of new ranges such the company wants to take a mo- located is the largest within the as this. www.leespring.co.uk ment to reflect on 2018. Czech Republic. The facility will be designed to accommodate two This past year, Sjogren In- floors of office space and will have dustries continued to expand state-of-the-art machinery and operations, improve efficiencies production lines. and extend its legacy of providing high-quality components and as- The new factory comes as part International Congress semblies for its valued customers. of the firm’s ambitious European of Spring Industry These were among the highlights growth plans. The factory will see Held in Germany for 2018: Advanex investing €5 million in the Czech Republic over the next The European Spring Federa- • Increasing Engineering De- five years. The new factory will tion, Hagen, Germany, will hold partment with the hiring of a produce precision metal compo- the tenth International Congress Senior Mechanical Engineer nents for supply to all industry of Spring Industry, September 27, and a 3D AutoCAD Designer. sectors. The facility will achieve 2019, at the Hyperion Hotel Ham- and maintain specific accredita- • New Horizontal and Vertical tions for supply into automotive, CNC milling machines to im- medical and aerospace markets. prove automation. www.advanex.co.uk • Addition of QC equipment More DIN-Plus including Comparators and Hardness Testers to improve Springs from Lee Spring quality. Lee Spring of the UK offers a • Showcasing our product line new Centenary Catalogue issue 25, at Wire China (Asia’s largest which includes a full new section trade show for the industry), of DIN-Plus parts 2 and 1 compres- and the world renown Wire sion springs. This extensive 525 Dusseldorf Trade Fair in Ger- series of new parts in end-closed many where Sjogren debuted passivated stainless steel wire or its new 90-page color catalog end-squared and ground plated and utilized a fully function- spring steel provides manufactur- ing wire-pulling machine to ers with a welcome resource for demonstrate the features and rapid delivery of standard parts as benefits of our innovative roll- well as a springboard for specifica- ers and straighteners. tion of custom units to suit those slightly different installations. In 2018, the investents of Sjo- DIN part 2 covers the Compres- gren Industries totaled more sion Instrument DIN (CID) stan- than US$3 million in combined facility improvements and added personnel to improve efficiencies, increase quality and lower prices for its customers. Founded in 1927 by Oscar Sjo- gren, the company has long been an innovator in the design and 16 Wire Forming Technology International/Winter 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

NEWS WIRE manufacturing of customized so- GFG Alliance in the North American industrial, lutions for the wire tooling trades. Completes Purchase of energy and financial sectors. Today Sjogren Industries delivers Keystone Consolidated high quality machinery, tooling KCI’s family of companies in- and accessories to a worldwide Sanjeev Gupta’s global GFG clude Keystone Steel & Wire, En- customer base with distributors Alliance took a substantial step gineered Wire Products, Strand located in Europe, South America, towards its ambition to become a Tech Manufacturing and Key- Asia and Mexico. For more on the major USA steel producer by com- stone Bar Products. products and services available pleting its purchase of Keystone www.gfgalliance.com from Sjogren Industries, visit the Consolidated Industries (KCI), website below. for US$320 million from Contran PPG Acquiring www.sjogren.com Corporation. Whitford Worldwide Timms Promoted The London-headquartered Al- PPG, Pittsburgh, PA, USA, has at MacDermid liance said the addition of KCI to reached a definitive agreement Performance Liberty Steel USA creates one of to acquire Whitford Worldwide the country’s largest producers of Company, a global manufacturer MacDermid Enthone Indus- wire rod and provides a platform that specializes in low-friction and trial Solutions, Waterbury, CT, for GFG to grow its US GREEN- nonstick coatings for industrial ap- USA, a division of MacDermid STEEL capacity to five thousand plications and consumer products. Performance Solutions, has an- tons per year by 2020. The transaction is expected to close nounced that Jonathan Timms in the first quarter 2019, subject to has been promoted Completion of the deal, which customary closing conditions. Fi- to Director of Sustain- was supported by large North nancial terms were not disclosed. able Excellence. With American banks including Wells more than 30 years in Fargo NA and BMO Harris Bank “The acquisition of Whitford the surface finishing (BMO Harris), along with funds will allow PPG to further drive industry, Timms has managed by BlackRock Financial value for its customers and share- extensive experience and brings Management Inc., a subsidiary holders by enhancing our range broad expertise and knowledge of BlackRock Inc., the world’s of product offerings, research and to the role. largest asset manager, helps pave development capabilities, and the way towards a proposed US global market reach in the growing Timms’ three-decade long ca- IPO of Liberty Steel USA, which industrial coatings sector,” said reer in the industry has seen him will be led by Credit Suisse. The Michael McGarry, PPG Chairman hold various positions in a diverse transaction follows closely on the and Chief Executive Officer. range of technical, marketing and completion of Liberty Alumin- business management roles in- ium’s US$500 million purchase Whitford, a privately held com- cluding time in surface finishing of Dunkirk, Europe’s largest pany in Elverson, PA, USA, was plant design and manufacture, aluminium smelter, which was founded in 1969. The company most recently holding the posi- arranged by Bank of America specializes in manufacturing low- tion of director of marketing and Merrill Lynch and a syndicate of friction, wear-resistant coatings strategic accounts in Asia. top tier international banks. for industrial applications in au- tomotive, aerospace, energy and In his new role, Timms will The acquisition of KCI rein- construction markets, and pro- work as part of the product mar- forces GFG’s credentials as a vides coatings services. Whitford keting team and will develop and significant foreign direct investor also makes nonstick coatings for drive the strategy of the Sustain- in North America. The business is cookware, bake ware and small able Excellence program, imple- moving into a new regional head electric appliances such as toaster menting this into the MacDermid office on Madison Avenue in New ovens, griddles, fry pans and irons. Enthone Industrial Solutions orga- York and is targeting several other nization. Timms’ skills, leadership major investment opportunities Whitford employs more than and experience will be critical in 700 people and operates 10 manu- reaching MacDermid Enthone’s facturing facilities located in Elver- goal to become the leader in son; Fostoria, OH, USA; Guelph, sustainability in the company’s Ontario, Canada; Runcorn, UK; chosen markets as well as end- Brescia, Italy; Sao Paulo, Brazil; user applications. Jiangmen, China; Zhuhai, China; www.macdermidenthone.com Tuas, Singapore; and Bangalore, India. “Joining PPG is a giant step for- 18 Wire Forming Technology International/Winter 2019

ward for Whitford,” added Dave NEWS WIRE effect of successful projects such as Willis, Whitford’s Founder and this shouldn’t be under-estimated, Chairman of the Board. “In one of their facilities and infrastruc- as we are now expanding with fell swoop, we will have access to ture. This is where we step in. Our new premises due to an increase new technologies, diverse R&D specialty, in advancing technolo- in demand.” facilities, strong financial support gies and automation, have been and global coverage in areas where utilized worldwide and to design Gibbs concluded, “The auto- we have wanted to expand, but did a world first for one of the world’s motive sector of our business has not yet have sufficient resources. leading spring manufacturers, is grown exponentially, hence the re- This is very good news for our cus- something we’re very proud of. cent purchase of an additional fac- tomers. And it’s also good news Reports suggest the UK automo- tory. With significant investment for our employees, in fact good tive sector is down, but ESP is in new spring coiling machines, a news for everyone.” www.ppg.com showing otherwise and the ripple ESP Installs System ASM-ADM for Lean Manufacturing wire straightener Taking the stress out of pre- INT180 stressing, European Springs & Feeding Pre-straightening Unit Pressings (ESP) has invested in a an invention, with the design and GQ manufacture of an automated pre- wire guide stressing machine. CA CAR CAR Working alongside Design straightening rollers & Automation Solutions and Bosch Rexroth, ESP has seen its wire and cable equipment conceptual plans taken from the drawing board, designed and Via Cabella Lattuada 41 - 23841 - delivered, with a new automated Annone di Brianza - Lc - Italy pre-stresser (which improves the +39-0341-263090 life and load bearing capacity of a spring), reducing waste across [email protected] multiple processes. www.cometo.ws Michael Gibbs, Managing Director of ESP in Cornwall said, Winter 2019/Wire Forming Technology International 19 “In the last decade, since we were acquired by the Lesjofors Group, we have seen turnover increase by over 700%, which has recently led to the acquisition of a second factory in Cornwall and a 40% increase in recruitment in the last year. Lean manufacturing has been key to our success and enhanced automation not only increases our efficiencies in opera- tions and production but also on the budget sheet, as we estimate a pay-back period within just five years.” Mick Stallwood, Director of Design & Automation Solutions added, “Manufacturers are under constant pressure. Multiple factors demand more out of them and manufacturers demand more out

new powder coating line and other NEWS WIRE QPQ (salt bath nitriding), zinc ongoing investment intentions, and manganese phosphate and a further adding to our Industry 4.0 an existing piece of FENN equip- wide variety of spray coatings, at capable manufacturing technol- ment. Dozens of add-ons and its South Houston and Humble, ogy, I have great confidence in our secondary operations are possible TX, USA plants. manufacturing future.” such as feeding systems, laser en- gravers, cutters, buffing systems According to President and European Springs & Pressings and welding systems, enabling CEO, William Howard, “Our Ltd. has sites in Cornwall, London the final product to be completely success is a direct result of a and Yorkshire. It is part of the customized for its intended final dedication to customer service, Lesjofors parent company with 28 application. and our outstanding, dedicated spring manufacturing companies people. HP&C strives to produce across Europe, America and Asia. At the show, FENN highlighted a ‘frictionless business’ environ- www.europeansprings.com the benefits of its integrated au- ment for its customers’ corrosion tomation systems including im- and wear protection needs by FENN: Customized proved equipment safety, reduced employing supply chain-based Automation Systems time in set up and production and solutions. HP&C has over 1500 reduced operating costs by maxi- active customers and processes A leader in customized machin- mizing efficiencies. over five million parts annually. ery solutions for over 100 years, Our dedication to quality, cus- FENN is pleased to now offer “Visiting the customer to really tomer service, and our employees customized automation systems understand their business and resulted in Products Finishing for a wide variety of manufac- production goals is an essential Magazine awarding HP&C a ‘Top turing operations. Last year at part of designing the right auto- Shop’ designation for both plating FABTECH 2018, FENN displayed mated solution for our clients” and spray coating processes, one an Automated Turn-Key Swaging commented Sales Manager, Mike of only four companies in the USA Solution, which included a FENN Geiger. “We work hard to fully to receive that prestigious double 3F Swager, a hydraulic feeder, understand the intended applica- award. The services we provide integrated robotics, laser engrav- tion of the machine, the process, are usually the last step in the ing and a cutting system. The the material to be used and the manufacturing process, so any system was focused on showing desired start and finished product completion delays cost money for automation related to swaging, but dimensions.” our clients. That is why we have systems can be developed for any continuously added capabilities of FENN’s product lines including FABTECH presented the ideal and expanded capacities to get wire forming and shaping equip- platform for FENN to commu- even the most complex jobs done ment, Turks heads, drawbenches, nicate that businesses can avoid and out the door, on time and on swagers, spring coiler machines the perceived need to coordinate budget.” and rolling mills. their own system and entrust the leading metal forming OEM in Howard came to HP&C 15 In addition to designing brand the industry to help their business years ago when he assembled a new systems, FENN can also ret- grow. www.fenn-torin.com group of investors to acquire the rofit an integrated system around company from its founder, Joe Houston Plating & Crutchfield, and began adding Coatings Celebrates services and facilities to meet 30th Year Anniversary the energy industry’s forecasted growth. Houston Plating & Coatings (HP&C), Houston, TX, USA, is He added, “During the 2015- celebrating its 30th anniversary of providing the highest quality corrosion and wear protection services to energy and other equip- ment manufacturers in a variety of industries across the southwest and the nation. A “one-stop-shop”, HP&C has grown to be one of the largest such service firms in the southwest by providing its customers with electroless nickel plating, SBN/ 20 Wire Forming Technology International/Winter 2019

2016 energy downturn we consoli- NEWS WIRE lar spring, cylinder spring, craft dated and streamlined most op- spring, battery spring, volute spi- erations while adding additional the Ground Floor, C Area of the ral, flat spring, clockwork spring, capacity, making HP&C an even China Import and Export Fair tower-shaped spring, snap spring, better, more efficient company. Pazhou Complex in Guangzhou, special spring, Belleville spring, We have recently contracted to be China. serpentine spring, constant force the first USA coatings company to spring, stainless spring and elastic acquire near-zero emission coat- Displayed at this event will be cell products. ing booths that will be installed all kinds of bearing spring, roll bar, at both plants, which will enable valve spring, motorcycle damping Also shown will be spring us to not only eliminate virtually spring, pressure spring, draught materials including spring steel all greenhouse gas emissions, but spring, torsion spring, die spring, also permit expanded services special shaped spring, rectangu- without concern for exceeding permit limits.” OCTOBER 1–3, 2019 • PITTSBURGH Houston Plating & Coatings is It’s a powerful experience to interact the “one-stop-shop” for corrosion with new people on the show floor. and wear protection services for The traveling nature of MEE allows petroleum equipment and other manufacturers in Houston, across us to share our equipment with Texas and around the nation since local companies who wouldn’t 1988. otherwise be attending. With some of the largest tanks in the nation, and 30 years of Jackie Flint Zenhye, Director of experience, Houston Plating & Marketing, Right Lane Industries Coatings has been providing the highest quality electroless nickel EDUCATION AND EXPERTISE plating, and many different kinds FOR THE ENGINEERED SPRING of spray coatings, salt bath ni- AND PRECISION METAL triding (SBN/QPQ), and other COMPONENTS INDUSTRIES. corrosion protection services to petroleum equipment and other Presented by Become an exhibitor or register to attend at manufacturers. metalengineeringexpo.org HP&C’s success is a direct result of its hard-won reputation Winter 2019/Wire Forming Technology International 21 for quality, dedication to customer service, and supply chain based solutions to customers’ corro- sion and wear protection needs. HP&C strives to meet or exceed customer expectations through innovative solutions to finishing issues. HP&C customers know and trust its commitment to get their job done right the first time, on schedule and on budget. For more information visit: www.houstonplating.com Spring & Wire Formed Parts Show in Guangzhou, China The 20th China (Guangzhou) Int’l. Spring Industry Exhibition takes place June 13 to 15, 2019, on

NEWS WIRE wire and stainless wire. Spring equipment including CNC spring end grinders, CNC spring coilers, computerized spring machines, spring testing machines and stress recorders will also be shown as well as testing equipment, spare parts and relevant technical equipment. To obtain additional information on the 20th China (Guangzhou) Int’l. Spring Industry Exposition, being held June 13 to 15, 20-19 in Guangzhou, China, visit the website listed below. www.julang.com.cn Ternium Barranquilla some 120 tons per hour with a coil demonstrating again SMS group’s Orders VCC® Line weight of up to three tons. expertise and position as a reliable from SMS group and leading partner in the world One of the most important of metals for plant supply, instal- Ternium del Atlántico SAS has features of VCC is its method lation, startup and commissioning. placed an order with SMS group of coiling the bar directly in the The result is 543 facilities for wire for the supply and installation vertical position. Plant operators rod, SBQ and special applications, of the VCC® technology (Vertical can therefore eliminate the need bars and merchant products the Compact Coiler) for its bar mill for turning manipulators and at company has supplied since 1950. in Palmar de Varela, Barranquilla, the same time reduce the process Colombia. cycle time, as all coils are formed To learn more about the prod- in the final position. The coils are ucts and services offered by SMS SMS group’s VCC is today’s ready to be stored immediately group, visit: www.sms-group.com state-of-the-art solution for pro- once coiling has been completed ducing compact and torsion-free and the coils have cooled down. Foerster Expands coils, and is now increasingly in & Modernizes HQ demand by rebar processors. The This order sets the score to compact coil is a crucial step for- 20 VCC units supplied by SMS Institut Dr. Foerster GmbH ward in improving the pack-up group worldwide since 1998 and & Co. KG is making a major quality of the final product. These is another important achievement coils have preselected dimensions that, thanks to VCC, remain con- sistent for all products processed on the same line. At the same time, the compact coil size is ideal for storage, transport and handling. This is particularly beneficial when coils are reworked next to construction sites, where there is a build-up of rebar stirrups and other concrete reinforcing struc- tures, especially in metropolitan areas with many space constraints. These are the preconditions that convinced Ternium to integrate this VCC technology into the exist- ing bar mill. Once in operation, the new plant will produce rebars from 8 to 16 mm in diameter at speeds of up to 35 mps. The output will be 22 Wire Forming Technology International/Winter 2019

investment in the expansion and NEWS WIRE tions in more than 60 countries. modernization of its headquarters Foersteris a technological leader location in Reutlingen, Germany. systems that are engineered for the and acts as a competent system Institut Dr. Foerster GmbH & Co. nondestructive testing of metallic partner and solution provider for KG is further strengthening its materials and metal detection as its customers. development department and at well as magnetics. the same time, the firm is provid- To learn more about the prod- ing its employees with long-term Foerster operates on a world- ucts and services that are available job security. wide basis and always maintains from Foerster, visit the company’s a close proximity to its customers website listed below. The new building will be home thanks to the company’s sales and www.foerstergroup.com to the technical assembly center service network of ten subsid- TECHNIKUM 2 as well as the iaries and qualified representa- new cafeteria. OCTOBER 1–3, 2019 • PITTSBURGH TECHNIKUM 2 will host wa- ter-coupled ultrasonic test systems Similar to the way Pittsburgh has evolved along with other projects. In order from a steel town to a technology to bring the development and hub, our industry is changing and system engineering departments MEE is where the collaboration up-to-date, their current offices and idea sharing begins. will also be remodeled and the hallway will be transformed into Chris M. Fazio, General Manager a bridge creating direct access to Diamond Wire Spring the cafeteria. Pittsburgh Plant Acting as a social meeting place, EDUCATION AND EXPERTISE Foerster employees and guests FOR THE ENGINEERED SPRING alike will have the opportunity AND PRECISION METAL to wind down from their busy COMPONENTS INDUSTRIES. schedules while at the same time enjoying a freshly cooked meal in Presented by Become an exhibitor or register to attend at a relaxed setting. metalengineeringexpo.org Architect Michael Frey of the Architectural Offices Schmelzle Winter 2019/Wire Forming Technology International 23 & Partner had already been in charge of the technical assembly center TECHNIKUM 1, the pro- duction department of the Test Systems Division as well as Lo- gistics. After his great successes with these projects, Michael Frey will again be the lead construction manager on the TECHNIKUM 2 project. With a recent groundbreaking ceremony, Institut Dr. Foerster GmbH & Co. KG President, Felix Förster, General Manager, Thomas Himmler and Head of Human Resources, Dirk Heimann, gave the official go-ahead for construc- tion to start working on the new company building. Since the year 1948, the name Foerster has been synonymous with quality and precision. The company designs, develops and manufactures equipment and

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 Successful CASMI Holiday Event lawsuit protection and tax reduction. He has au- Provides Contribution for Those in Need thored and co-authored several articles and books on the subject including, The Asset Protection Bible Nearly 80 CASMI members and their guests at- and How to Achieve Financial Peace of Mind through tended the organization’s Annual Holiday Event Asset Protection. to celebrate the past year and look forward to 2019. It was held December 13, 2018, at Carlucci Details on the March Member Meeting, including in Rosemont, IL, USA. For the fourth consecutive registration, are available on the CASMI web site year, the organization accepted donations from at- listed below. tendees for the Mercy Home for Boys and Girls, a CASMI’s 2019 Scholarship Program Is Open privately funded child care and residential home for abused, homeless and neglected children or children The Chicago Association of Spring Manufacturers struggling with family issues. CASMI members (CASMI) is proud to announce the 2019 CASMI contributed US$1520 (including one generous and College Scholarship Program to benefit employees anonymous contribution of US$500) to support this and children of the employees of CASMI Primary organization’s mission (spring manufacturer) and Associate (supplier) member companies. In 2019, CASMI plans to award a total of 19, US$1500 undergraduate scholarships and two US$2500 schol- arships for post-graduate study (Primary members only). Since the program’s inception, CASMI has provided US$787,000 in scholarships to under- graduate and graduate students. March Membership Meeting CASMI thanks Rosemont Exposition Services, Will Focus on Protecting Your Business which funds the annual US$2500 Terry & Jerry Reese Postgraduate Scholarship, and the Joseph H. Gold- CASMI will meet March 21, 2019, in Schaumburg, berg Family Foundation and International Spring IL, USA, for its March Membership Dinner Meet- Co., which provided US$2500 in direct funding for ing. Larry Oxenham, Author and Senior Advisor, one post-graduate scholarship in 2019. American Society for Asset Protec- tion, will present Don’t Kill Your “A major reason why CASMI exists is to support and Golden Goose-Protect & Perpetuate give back to the spring manufacturing industry,” Your Business. Members who attend this session will discover the tools you can use to become invincible to lawsuits, save thousands in taxes and achieve financial peace of mind. Larry Oxenham is one of America’s top asset pro- tection experts, having helped thousands of profes- sionals achieve financial peace of mind by teaching them how to properly structure their assets for 24 Wire Forming Technology International/Winter 2019

says Tony Pesaresi, President of CASMI. “We can The day’s activities include lunch, shotgun start think of nothing better than to help young men and women through this scholarship program.” golf tournament, cocktail hour and dinner. Various Details are available on the website listed below. prizes will be presented throughout the evening. CASMI Golf Outing Takes Place This June All CASMI members, SpringWorld® 2020 exhibitors CASMI will host its Annual Golf Tournament at the competitive Bloomingdale Golf Club, Bloomingda- and suppliers who are interested in exhibiting at le, IL, USA, June 18, 2019. The course will welcome the average player and will challenge everyone. 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. www.casmi-springworld.org WFTI More About CASMI: CASMI was founded in 1944 as an independent, not-for- profit trade association dedicated to the development of good business practices, and sharing of technical informa- tion through ongoing communications among the job-shop spring manufacturers in the greater Chicago, IL, USA area. While membership is predominantly located in Illinois, In- diana and Wisconsin, the organization provides support to spring manufacturer and supplier members throughout the USA. Although CASMI works closely on several issues with the Spring Manufacturers Institute (SMI), a national or- ganization, both organizations are independent of one anoth- er, with unique missions, programs, services, and members. CASMI sponsors the SpringWorld® Trade Show every two years. www.casmi-springworld.org Winter 2019/Wire Forming Technology International 25

All Things by: Randy DeFord, Engineering Manager Springs Mid-West Spring & Stamping 105 Etna St. The Quick-Fix Spring Rate Mentone, IN 46539  USA Compensation Formula E-mail: [email protected] for Coilers Only www.mwspring.com One of the daily challenges for springmakers/coilers all divided by the rate you need. This math will yield is the adjustment needed to yield nominal rate. As all the adjusted active coils needed to get rate back to spring manufacturers know, the only bill of material for nominal. a spring is the material used to make the part. That very material has a list of properties that vary from Here is an example. The spring coiler coils a spring wire lot to wire lot. These properties are modulus of that calls for 12.0 total coils (10.0 active coils) and elasticity, tensile, material size and out-of-roundness. a rate of 56.0 #/inch. He/she makes the first set of samples for testing, only to find the rate is actually Any or all of these properties will have slight variations 52.4 #/in. What to do? and the end user has no control over the chemistry of the material that is brought to his/her spring coiler for Using the above formula, the answer is: processing. Much like stack-up tolerances, a variation in each property will have a noted effect on the elastic    New active coils needed = (10 * 52.4) / 56 reaction of the resulting spring. And since a spring is a rate-producing mechanical device, its very purpose (Remember to use the active coils, not the total coils) is to produce a force, based on the spring rate. That spring rate is born from the amount of active material in the spring... period.    New active coils needed = 9.36….or 9.4 So... what does a springmaker do if a spring is set up identically to the previous order, but produces a different rate, even though all physical dimensions are identical? Well, I have an answer for that question. This simple formula should serve the spring maker If you review the spring rate formula you’ll find that well and take away the guess work associated with rate and active coils are inversely proportional. This coil change for rate adjustment. means that if a coiler sets up the coiling machine and the sample spring is a bit high on rate, he/she As useful as it sounds, there are a couple of issues will need to add some material length to lower the (as seen below) to keep in mind when amending the spring rate to the acceptable tolerance. Many times active coils. this is a tweak based on past experience with no math involved. However, there is a way to calculate the CAVEAT 1 — If the coil change requires coil to be change required with a minute of investment. removed, that change will increase the pitch and that will raise the stresses. Be sure the change is not ex- By eliminating all the algebraic variables in spring cessive or that increase in pitch could allow the spring formulas and stripping down to just the coils and rate, to take set sooner in its deflection and this could be this formula appears. an issue. See an engineer if the change is excessive.   N2 = (N1 * R1) / R2 CAVEAT 2 — If the coil change requires coil to be Or... the rate you seek is equal to the number of active coils of your sample, times the rate of your sample, added, that change will decrease the pitch and this will add to the total solid height. Compression springs are quite commonly held to maximum solid heights to be certain they can deflect the total travel required. Be sure the change does not add so much coil that the maximum solid height is breached. 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. 26 Wire Forming Technology International/Winter 2019



The Strength by: of Steel Dr. Roger N. Wright Roger N. Wright, LLC Wire and Rod Tensile Testing – Part I 600 State Street Lawrenceville, IL 62439 USA E-mail: [email protected] www.rnwinc.com Having pretty much finished up our metallurgical discus- extension and rate of extension are either measured by an sions for the time being, I think that it is time to go back extensometer attached directly to the specimen, or directly to some basic observations on testing. We have said a lot from the crosshead extension (in some cases the wire may about structure, properties and processing (the three cor- be too thin for the attachment of an extensometer). ners of the materials engineering triangle!), but we have said less about the nature of testing, per se. And after all, if we do not have good test technique and evaluation, our materials engineering triangle may not be as solid as we would like. So, let us start with the most important wire and rod test, namely the tensile test. For this test, a given length of wire or rod, l0, of cross sectional area, A0, is subjected to pro- gressive elongation, usually at a constant rate of elonga- tion. A schematic representation of the starting configura- tion is shown in Figure 1. The data collected are the pulling force, F, and the extent of elongation, (l – l0), where l is the length to which the initial section, of length l0, has been extended at a given stage of the test. Except for heavier gage rod, such wire and rod tensile test- All right, we have our specimen and our testing machine. ing is generally performed on a length of stock cut directly Now let’s obtain some data. If the test is successful and the from an as-finished, straight-drawn length or a section of wire or rod material reasonably ductile, the raw data will coiled stock. Generally, no reduced-diameter section is look something like that in Figure 3. We will talk about the prepared. This is because the preparation of a reduced A, B, C and Ds of tensile testing next time. diameter gage length is tedious, and the reduced sec- tion may be unrepresentative if the wire or rod has a ra- In the meantime, take a look at some of your own data. dial strength or residual stress gradient. Moreover, it is un- necessary, assuming the wire or rod does not break in the Good luck!!!! WFTI grips, and breaks within a designated gage length or within the measuring range of an extensometer. This response is often the case, unless the wire is cold drawn, and/or prone to necking at small elongations. In the worst case scenario, one simply has to cut another length of wire or rod and try again. ASTM Standard E8/E8M-08 addresses the tensile testing of wire. The tensile test may be conducted on an apparatus such as illustrated in Figure 2, with one end of the sample se- cured to a fixed platen, while the other end is gripped by a moving, screw-driven crosshead. The force is monitored by a load cell attached in series with the specimen, while 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 28 Wire Forming Technology International/Winter 2019

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European Perspectives by: trade tariffs, smaller high-end players such as Aston and McLar- Dipl.-Ing. Konrad Dengler en believe their affluent customers could absorb extra costs and Industrial Journalist are more concerned about customs checks and delays. Finkenweg 6 D 91091 Grossenseebach In the event of a no-deal “disgrace”, the aircraft manufacturer Germany Airbus could shift its manufacturing operations out of the UK, [email protected] says the “Engineering and Technology” (E&T) magazine. The European aerospace giant, which is largely based in Toulouse, Some Consequences of a Hard Brexit France, directly employs 14,000 people across 25 sites in the UK where its wings are designed and manufactured. The com- In June 2016 a majority of British voters decided that the UK pany has more than 4000 suppliers in the UK, with approximate- should leave the European Union (EU). The decision called ly 110,000 jobs connected to its supply chains. “Brexit” will come into effect on 29 March 2019. Currently the British Parliament is deeply divided over the further procedures. https://www.irishtimes.com/news/politics/brexit-explained-why- There are indications that the country will leave the EU with- does-the-border-matter-and-what-is-the-backstop-1.3661518 out deal which regulates the further mutual relations. In this case called “Hard Brexit”, enormous difficulties are expected. https://in.reuters.com/article/britain-eu-astonmartin-idINKC- A sticking point in Brexit negotiations is the “border matter”. As N1P1163 explained by Simon Carswell, a journalist of the “Irishtimes” newspaper, after Brexit, the nearly 500 km long border between https://eandt.theiet.org/content/articles/2019/01/uk-aerospace- Northern Ireland, which belongs to the UK and the Republic of sector-at-the-precipice-warns-airbus-ceo/ Ireland, will become the only land border between the UK and the European Union (EU). The border is currently invisible. If What if all Cars were Electric? the UK is leaving the EU, however, a visible (“hard”) border and the corresponding infrastructure along the border would be re- Are electric vehicles (EVs) really the solution to Europe’s envi- established because of different customs rules, regulations and ronmental problems? And if so, what happens if everybody rush- standards in the neighbouring countries. The general fear is that es to adopt them? Could the electricity grid and materials sup- the return of a hard border with customs officials and a police or plies possibly cope? These are among the competing scenarios military presence to protect check points would be so unaccept- for 2050 tested by the engineering, research and consulting able to people who travel freely across an open border that it company Ricardo plc, Shoreham-by-Sea, UK, in a new study. would lead to anger and, potentially, violence as during the 30- The results are described in the “RQ Ricardo Quarterly Review” year Troubles before in 1998 Belfast Agreement brought peace Q4 2018 issue. In conducting this study Ricardo and its partners to Northern Ireland and removed the need for border checks. No did not aim to establish the rights and wrongs of any particular party to the Brexit negotiations wants to see the return of a hard technology, nor to provide predictions for how light-duty transport border but cannot agree a plan on how to achieve this. might evolve over the next 30 years. Instead, the work revolved around exploring two deliberately contrasting scenarios which Other consquences of the Brexit will affect the industry. British pushed competing trends to extremes – to help understand the carmakers, for example, fear their just-in-time production will pressure points within each scenario. grind to a halt if there are delays imposed after Brexit. Britain’s car industry, which employs over 850,000 people and is one of But major policy choices such as this are rarely binary, and the the country’s rare manufacturing success stories, has warned rational approach is to make the best and most balanced use of that leaving the EU without a deal would add costs and could the resources that will be at Europe’s disposal by the mid-point halt output due to snarl-ups. Costas Pitas, a journalist working of the century. At the same time the study’s findings provide a for the new agency Reuters, described how the British carmaker planning tool to judge the implications of any chosen position on Aston Martin has triggered contingency plans to cope with a the spectrum between those extremes. One conclusion shines potentially disorderly Brexit, including hiring a new supply chain through very clearly, as even fuels industry representatives con- chief and preparing to fly in components and use ports other cede. In most situations, passenger cars and light vans will be than Dover (“Exclusive: Aston Martin triggers contingency plans most efficient with batteries directly charged with electricity. But for no deal Brexit”). Aston Martin joins a growing list of compa- most heavy duty vehicles are less well suited to battery technolo- nies readying for a no-deal Brexit. Data showed manufacturers gies and certainly for next few decades low-carbon liquid fuels ramping up stocks in preparation for potential border delays. As- would be best directed at trucks and aircraft. ton is signing deals with supplier DHL to allow for the use of ports other than Dover and has authorised its supply chain team to Much depends on the future availability of renewable electric- make air freight bookings. ity. Given that the supply of renewable electricity is likely to be limited, the crux question becomes this: What is the best use Aston Martin, which built more than 6000 top-end models last of that electricity? On this, the engineers are unanimous: “On year at its central English plant in Gaydon is also holding a stock a fundamental level it is more efficient to use this renewable of cars in Germany. But different manufacturers face different electricity directly in the vehicle rather than by turning it into an challenges. Volkswagen Group, Britain’s favourite carmaker eFuel,” notes Nick Powell, one of the researchers. Though there accounting for over 20%, builds only 11,000 Bentleys in the could be a convincing case for eFuels as a means of storing country, while Ford counts Britain as its third-largest market but energy and transporting it from remote locations inaccessible makes no cars there. Nissan, which builds around half a million to grid connections, on a windfarm-to-wheels basis light elec- cars at its Sunderland plant, and Toyota export the overwhelm- tric vehicles are several times more efficient than those using ing majority of their British-built vehicles to the rest of the EU. combustion engines. Overall, says Nik Hill, another researcher, it amounts to “a massive difference” in the primary energy need- While mass-market brands are most worried about potential ed to power a vehicle with eFuel versus a pure electric. “That’s why,” he concludes, “if you had to choose, you’d definitely put that energy into an electric vehicle.” One should consider a broad range of solutions, making the best use of existing energy supply infrastructures. https://ricardo.com/news-and-media/ricardo-quarterly-magazine 30 Wire Forming Technology International/Winter 2019

EU Automotive Suppliers’ Outlook on 2019 “Courthouse News” EU reporter Cain Burdeau. Venice is one of the world’s top travel destinations with more than 20 million According to CLEPA, the association of European automotive visitors a year. In recent years, damage caused by mass tourism suppliers, the year 2019 promises to be a challenging year for the has been exasperated by cruise ships wich dock at the city’s automotive branch. The global economy is slowing down, most edge. Starting in May, the city plans on charging a US$3.40 fee pertinently in China and Europe, global trade tensions are aggra- a person. The plans still need the city council’s approval. Accord- vating matters; moreover, there are the new EU CO2 emission ing to the Mayor Luigi Brugnaro, the expected earnings of up targets, which are causing dramatic shifts in the vehicle manu- to US$57 million a year will be used to pay the costs for main- facturers’ new-car portfolios in the absence of charging infrastruc- tenance measures which have always been paid by the inhabit- ture and knowledge of how consumers will respond, and last but ants. Residents and others visiting Venice for specific reasons not least Brexit with potentially long-lasting effects. For 2019 this – for example, people on official business, people with Venetian means adjustments by and in the industry. Close coordination with ancestry or visiting family members, students and sports com- customers and societal stakeholders. Competition for new mar- petitors – won’t have to pay the fees. Also people who spend the kets, both in Europe and in other geographies. Beating the macro night in Venice and pay a tourist tax charged at hotels will not trends with targeted strategy; building on key competencies, inno- have to pay it. vative power and a deep understanding of the longer-term direc- tion that mobility of people and goods will take. The World Travel and Tourism Council estimates that tourism In Brussels, it’s going to be a transition year moving from one brings in about US$3.4 billion in revenues to Venice and makes Commission and Parliament to another. Industry still hopes to make as much progress as possible with pending files before the up more than 11% of its economy. European elections in May. At so-called working level, the shaping of policies for pollutant emissions reduction and access to data https://www.courthousenews.com/overcrowded-venice-to- will surely continue. In Geneva, UN-ECE will progress its impor- charge-tourists-entry-fee/ tant work on highly-automated vehicles. WFTI https://clepa.eu/mediaroom/clepa-newsletter-editorial-january-   Dipl.-Ing. Konrad Dengler is an industrial journalist and 2019-outlook-on-2019/ specialized translator serving the wire/cable technology, tube technology, materials and production technology Venice to Charge Tourists an Entry Fee and quality testing industries. Venice, a world-famous Italian city strained by mass tourism and He can be reached by telephone at +49 9135 6982 or a loss of residents, plans to charge tourists an entry fee, writes by email at [email protected]. Winter 2019/Wire Forming Technology International 31

Wire by: Product Alan Thomas, Marketing Department Testing ZwickRoell Limited Southern Avenue The Importance of Materials Leominster Test Machine Alignment Herefordshire HR6 0QH United Kingdom Technician adjusts test machine alignment www.zwickroell.com guided by special software. stresses during the application of tensile and compres- There are direct connections between reliable test re- sive forces, which can cause erroneous test results. sults and test machine alignment. Machine alignment Misalignment also creates an increased risk of break- is integral to accuracy in measurement, regardless of age near the point at which the specimen is gripped the application, and precise alignment prevents the and therefore elevates the risk that the measurement risk of inaccurate measurements. Increased stringen- result will be inaccurate. cy in quality evaluations of materials and components Misalignment can cause significant issues when test- has led to tighter performance tolerances and an even ing brittle materials. Stiff and brittle materials break greater emphasis on confidence in measurement re- with seemingly low tensile stress and strain in the area sults. Ensuring the traceability of the geometrical align- of the largest bending. This is where ZwickRoell’s ment of materials testing machines has therefore be- alignment services come into play. A highly developed come an important consideration in today’s materials procedure enables visualization of the specific bending test laboratories. The concept of traceability refers to strain with the help of strain gauges, and information to the full and complete documentation of a measured indicate the required adjustment to correct any meas- result. ured misalignment. To ensure that testing complies with test methods that Based on ASTM E1012, strain gauged alignment limit the permissible amount of misalignment, periodic transducers, which preferably conform to the geom- alignment verification is recommended. Alignment ser- etry of the specimen to be tested at a later time, are vices should be performed in accordance with ASTM required. An experienced service technician positions E1012, Standard Practice for Verification of Testing the strain gauged alignment transducer in the test axis Frame and Specimen Alignment Under Tensile and of the testing system and it is then loaded in the elastic Compressive Axial Force Application. In accordance range. with the standard, a recorded inspection of test axis alignment is completed. The electronic measurement Typical strain gauged alignment transducers. of bending influences that can arise as a result of the In the event of non-uniform force application to the smallest angular errors or offset in the test axis, is a specimen, the applied strain gauges will register dif- requirement in the scope of the performed procedure. ferent strains. These are digitized through a connected Misalignment of the test axes causes non-uniform force electrical measurement amplifier and transferred to a application to the specimen. This also creates bending special software test program. A simple, structured evaluation in the special software enables a service technician to identify errors in the test axis and the alignment software provides adjust- ment recommendations for the alignment unit, allow- ing detected misalignment to be corrected easily and conveniently. 32 Wire Forming Technology International/Winter 2019

gree of comparability with customer-specific specimen dimensions Convenient alignment software with adjustment dia- grams, directly displays the individual components of the alignment error and adjustment instructions for the technician. Complete, detailed recording of measurement results, as required by the standards and beyond (including in- corporation of images) is available. WFTI Typical strain gauged alignment transducer ZwickRoell, one of the world’s leading suppliers with measurement amplifier. of materials and component testing systems, supplies both standard and tailor-made solu- Key Benefits of Machine tions for the most demanding requirements—in Alignment Services research and development, production and quality assurance—across more than 20 in- By utilizing standardized strain-gauged alignment dustry sectors. Privately held, the company’s transducers, the procedure can guarantee a high de- consistent focus on innovation and commitment to outstanding quality has supported its growth in markets worldwide. Additional information about ZwickRoell may be found at: www.zwickroell.com Winter 2019/Wire Forming Technology International 33

Ahead of the Game for 100 Years by: A cohesive company positioned for stable Daniel Kromberg for development announces an expansion. Dorstener Drahtwerke (DDD) H.W. Brune & Co. GmbH Marler Straße 109 D-46282 Dorsten, Germany www.dorstener-drahtwerke.de A company firmly rooted in its region and yet inter- Firmly rooted: Tobias Stockhoff (Centre), Mayor nationally positioned, Dorstener Drahtwerke (DDD), of Dorsten, gave a laudatory speech during the celebrated its 100th anniversary in 2018. This makes the anniversary celebrations of the Dorstener Drahtwerke firm one of approximately 1.4% of all German compa- nies that have already reached or exceeded that age. with the brothers Ruediger (left) and Volker Tueshaus (right). © Moritz Brilo Since the company’s founding in 1918 by merchant, Heinrich Wilhelm Brune, a great deal has happened. As part of a factory tour, the production was explained in The original wire drawing plant became a globally detail to interested visitors. © Moritz Brilo successful technology company in the Ruhr area, op- erating as the DDD Group with subsidiaries and af- The cohesion of the company with the community filiates in nine countries. This successful development of Dorsten was reaffirmed with a generous donation was made possible to a large extent through continu- in favor of the regional educational institutions. So ous adaptation of the company’s product portfolio it comes as no surprise that the planned expansion to always meet the requirements of customers in an of production capacity will not only be achieved by always-changing market. new buildings in foreign countries, but especially by another extension of the Dorsten site. This news One hundred years ago, wires for wire stitching of all kinds made up most of the sales. Nowadays, the port- folio includes ultra-fine woven mesh and wire meshes in various designs, sieve and filter products for process engineering applications and highly specialized wires for the graphics industry, medical technology and modern automotive applications. The use of wire meshes is no longer just a technical necessity, but in many cases has also become an ex- pression of taste and aesthetic sensibility. In the 1990s, Dorstener Drahtwerke introduced with “MeshArt” a range of products that combines the natural proper- ties of robust, refractory metals with their optical advantages. Since then, the company has become well-recognized as one of the top manufacturers for high-quality wire meshes made of steel, brass or cop- per by internationally renowned architects’ offices, shop designers and artists. These customers use wire mesh, e.g., for translucent room partitions, as wall decorations or in object design. Even in the context of global markets and increasing digitization, the owner-managed company is still focusing on conservative values, which were empha- sized again during the anniversary celebrations at the Dorsten, Germany, site, 100 years after its founding. “Without the people behind the products, without their performance, their loyalty and their ideas, our success story would not have been possible. We expressly thank all former and current employees of the DDD Group for everything we all together have managed to accomplish so far!” said Managing Director, Ruediger Tueshaus, during the celebration. 34 Wire Forming Technology InternationalWinter 2019

DDD Group’s Managing Directors, Volker (left) Company Profile: and Ruediger Tueshaus (right), present wire products Tradition, customer orientation, innovation and competence are the basis for the successful produced by their company. © Moritz Brilo international activities of Dorstener Draht- werke. Since 1918, Dorstener Drahtwerke has was revealed by the Managing Directors during the manufactured top-class drawn wire, wire cloths anniversary celebrations, and was warmly welcomed and welded mesh. The company steadily ex- by the DDD employees as well as the locally invited pands its know-how basis with input from very representatives from political, business and cultural diverse industries and permanently develop groups. Moreover, it was a sign of stable development product improvements for its customers’ pro- for future times to the whole DDD group of companies. cesses. The many fields of application of Dor- stener Drahtwerke’s products direct the com- On that day, the delegations of business partners who pany to the graphical industry, the automobile and aerospace industry, to energy production were invited from all parts of the world could more and environmental engineering, food engineer- ing and agriculture, construction and architec- than ever before feel parts of one big family. WFTI ture, chemistry and water management. www.dorstener-drahtwerke.de www.dorstener-drahtwerke.de WIRE – STEEL WIRE AND WIRE MESH PRODUCTS FROM STEEL CONNECTING PEOPLE STEEL WIRE AND WIRE MESH PRODUCTS FROM STEEL Wire products from Dorsten DDD’s history: it was already high-performance stitching It’s the people who make their joint connection to 100 YEARS can be found wherever produced by Gebr. Renzing wire, POWERBIND™, offers the DDD Group of Companies the wire industry, but also DORSTENER DRAHTWERKE you look. They are used for before H. W. Brune joined the considerable quality and cost what it is. Both in Dorsten through their shared day-to- fastening, stitching, carrying, company in 1918. Whether advantages in wire stitching and in all its subsidiaries and day working environment. 1918 – 2018 protecting, sifting and for brochures, catalogs, or processes. EASYDRUM™, partnerships, our people However, these work settings JOIN US FOR THE FUTURE filtering. They are present in boxes, for cartons or horse the system for torsion-free work with great dedication have changed hugely in brochures and packaging, saddles, to this day Dorstener winding of stitching wire, to secure success for the recent years. A few col- cars and airplanes, medical stitching wire ensures gives customers real produc- company all over the world. leagues agreed to share their equipment, as well as in optimal fastening of the tivity gains. And under the They are all connected with thoughts on this subject. machines and large chemical widest variety of materi- BINDSERVICE™ product name one another, not just through industrial plants and equip- als, also meeting the most DDD offers various tools for ment. Whether in a short rigorous demands in terms further processing, from or long format, welded or of tensile strength, elasticity unwinding devices to eco-fri- woven, DDD wire holds our and surface quality. endly reusable spool logistics world together in many ways. and special lubricants. Dorstener Drahtwerke specia- The range of products that lizes in stitching and binding With 100 years’ experience Dorstener Drahtwerke has wire for the graphic indus- behind it, DDD has built put out during its 100-year try. And DDD wire works in up unique expertise that is history is staggering, a direct multifunctional systems that continually incorporated reflection of the attribu- perform printing, scanning, into further developing the tes that have typified the copying and stitching in product that has traditio- company right through to modern offices, as well as in nally been the company’s today: adaptability, flexibi- inline stitchers in high-speed main focus – stitching wire. lity, willingness to innovate rotary printing machines Since 2017, the DDD Group and a close relationship of printing plants. DDD has ranked as the true with its customers. DDD works closely with graphic world market leader in this has continually tapped new equipment OEMs to further segment. markets and pioneered new develop the qualities of the and innovative applications stitching wire in line with NEW WIRE MARKETS for wire and mesh. ever-increasing customer demands. Stitching wire is of course INNOVATION FROM not the only product in the TRADITION: 100 YEARS OF With its innovative and drawn-wire portfolio. The full STITCHING WIRE flexible solutions for all array of steel wires produced stitching wire needs, by Dorstener Drahtwerke Stitching wire goes right Dorstener Drahtwerke con- can be seen today in electric back to the beginning of tinues to set standards: the and thermal applications. Dorstener Drahtwerkehas written down its history in a 105-page book, which can be downloaded at www.dorstener-drahtwerke.de/en. The cover page (inset) and a few inside pages are shown here. Winter 2019/Wire Forming Technology International 35

Twin-Turret, Twin-Head Wire Bending Machine by: Ideal for medium-to-long Jennifer Taylor parts with multiple bends. BLM GROUP USA Corporation 46850 Cartier Drive Novi, MI 48377  USA www.blmgroup.com BLM GROUP USA announces the availability of its Twin-turret, twin-head DH4010VGP wire bending machine. all-electric DH4010VGP wire bending machine featur- ing twin turrets and twin heads capable of doubling programming software, which manages the entire sys- productivity and/or completing highly complex wire tem from a single point. Using part geometry data or bending jobs. The DH4010VGP is especially well- 3D CAD data, VGP3D creates a part program, checks suited for medium-to-long part lengths with multiple for part feasibility and calculates the real cycle time. bends, symmetric parts and parts that close back onto By simulating the machine, tooling and the part bend- themselves. The machine cuts wire free from the coil ing sequence, it eliminates the risk of collisions, which prior to the bending operation, eliminating twisting typically occur during a first test run. that can occur when working from coil to deliver perfectly flat bent wire parts. Additionally, the machine automatically considers material composition and calculates the behavior of The DH4010VGP can be fed via coil stock or pre-cut the part to minimize waste and guarantee part repeat- straight lengths of wire in diameters up to 10 mm ability, process control and accuracy even for complex (0.39\"). The machine cuts wire free from the coil prior parts. Part marring that can be caused by slippage at to the bending operation, eliminating twisting that can the end of a bend or wear tool is also reduced. occur when working from coil to deliver perfectly flat bent wire parts. The systems can use tools that produce All part bend positions, tooling information and power superior surface finishes, making the DH4010VGP parameters are saved within the part program, provid- ideal for furniture and design applications. ing easy recall of the recipe when a job is repeated. This guarantees quick set up and changeover and provides By working with two heads at the same time, the lot-to-lot repeatability. For more information on the unsupported length of wire is reduced as well as the DH4010VGP, visit: www.blmgroup.com potential flex that can occur during the bending opera- tion. This allows the machine to bend parts faster. The Company Profile: retractable 3D handler feature enables the last bends to be made with the bending heads in mutually adjacent BLM GROUP is a global leader in tube and sheet position, minimizing the intermediate stretch between metal processing solutions. Its product line includes the two bending branches. This enables parts to be laser tube and flat sheet cutting, cold sawing, bending, made that would otherwise be impossible to fabricate. end-forming, end-machining and wire bending ma- chines. The company has more than 60 years of experi- “All Electric” Benefits ence and thousands of applications in the development of tube and sheet metal fabrication equipment. With With the DH4010VGP, the electric axes are managed headquarters in Italy, the North American location in by the CNC and all position and power parameters are Novi, MI, USA, provides tube processing solutions to saved together with the part program for quick setup the USA, Canada and Mexico. www.blmgroup.com and highly accurate positioning. This helps eliminate the need for a dedicated specialist to run the machine. Additionally, since there are no hydraulic parts, main- tenance is greatly reduced while reliability and safety are improved. These machines are extremely quiet and clean, providing high performance while only requir- ing 4 kW of energy. One Click Proprietary Software A key differentiator of BLM GROUP’s wire bending equipment is the company’s VGP3D three-dimensional 36 Wire Forming Technology International/Wnter 2019

Which Wire Bender die bending (flexion bending), variable ra- is the Ideal Model for You dius—generated bend, strike bending, inter- polated and flexion-stretching bending and Pick your machine edge bending. Combine the functions you expect and easily identify the product that is the most suited to All Electric, All Easier your needs: All BLM bending machines use “All-Electric” technology providing a host of advantages. Double-Headed Wire Benders This incudes minimum setup times and con- Double-headed wire bending machines are stant accuracy. All movements are controlled well suited for medium-to-long length parts via an electric axis and all position and power with many bends, symmetric parts, parts that parameters are saved together with the part close back on themselves or wire-wound re- program. The absence of mechanical adjust- sistors. Feed these machines from coil or ments guarantees quick setup and accurate, load cut lengths. positioning. This eliminates the need for a dedicated specialist to set up the machine. Singe-Head Wire Benders Single-head wire benders are ideal for pro- Low maintenance and high reliability are also cessing shorter parts with complex shapes featured. Simplified wiring and the elimina- and three-dimensional developments, using tion of hydraulic parts reduces the need for different types of bending techniques. maintenance and risks related to component wear. The obvious advantage is that the ma- Freedom of Shape chine is more reliable and safer. BLM Group machines provide wire bend- ing capabilities that include bending using a For more, visit: www.blmgroup.com WFTI standard bushing (flexion bending), double 060-6000-0113-08.indd 1 10/24/18 2:38 PM Winter 2019/Wire Forming Technology International 37

Top Products of 2018 These are the winners in our 19th annual article on the top products of the year. Results are based on selection by the Wire Forming Technology International Editorial Staff. Flexible Welding Machine Eliminates The AKK Series welding mahcine is capable of producing All Line Wire Decoilng Stations large and small batch orders consecutively without any downtime. The concept behind the AKK series machines Eurobend GmbH of Germany offers the AKK Series high- allows automatic mesh spacing and dimensions changes, output flexible welding machine that eliminates all line making it the only flexible high-production, coil-fed mesh wire decoiling stations. The AKK sets standards in mesh welding line, as it can produce all mesh types instantly production. Its design eliminates all idle times and at without any adjustments. Also, it offers a compact system least doubles productivity in comparison to conventional layout requiring minimum floor space requirements. welding lines. All advantages from off-coil and pre-cut www.eurobend.com welding machines and more are combined in one machine. Cost-Effective, World-Class Chain Link Weaving Machines Bergandi Machinery Company, Inc., offers world- class chain link weaving machines. These cost- effective machines are available in two models, the L7 and A6. The L7 machine is available in 2 to 3.6 m heights, runs 1.8 to 3.15 mm wire diameters and mesh sizes from 45 to 63 mm. Additional mesh sizes are also available. Output rates will reach 160 m2 per hour. The A6 comes in 1.8 to 3.6 m heights, runs wire diameters from 1.8 to 3.90 mm and mesh sizes from 45 to 63 mm. More mesh sizes are available. Output rate is 260 m2 per hour. The machines are equipped with a Smart Technology control system featuring a fully integrated machine control system, combining machine drive and PLC functions in a single unit. The end finish system (knuckle and barb) is easy to adjust for height changes, reducing set-up time, maintenance time and maintenance expense, and to improve machine uptime. The take-up system has been integrated into the main frame of the machine, reducing the number of parts, simplifying the operation and reducing the footprint of the machine by 30%. The take-up is closer to the weaving section of the machine to “tighten” the process, reducing mis-weaves and significantly allowing for higher standard operating speeds. www.bergandi.com 38 Wire Forming Technology International/Winter 2019 The WFTI Editorial Staff did not test these products and is not attempting to endorse them. We do however, applaud these product developments and marketing efforts.

Intelligent, Guiding, Straightening & Transporting of Wire & Cable Materials WITELS-ALBERT GmbH, Berlin, Germany, offers robustly designed RK VE series roller boxes that stabilize the path of process materials in a defined horizontal and vertical direction. The RK VE series roller boxes permit both radial and axial displacement and securing of the individually positioned rollers. The company’s RK HM series roller guides utilize tungsten-carbide bars placed over the roll circumference. The bars are supported by a rotation-symmetrical design ele- ment, which houses the bearings of a guide roller and the axle studs. Additionally, there are nine RA H PO straightening machines available from WITELS-ALBERT GmbH for the straightening of wire in ranges of 9 to 15 mm, 15 to 25 mm and 25 to 40 mm. All of these systems provide intelligent, guiding, straightening and transporting of wire and cable materials into production machinery. www.witels-albert.com RK VE SH series RK HM series RA 7 H PO system roller boxes al- roller guides have straightens wires low the defined been designed for adjustment of the tough conditions ranging in size wear point on each found in the wire from 9 to 15 mm, roller individually. 15 to 25 mm and industry. 25 to 40 mm. Rebar Cutter/Bender Blast Wheel Especially for North American Customers Die Quip Corp., Bethel Park, PA, USA, provides the DBC-16H Combination Rebar Cutter/Bender. This is an Wheelabrator provides a blast wheel for North American innovative portable tool that cuts and bends rebar all customers. The EZX model is engineered to help foundries in one tool. The unique design of this combination unit ramp up production while saving time and costs. Designed provides the operator the ability to cut and bend rebar for as a successor to the long-standing, EZEFIT fit, which is in-place rebar or stationary fabrication applications. This trusted by customers in the USA, Canada and Mexico, electric-hydraulic, heavy-duty unit can handle up to #5 the EZX incorporates cutting-edge engineering for the (16 mm) Grade 60 rebar cutting and bending. same price. The EZX blast wheel has been specifically www.wirecutterstore.com designed to meet the needs of Wheelabrator’s North Ameri- can customers and to help them save time, resources and money. Built to solve complex production challenges, the EZX can be used for a variety of applications including tum- blast equipment, table machines, hanger-type machines, horizontal belt machines, plate machines and wire mesh belt machines. www.wheelabratorgroup.com Bar Code Oven Setup Capability UTV Performance Spring Kits HSI and Forming Systems, Inc., Schoolcraft, MI, USA, Hyperco, Chicago, IL, USA, an MW Industries company, offer the Bar Code Oven Setup option for HSI conveyor provides high-performance suspension spring kits for the and box ovens. The barcode scanner interfaces with the Polaris XP1000, Polaris XPT and Polaris RS1 UTVs. The 485H HMI Temperature and Conveyor Speed Recorder or kits offer a smoother ride quality and improved vehicle HMI with PLC control system for monitoring temperature performance using the same race-winning spring tech- and belt speed. The scanned barcode will define oven nology Hyperco has been known for since the 1960s. The temperature and speed, automatically setting the oven for company has focused on the growing UTV market where the correct production conditions corresponding to part its springs deliver an improved, longer-lasting and higher- number, temperature setting and time in heat on the moni- tor of 485H or HMI. The furnace will automatically change performing ride com- oven working conditions to prevent mistakes and facilitate pared to stock springs. production management. www.formingsystemsinc.com Hypercoils® give the rider more confidence and more comfort. Ex- act spring kit contents will vary depending on the vehicle, but all include the Hypercoils coil-over springs and hardware components needed for a complete spring upgrade. www.hypercoils.com Continued... Winter 2019/Wire Forming Technology International 39

Top Products of 2018...continued Easy-to-Learn 4-Slide Machine Desktop CNC Wire Bender The Bihler 4 Slide-NC is a joint venture of Bihler of Pensa & Pensa Labs, Brooklyn, NY, USA, now provides America and Otto Bihler Maschinenfabrik of Germany, the DIWire Bender, which is the first desktop CNC wire both world leaders in developing and producing technol- bender. A new archetype for desktop manufacturing and ogy and machinery for forming, assembly and welding rapid prototyping, the DIWire transforms drawn curves processes, for a wide range of global industries. According into bent wire that can be assembled to make just about to Bihler, many experienced plant operations personnel anything. It can bend various metals and plastics, allowing in manufacturing industries are at or near retirement age. for output to be used as the final product. Potential uses The Bihler 4 Slide-NC offers an ideal solution to this prob- include spring forms, short-run wire forms, prototypes for lem. Due to the ease of operation of a Bihler 4 Slide-NC antennas, jewelry, architecture models, design prototypes, machine, a newly-hired machine operator can be trained art, furniture, small crafts, surgical implants and the list to use it in less than a day. Both set-up and changeovers goes on. While 3D printers form volumes and laser cutters can be completed very quickly. www.4slide-nc.com create planes, DIWire is the only desktop manufacturing tool for manipulating lines. By being transportable, ac- cessible and affordable, DIWire bridges the market gap between time-consuming hand-bending and large scale, mass production CNC wire bending. www.PensaLabs.com / www.PensaNYC.com Highly Flexible & Versatile Composite Plastic Springs Spring Forming Machine Lee Spring Company, Brookyn, NY, USA, offers plastic SIMCO Spring Machinery Co. of Taiwan offers the springs that are available in the UK and Germany, and SIMCO Spring Forming Center—SFX-20. This spring which comprise Lee Spring Company’s LeeP™ plastic forming machine provides its user with a design that composite spring range available ex-stock. These com- faciltates extreme flexibility with four sliding tables that posite plastic springs provide users the benefits of being allow two dimensional movements. And this flexibility nonmagnetic and inert to most industrial chemicals. And facilitates the user’s design ideas to be easily carried out. where weight considerations are primary, plastic compos- The SFX-20 Spring Forming Center’s patented spring ite construction offers a high strength-to-weight ratio with program software allows easy setting of the machine’s an exceptional performance in low mass. This makes these working axes. Additionally, the SFX-20 spring forming plastic springs suitable for a broad variety of applications system includes a time-line-basis feature that helps to such as aerospace where light weight is at a premium. LeeP reduce the time gap between each axis in order to gain springs are made of Ultem PEI (polyetherimide) resin for a higher degree of machine productivity. To learn more, good thermal stability and electrical insulation proper- visit: www.simcotw.com ties, while being noncontaminating. The plastic springs offer low flammability, are recyclable and are available in red, orange, yellow, green and violet in ascending order of strength. Find additional information on LeeP plastic composite springs at the website: www.leespring.co.uk LeeP™ composite plastic springs available ex-stock from Lee Spring Company. 40 Wire Forming Technology International/Winter 2019 The WFTI Editorial Staff did not test these products and is not attempting to endorse them. We do however, applaud these product developments and marketing efforts.

Two-Plate Variant of Spring End Grinding Machine Following the success of the one-plate variant model intro- duced in 2017, WAFIOS AG, Reutlingen, Germany, offers the two-plate variant of its G 450 spring end grinding ma- chine. The G 450 spring end grinding machine is installed with the latest version of the WAFIOS WPS EasyWay 3.2 control program. Easy to use and boasting a high level of operational safety, the WPS 3.2 EasyWay is also ready for operation in future Industry 4.0 applications such as predictive maintenance. Other G 450 grinder features include iQtemperature and the particulate deflector. With iQtemperature, the temperature of the workpieces can be measured and the process instructions controlled ac- cordingly while the machine is “in process”, for example, during the grinding process. This significantly increases production rates while also guaranteeing that quality standards are met. www.wafios.com New-Generation Compact 3D Bending Machine AIM Inc., located in Addison, IL, USA, provides the wire formed parts industry with the AFC-3Dx compact 3D bender, which bridges the gap between low-end, straight-cut-wire fed benders and high-end, full-featured machines. According to AIM Inc., this is the missing link that offers maximum value for minimum expense. A standard one-year warranty, Slip Ring Technology, DXF/XYZ Importation, Animation Simulator and ease of programming are just a few of the features on the AFC Series machines. In addition, robotics, external chamfering and other ancillary devices can be integrated with this equipment. Additionally, completely automated work cell solutions can take wire from coil, form, weld and systematically arrange the finished parts. In all instances, wire can be fed directly from a coil, straightened, bent and cut using a software package that provides flexibility and simplic- ity in programming and is offered in all universal languages. Single and double bending head machines with Fanuc robotics integration and complete automated systems are available from AIM Inc. Visit the AIM website to find additional information and technical specifications. www.AIMmachines.com Straighten & Cut Machines for Tighter Wire Diameter Control Lewis Synchro/Cut series of straighten and cut machines from Rockford Manufacturing Group (RMG), South Beloit, IL, USA, is designed for applications where tighter control of wire diameter and reduced work hardening of the straighten and cut product are important. The Lewis Synchro/Cut series represents the next generation of “Trave-Cut” F Series machines, which have been supporting the wire industry since 1936. The Lewis Synchro/Cut machines have been developed with a novel moving shear. The newest machine, the 8TM Synchro/Cut, has a cutter that is activated by a rotary cam that moves exactly with the wire speed, so there is no wire feed stoppage during the cycle. In addition to eliminating the swell spot during cutting, the 8TM will produce cleaner cuts and less wire marking, while accurately controlling length of cut. The 8TM has a wire diameter capacity of 0.062\" to 0.315\" (1.6 to 8.0 mm). Maximum wire diameter, 0.315\" (8.0 mm), is for a metal with 90,000 psi (600 N/mm2) tensile strength. With a wire tensile strength of 140,000 psi (975 N/mm2), a 0.250\" (6.35 mm) wire can be cut. The 8TM Synchro/Cut features include continuous straightening action with moving cut, computer-control with touch-screen station, programmable part counter, arbor and feed speed ad- justments with digital feedback meters, programmable safety shut-down timer and electronic pneumatic feed head pressure adjustment. www.rmgfelm.com Continued... Winter 2019/Wire Forming Technology International 41

Top Products of 2018...continued Straightening, Cutting High-Speed Compression & Marking Machine Spring Coiling Machine Cometo of Italy manufactures and supplies the MTF20-4 The SIMPLEX RAPID high-speed coiler for the pro- straightening, cutting and marking machine. It offers users duction of compression springs (right handed and left fast and silent operation, and its electric control system handed), available from NIMSCO, is equipped with the offers a high level of precision. The MTF20-4 machine also latest generation Numerical Control for the direct control provides the capability of changing the bevel’s size during of seven axes (wire feed, diameter, vertical pitch, horizon- wire or rod processing. www.cometo.eu tal pitch, retracting mandrel, vertical mandrel, cutter). It features a design for quality, is rational and sophisticated Two-Point/Single-Point and is made from materials and craftsmanship of the high- Multi-Axis CNC Coiler est quality. Reliability results from a significant reduction in the number of mechanical parts, improved maintenance KINECOIL Division, Kinefac® Cor- (automatic lubrication oil and grease—double pump) poration, headquartered in Worcester, and greater protection of electronic components. High MA, USA, provides spring manufac- performance results form lower mechanical inertia, less turers with the Two-Point/Single-Point parts subject to wear and play, hardware and software Kine-Coiler multi-axis CNC coiling with superior performance. The machine lowers mainte- system designed to produce springs nance costs, increases productivity, reduces footprint and using wire diameters from 0.127 to optimizes power consumption. Standard accessories for 0.762 mm (0050\" to 0.030\"). This ma- this sprng coiler include touch screen display, electronic chines operates at the level of precision hand-wheel for all axes manual control and software with that is required by many of today’s auto programming (PG) as well as graphic programming demanding tight-tolerance manufac- (2D 3D). www.simplexrapid.it turing applications. www.kinefac.com Software Automatically Optimizes Bending Processes WAFIOS Machinery Corp., Branford, CT, USA, offers the iQsmartbend award-winning software solution designed to automatically optimize bending processes for wire and tubes. Through iQsmartbend, WAFIOS provides a technique that calculates the best machine parameters for the bending sequence and transfers them directly to the WAFIOS EasyWay machine con- trol system. Not only can it lead to an absolute reduction in set-up times, but it is also possible to boost output significantly depending on bent part geometry, while maintaining or increasing the required part quality. The hybridization presented here involves data transfer, external computing power and optimization of algorithms especially developed for tool movements. iQsmartbend is one of the building blocks of WAFIOS’ ‘Smart Factory 4.0’ initiative. WAFIOS is expand- ing the Smart Factory element of the Industry 4.0 technology by add- ing new business models such as coupling production and services using the patented iQsmartbend (hybridization). To learn more about iQsmartbend software, visit the WAFIOS Machinery Corp. website. www.wafios.us.com 42 Wire Forming Technology International/Winter 2019 The WFTI Editorial Staff did not test these products and is not attempting to endorse them. We do however, applaud these product developments and marketing efforts.

Simple or Complex Reinforcement On-Line Learning Tool for Benders Meshes Produced on Flexible Machine AIM Inc., Addison, IL, USA, has developed the Learning The MSM-H mesh welding machine from mbk Mas- Management System, (LMS), which is an on-line learning chinenbau GmbH, Kisslegg, Germany, is capable of tool that is available on-demand, 24/7. With secure log- ins, your team is given access to this innovative training Welding Innovationproducing list, drawing and reinforcement meshes. The platform. Your employees can access AIM’s LMS training MSM-H mesh welding machine has been designed to modules to receive instruction how to set up and run your AIM bending machine. The training modules lead you produce simple as well as complicated reinforcement through the most basic description of your AIM machine like ‘What’s a payoff’ and ‘Wire Straightening Fundamen- w machinmmeaeschhdeinseei’nssashiflgoerxtnibceolendavnerdtsoieoffinpctiiemrnoet ,mdthauennhceirge.hTehsstaindmkesgrtpoeeltheoef tals’, all the way through ‘How to program wire forms’ ll as comflepxilbiiclitay ctaendbe arcehiienvefdo, wrhcicehmmaekens tthemMSeMs-Hhweesll using AIM’s SMART EDITOR program. Employees learn and efficient manner.suited for Just-In-Time (JIT) production. Also, the machine at their own pace. And if they miss something or want to exible processes rods with the cross and longitudinal wires cut to look at it again? No problem. It’s ready when you are. length. Longitudinal and cross wire stacking has a positive www.AIMmachines.com d econ- influence on the pre-assembly. www.mbk-kisslegg.de GmbH, ng ma- oncrete ments to s about quickly duction y influ- routine hich is a Pass Through Testing Software Option Safe Alternative to PVC Coating welder ng and Larson Systems Inc., Ham Lake, MN, USA, offers the in- Plascoat Systems Limited, acquired by Axalta Coating dustry a software option for use on the company’s SDHT Systems, Cologne, Germany, offers the industry a safe-for- ange of GEN 2 model testers—Pass Through Testing. This software the-environment PVC alternative. Axalta’s Wireguard G50 GmbH option has been designed to allow the capture of one or is a cost-effective and environmentally friendly alternative n more two data points in one fluid deflection of the spring for to PVC coatings. The coating does not require a primer untries much faster testing repetition. The Pass Through Testing and its application can be performed at significantly lower nology, software option on Larson Systems’ SDHT GEN 2 model temperature, which enables a noticeable savings in energy. testers can save considerable operational time. Larson Wireguard G50 coating emits no hazardous fumes during esigned Systems recommends that SDHT GEN 2 users include application. The coating remains flexible to minus 40°C, it nforce- the Pass Trhough Testing software option going forward. is extremely resistant to salt spray and will not crack, chip Thanks www.larsonsystems.com or flake. www.plascoat.com / www.axaltacs.com/Abcite highest kes the between 5 and 12 mm and the cross wire diameter Winter 2019/Wire Forming Technology International 43 me (JIT) is from 5 to 12 mm. The quantity of the longitudinal wires is calculated according to the machine width. The process- ires cut ing has feed of mplshed plished re feed machine a maxi- ge from

Top Products of 2018...continued Air Filtering Systems Single-Head Tube Bending Machine Forming Systems, Inc., Schoolcraft, MI, USA, and HSI WAFIOS AG, Reutlingen, Germany, offers the Single- offer the ECO series of electrostatic air filters available for Head Tube Bending Machine RBV25R for the production of bent tube parts with high output. High flexibility and use on the HSI extensive line of HSI conveyor ovens. ECO operating convenience are ensured. The machine lowers filters are designed to remove contaminants like smoke NEWSprogramming/set-up times. www.wafios.com and oil mist from the manufacturing work environment. ECO filters will remove up to 99% of oil mist or fumes. Also offered on the HSI Conveyor Ovens is the HM13 interface that includes functions for most of the advanced HSI options. A temperature recording capability is also NEW PRODUCT ANNOUNCEMENT built in. The HM13ECO Series of Electrostatic Air Filters interface has a reserved connection for LAN cable, which allows for setup with an IP address.HSI introduces the new HM13 (HMI Control Panel) now available on the HSI Conveyor Ovens. The new HM13 interface includes functions for most of the advanced HSI options. A temperature The system can be connected to the network or factoryrecording capability is also built in. The HM13 interface has a reserved connection for LAN cable, which allows for setup with an IP address. The new system can be connected to the network or WIFI for monitoring by smart phone or laptop by VNC.factory WIFI for monitoring by smart phone or laptop by VNC. The HM13 can use several different www.formingsystemsinc.comcommunication protocols, including Profinet (Siemens). For additional information, please contact Forming Systems, IncNN. EaEWtWinPfPoRR@OODfDoUrUmCCTiTnAgAsNyNNsNtOeOmUUsNNinCCcE.EMcMoEmENNoTTr call 269-679-3557. EECCOOSSeerrieiessooffEEleleccttrroossttaatticicAAirirFFilitlteerrss FFSSIIaannddHHSSIIoofffeerrtthheeEECCOOsseerrieiessooffeeleleccttrroossttaatticicaairirffilitlteerrssaavvaailialabbleleffoorruusseeoonntthheeHHSSIIeexxtteennssiviveelilnineeooff NEW PRODUCT Electrostatic air filterAHNHSSNIIccOoonnUvveeNyyooCrroEovvMeennsEs..NEECTCOOffilitlteerrssaarreeddeessigignneeddttoorreemmoovveeccoonnttaammininaannttsslilkikeessmmookkeeaannddooililmmisisttffrroomm NEW PROSDAUSCTTEASNTNEORUS NACLETM-at2tahchcEet0etiNvim0vmeeTa0acncan/auru5rbfbfaoa0ocnctn0tufufri0rliitlnitenHegrgrwwIwwGoiolirlrHlkmkmeeinSninnviPvmiimriEroizoiznEenemmDaanenenyAnytot.o.UddEoEoCTrCrOsOOs..ffi-litClteeOrOrssMwwovilinlPelrreRnemHmEooS(vSvlSeeeIIuuOfppCttNto)oo99Sa9n9P%n%vRodofIefNooyEiliGlmomCiTrsistOtEooSrrfTfuuEmmReess.. AAnn TRADE FAIR TTEESSTTEEvTSRRoAhSSleSuiAnTmALtErTLeoST-2dT-p02uEr00coRe00dSs/0u5itnch0atte0nrio0donAafwpndaAwfpHrenArlpoon.lepouwoepImiraLpmdiGrkaldckislTeicisEeAneieHcEaaneD-aagDltLsgc5ltMicseSoMoTiseooo0tqonnPq-lpnnhuul0ps2tuuErstiatreompia00tiomEpcoicmcoc0tameDntanecnyeFs0,yeFs,saenoipsAnoeniptrenarnwtsrc.rmoUsc.,monl,vulWrbvuWirTidedAindiednhdemeOghimeLgnAeineroSngT-ruoeSngLveyCvmpyo-aTsmspoaOs2oulteoo-ultoerto50vertoMtsdvmftsaaimf0a0adislbdsslbmPi0eos0ime,noli,fil0RvoIftivoIntseyaknsveEykmchnemacnnea.Sato.inationagdaSrnikadnnkdtnigheItdgeoedOiAeiainadsiansuadsnsfLNunnpsfouOydnsosTydots@eotmf@Sttm-efcutfevu5afPformoaforroomdnvaoo0nRevmrenemroeem(i0saoImmnspfmNwbrpfu0iiwtefrintgeirenoGntoieeowfignoluhmogtndlmstndlsoTiyrmilfoniysoigffonsastEtfogstttrtgrhaettrtwSerheohesheoitsmesTptromessiptsrecsroEeseponrEersaavisrreRavcisneseeasnlstennCoicltnri:eicenori.ee.om.vced.dnvcldOoinilFnoiseiFnsempo,gvmo,agvHroriroorniuraooinearovgaovrggdtesSoirdoeicondoslircndhvlaIsmviiamesmito,letfi,lintirlionsinr2oes)sat2esnl,tm6n.,m6ftsat-f9ratho9riploho-lcoev-6imevrn6iman7Eaic7flEnmC9floomCo9ooO-grfOe-3rfmem3tsmf5tstaf5miaaml5ielatlp5ltto7esto7eirkr.iotkr.oeeineesinsDDLWs,r,OssüUirisCRefosoAAe&nrTTldTIIhsOOoupirNbNgfr,ehiGn2eg0r1mt8eansyters Stirrup BenderSAS for high Oa SliCneAoMf ,nTeowriannod, Italy, provides manufacturers withSAS TvohleumALeT-p2r0o0d0ucatniodnAA. LuTt-o5-0f0e0edcianngb, eseutsteindgi,ntveasrtiionugsacnodnfsigourrtaintigon(5s:ways, 3 ways, or 2 ways). 16im- 20pArproil 2v01e8d stirrup  Auto-feediAngu,tsoe-tfteinegd,integs,ttinegstainndg saonrdtinsogr(t5inwga(y5s,w3awyasy, s3, owra2ysw,aoyrs)2. ways). bending machines.  Auto-feediMnga, nteusatilnfgeeadndinsgo,rsteintgti(n5gw, taeysst,i3ngwaanysd, osor r2tiwngay(s5).ways, 3 ways, or 2 ways). These machines are  Manual feeMdianngu, saeltfteinegd,itnegs,titnegstainndg saonrdtinsgor(5tinwgay(5s,w3awyasy,s3, owra2yws,aoyrs)2. ways). designed for versa-  MSahnowunahlefree eoOndHpinCtFgi2o,60nt-eStEso4tiwni/ngEcnaleunrgddy SesaovIiDnrtgiHonorgodO(5Dwcahyes,c3k wofacyos,morp2rewssaiyosn). springs. tility and flexible INVITATION TO THE WIRE T  Optionto iSnecltuudpefIoDrosreOttDincghoencklyo.f compression springs. manufacture. For DÜSSELDORF 16 - 20 AP  Setup for setting only. crosshead can move at speeds from 0.0004\"/s (0.01mm/s) to 4.9m2\"o/sre(12o5nmmth/se)sfeullyma- The ALT-2000/ALT-5000 TdphirsoepglAraaLymTin-m2gdpt0rae0irebsso0ppltge/oslArarueaLtyssamTiinns-o5myggf0daara0ealnb0ltpdltacehorisernouatstsfsvuusiEeEnhoCniCdtOegfcOivawtdAaiAdeoiahlirl.rnctiFtlFaasiehliltntoeseteraefmrfsvauoteirnvndeecggwt.auiPotlharnsiorlpsegmeorteaoefdmtsaostsrfirinroezogefgHmH.dsuSSpPIlsI0arOrpOi.orvn0rvegimge0nnnr0gsawow4emtt/\"t/eouE/EssCsrpCtiOoO(ezs0efrAaA..id0srirTrep1FshFirmilspetlittenremorsirgnro/efgsstde)wtttmeouasrapt4ekes.i9irnna2.gcr\"Tels/uhesdsett(eu1ossp2roSe5ofPmtdfCwdmmfaiuf/rafnseek)criiwcftennuinVTohgclhtlnwilyissuessneipdtfwstroeeiuzuirnssep.sgo,SaoPavsnfCtdcidosafiimufuimfntper:cort.terrctianoaontdncmessepffrooaifrnitrghestWanired 13.A45 in Hall 13 be demonstrated with Discover more Düsseldorf trade fair can On our trade fair s tests easy and intuitive. a whole range of impressive figures. In 2016, the leading trade fair for the industry we are displaying Production rates up to 3000 parts per hour (pph) are possible when setting and testing onreegfiostrecredaat hreeciogrhdtnaunmdbeursoinf 1g,3a37 exhibitors and visitors from more than 53 countries. which processes r Auto-Compression Spring Testers CReubttainr gS,trBaeinghdtienngin&gW, eldingwPsmrhoaedlrluesctvtriioobknswraemrShta(iaeontAlernolestsSsetuvtrapitTobhbtkraieolaeitzst3pa(it0onrteoi0noord0tnssuepticasaotthbrinofftaieslniteezprdpareaertrstoideoh)tdno.whuSuiiceelsrltt(binAtpoieenpnLegrherd)Tiadseatu-adrec2ec)eh.w0pdiSeo0ielwvsl0tesbittidibeahnlinegmrnewdipudsalhutaAreicapcnelhlLledesieTeltwevtt-otseii5ttndthpe0giosmn0atinin0pnudtgalshttr(iaeapuinsglsltldeieinhnlltgage-truossogptpentpee1seost,ferto2ioindrnkotcgesers(3aa,untassdenhintdeltgai/ignoruhggrptelaiaArgc1esnttht,bidWrto2aonsurI.kopRssTe)rirEnihswn3gew,giasateWshensItdRht/iaEnolligrnbtlaeeigcrdnthriaatotwnisopisnn)ragiwlnatgrittatsehdnetiofanirtwoislltbraeighhetlednfirnogm, c1u6tti-n2g0, bAepnrdiliningDaünsdsewldelodrifn.g no reductinoonariunetdtohurcmotuioganhtpiinuctt.hcroomughppruet.ssion spring testers for high-volume bender with remo The ALT-2T0h0p0eriAsoLcdTa-pu2a0cb0lte0iooisfntce.aspTtianhbgleecooAmfpLtreTesst-sin2iog0nc0sop0mrinapgrnsedusspioAtonL4s5pT0r-libn5fg0(s20u00p00tcNoa),4nf5r0ebelbelfe(nu2g0tsh0es0duNp)i,tnfore4e\" Both systems will diametersduivapmatore1iteo.8ru8s”us(p4c8tmoomn1.fi)8.8g”u(4r8amtimo)n. s including auto-feeding, setting, PTrhoisgyreearstsheMre aarsecshevienrael gnoo&d rAeausotnosmforalotoikoinng AforGwa,rdlowcitah teeagderinanBticripiaxtieonn, you on our cust (l1e0n0gmthmIstt)auoapltnyhdtiso,oot4uraff\"tds(iee1dr0efas0ir.mthme) iannddouusttsridyethe automatic stirrup bender with You will also see a removal robot. This system is from the EBA S 3D range. we understand by testing and sorting; auto-feeding, testing and sorting; www.progress-m.com The ALT-5T0h0m0e iAas LcnTa-up5aa0b0lle0ofisef tceeasdptiainnbglgeco,omfsptereeststtsiniiongngcsop,mritnpegrsseustspiinotong1s1pa2rn4inlbdgfs(u5sp0o0tr0oNt1i)n,1f2rge4;elblmfen(5ga0thn0s0uuNpa),tlofre5e.9\"le(n1g5t0hmsmu)patnod5.9\" (150mm) and outside dioamufteesteieddresidunpiagtmo,e4tt”ee(rs1s0tu0ipnmtgmo)4.a”n(1d00smomrt).ing; and option to include ID For additioFnooarlraindOfdoiDrtmioanctaiholnein,ccfkoornmotafacttciFooonmr,mcopinnrgteaScsytssFitooemrnmss,inIpngrcS.inyatsgtiensfm.o@s, fIonrcm. aintgisnyfsot@emfsoirnmc.icnogmsyosrtecamlls2in69c.-c6o7m9-3o5r57ca. ll 269-679-3557. You can alYsoowusewceatnwhae.lnsfoeowsremAeLTtih-n2e0gn0s0eywTseAsttLeTSmy-2st0se0im0naTcte.tcshtoeSm2y0s1te8mCAaStMthI eSP2R0IN18GCWAOSRMLDI SSPHROINWG. WORLD SHOW. ALT-5000 ALT-2000 ALT-5000 ALT-2000 Precise, computer-controlled removal of stirrups WFTI High-performance st 44 Wire Forming Technology International/Winter 2019 The WFTI Editorial Staff did not test these products and is not attempting to endorse them. We do however, applaud these product developments and marketing efforts.

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Intricacies of Induction Heating of Wires, Rods, Ropes & Cables by: Heating by means of electromagnetic Justin Mortimer and Dr. Valery Rudnev induction has become an increasingly Radyne Corp., USA more popular method for heating ferrous an Inductotherm Group company www.radyne.com, and Dave Clowes and Bob Shaw and nonferrous wire-type products. Inductotherm Heating & Welding, UK an Inductotherm Group company required temperature of the wire/cable being processed at www.inductoheat.com speeds up to 5 mps are also noticeable benefits of compact induction systems compared to fluidized beds, infrared heat- There are several ways to heat wires, ropes, rods and ca- ers and gas furnaces. Frequencies that are in the range of 10 ble products including gas furnaces, electrical resistance to 800 kHz are commonly applied. heaters, infrared furnaces, electric ovens, molten lead As an example, Figure 1 (left-bottom image) shows Ra- baths, salt baths and induction heaters. Heating by means dyne’s induction heat treatment line for the hardening and of electromagnetic induction has become an increasingly tempering of 1060 carbon steel spring wire in the diameter more popular method for heating ferrous and nonferrous range of 4 to 8 mm (0.162\" to 0.312\") using a dual-frequency wire-type products in such applications as heat treatment design concept1-3. Heating below Curie temperature is done (hardening, tempering, stress-relieving, annealing, relaxa- using a 400 kW/10 kHz inverter. A 420 kW/200 kHz inverter tion, etc.), heating before encapsulation, thermal diffusion, provides heating above the Curie temperature. Tempering wire pre-heating prior to metallic or organic coating, drying, is also carried out by means of electromagnetic induction. plating, cladding and others (Figure 1). This article reviews subtleties of the most common single- and multi-wire processing applications where the IH is used for the heat generation. Several related case studies will be revealed to illustrate process features. Fig. 1 — Electromagnetic induction method for heating High Speed Processing of Spring Wires ferrous and nonferrous wire products in applications such as hardening, tempering, stress-relieving, anneal- Some of the most critical properties in manufacturing spring ing, relaxation, heating before encapsulation, thermal wires are high quality surface finish and integrity, and supe- diffusion, wire pre-heating prior to metallic or organic rior strength while retaining a good ductility. Elimination of traces of alkali and minimization of the carbon deposition coating, drying, plating, cladding and others. on the surface of the wire are essential for manufacturing quality wires2,3. Growing environmental concerns for global warming in combination with the requirement of increasing production Materials for spring wire fabrication are commonly ranging with reduced equipment footprint have resulted in induction from carbon steels and low alloy steels (e.g., SAE 4140) heating (IH) becoming the dominant method for heating of through to specialty steels such as SAE 9254 (Cr-Si alloy) both ferrous and nonferrous wire-like workpieces1-3. Thanks and SAE 9254V (Cr-Si-V alloy), for example. Wire diameters to IH, the use of molten lead and salt baths for heating of wire are from 1.27 to 15.75 mm being processed at production products has practically been eliminated. Other advantages rates up to 6600 lb/hr (3000 kg/hr) with line speed up to of IH include instant heat generation and the possibility of 590 fpm (180 mpm) (Figure 2). Combination of tensile incorporating a protective atmosphere (for example, for strength (greater than 2000 MPa) and ductility (exceeding bright annealing applications). 40% ROA) are some of critical features. Advanced payoff and take-up systems designed to allow continuous produc- Quick response and the ability to provide a rapid change tion with maximum uptime. in the process operating parameters to accommodate the Wire Annealing Systems 46 Wire Forming Technology International/Wnter 2019 Annealing is a broad term that is used by heat treatment practitioners to describe a variety of processes and properties related to microstructure, machinability, formability, reliev- ing internal stresses, enhancing certain electrical properties and the like1. Sometimes, certain corporate terms, or slangs are also used

Fig. 2 — System for processng wire in diameters from microstructural changes and modification in mechanical 1.27 to 15.75 mm production rates up to 6600 lb/hr properties are achieved without austenization1. Thus, the (3000 kg/hr) with line speed to 590 fpm (180 mpm). temperature range for SA is always below Ac1 critical tem- peratures. SA represents an intermittent stage between a by steel processing organizations to designate particular fully annealed condition and a cold worked condition (i.e., process specifics. In carbon steel wire applications, this rolled or drawn). Work hardening takes place as a result of includes recovery annealing (200°C to 550°C), recrystal- a cold work increasing a number of dislocations (crystal lization annealing (400°C to 760°C), intermediate annealing imperfections), changing a dislocation pattern, producing (300°C to 760°C) and some others. elongated grains and increasing hardness and brittleness. The following are some basic forms of annealing related SA helps to adjust the hardness and grain structure of prod- to carbon steels: ucts processed on previous operations (e.g., cold-worked steels); otherwise, it might be too difficult to continue cold • Full annealing working. Therefore, SA can be applied between certain process stages (e.g., drawn wire/rope) when steel softening • Intercritical annealing is needed. Transforming elongated grains into predominantly equiaxed grains, restoring toughness and ductility of steel, • Subcritical annealing (process annealing) will improve its conditions before the next cold-work pro- cess. Several critical engineering properties of steel (e.g., • Spheroidized anneal or spheroidizing yield strength, fracture resistance, the ductile–brittle transi- tion temperature, etc.) can be enhanced. Intercritical annealing and subcritical annealing (process annealing) are two of the most typical annealing process According to SA, a carbon steel workpiece is typically where IH is used as the heat source. heated to temperatures of 20°C to 200°C below the lower critical temperature Ac1, held for some time at a tempera- In some cases, it might be beneficial to heat a steel to tem- ture (if required), and then cooled in air, gas or using some peratures between the upper critical temperature (Ac3) and the aqueous medium or their combination. In some cases, the lower critical temperature (Ac1), obtaining partial austeniza- needed time for holding is only a few seconds; however, in tion (to different degrees), holding the steel at a specified other cases, it might be substantially longer. In subcritical an- temperature range followed by cooling in air or applying a nealing of plain carbon and low alloy steels, softening starts controlled cooling. This is where the term intercritical an- with recovery that leads to a redistribution of dislocations. nealing is derived from. The final multiphase microstructure This process intensifies rapidly with a temperature increase. can be adjusted by changing the time/temperature/cooling rate combinations. There are two ways to implement SA of long products: box/ batch SA and continuous SA. With batch annealing, a stack Upon reaching target intercritical temperatures and depend- of rods or wire coils is heated in an enclosed furnace (e.g., ing on the application specifics, it might be required to hold infra-red or resistance furnace); care should be taken to the steel at a temperature for some time. IH can be used for insure that internal areas of a stack are sufficiently heated. intercritical annealing when relatively short holding times are needed or as a booster heater. Whenever long holding Continuous SA can be done in furnaces (e.g., rotary-hearth times are required, it typical to use holding ovens, which are or pusher type) or using induction heaters in particular when either gas or electric heated. Although IH at the front end no holding time is specified or a relatively short holding time can be very effective at rapidly and efficiently preheating to is sufficient. At temperatures suitable for SA, carbon steels the hold temperature for these applications. retain their ferromagnetic properties, allowing extremely energy efficient IH of thin wires at high production rates. Subcritical annealing (SA) of carbon steel wires (also called process annealing, recrystallization annealing or tempering) In drawing wires made of austenitic stainless steels, an ex- represents a large group of heat-treating processes where cessive work hardening might also take place making the wire to be too hard to continue to be drawable. Recrystal- lization annealing helps to make a stainless steel wire suf- ficiently soft, improving its drawing capability. In contrast to carbon steels, this is commonly accomplished by heating austenitic stainless steel wire to temperature of the 1050°C or so followed by rapid cooling to avoid precipitation of car- bides, which could worsen corrosion resistance properties. Direct water spray quenching does not apply here at first. Instead, specially designed water-cooled tubes/jackets filled with protective gas are used during initial and intermediate cooling stages1-3. There is a group of applications where IH is effectively used Winter 2019/Wire Forming Technology International 47

Intricacies of Induction Heating of Wires, Rods, Ropes & Cables ...continued to heat treat wires or thin-wall tubular products: “black,” containing following features2,3: “dull” and “bright” annealing of metallic materials includ- ing stainless steels. • Automatic speed sensor controls power proportionate to line speed. Recipe storage and retrieval. Wire sizes: Stainless steel wire can be heated to temperatures of about 2 to 16 mm diameter. 1050°C to 1150°C range and then progresses through a gas quench tunnel filled with a hydrogen-nitrogen atmosphere • Integrated temperature sensing. to prevent surface oxidation and provide a bright appear- ance. Of course, care should be taken for safe processing • High wear resistant tube guides. The ceramic tubes because gas mixture can be explosive owing to the presence guides allow the surface heat loss to be minimized and of hydrogen in an amount greater than 4% or so. In cases somewhat assist with mechanically constraining the where only a nitrogen atmosphere is used, the surface of the movement of the wire. product appears dull and the process is called dull anneal- ing. Without using a special atmosphere, the surface will • Integrated pumping system. be oxidized and the process is often referred to as “black” annealing. IH can be used for all three processes. • Solid state inverters, operating in both medium and high frequencies. As an example, Figure 3 shows two Radyne Bright Anneal- ing Wire Systems implementing a modular and expandable Quench details: design concept and meeting virtually any line speed and product dimension for heat treating oxygen-free copper, • Optional inert gas quench available. brass, titanium, stainless steel, nickel and other materials. Such systems can either be placed standalone or in-line • Optional gas recycling. with reduction equipment to create an inline processing. Innovative design allows for easy operation, maintenance • Optional gas manufacturing and mixing systems. and changeover from product to product. Each system is equipped with automatic and precision process control • Contained Atmospheres—Nitrogen, Nitrogen with up to 4% Hydrogen, Helium, Argon, Argon with Hydrogen. • Gas Impingement Quench—Finished, high quality surface. • Water Quench – leaves micron level oxidation, accept- able for the majority of inter-process annealing. Multi-Wire Processing Besides the case studies discussed above, there are other ap- plications where it is required to heat multiple wires running in parallel or processing cables consisting of many wires and strands or wire bundles. In most cases, a multi-wire induction system utilizes an oval bore coil with multiple openings and individual guides for multiple wires to pass through (Figure 4, top). Multi-turn solenoid inductors are commonly used for heating single wires or multi-strand cables (Figure 4, bottom). Fig. 3 — Two Radyne Bright Annealing Wire Systems Fig. 4 — Sketch of transverse cross section of with a modular/expandable design concept and meeting inductor for heating multiple wires (top) and virtually any line speed and product dimension. multi-strand cables (bottom)1. 48 Wire Forming Technology International/Winter 2019