News

Flash 42

Electromagnetic shielding - Electroconductive Silicones and Fluorosilicones for gaskets

The silicones and fluorosilicones displayed at Alumotive and used for restoring electric continuity on electric devices ensure electromagnetic shielding and prevent thermal dissipation.

These products presented by Soliani Emc combine the qualities of silicone with the possibility of being loaded with metal fillers (nickel, silver, silver/aluminium and gold). Their electric properties have solved many problems of electromagnetic interference but also of thermal dissipation.

Flash 41

Electroconductive textiles and textile structures for electrosmog shielding

Electroconductive fabrics can be used to manufacture sensors that take advantage of different electric conductivity and also in association with composite materials. The current trend of making means of transport lighter can be achieved by replacing metals with composite materials which are lighter, mechanically resistant and even more radiation-permeable.

Control units and electronic control systems are exposed to radiation. Electromagnetic protection can be guaranteed by using electroconductive finishes even though the vibrations which the structures are subject to may cause problems with time. The coating of fabrics through an electrochemical process allows to obtain electroconductive leather which is very efficient in electrosmog shielding.

Electroconductive textiles have been employed for:

• AIRBUS A 400 M  Eurocopter Marseilles parts for helicopter panels
• Crafts for the Financial Police ELETTRA of the Offshore yard of Gaeta.
• Shielding panels for the protection of telecommunication transmissions
• Vehicle parts with glass fibres Iveco Bolzano
• Military vehicles Renualt
• Gearcases Yamaha motorcycles

New applications are emerging. Besides the already tested frequency range from 10 Khz to 18 GHz, a programme in collaboration with the Polytechnic University of Milan has tested materials up to 40 GHz. These textile structures have also given good results with regard to the thermal dissipation for the transfer of metal on the fibres.

Flash 40

New CAM programme for pipe machining

CAM PowerMILL is the programme presented by Delcam for machining engine pipes. It allows the automatic division of the pipe machining process in areas that may be reached using 3-axis techniques and areas that require positional 5-axis or continuous machining.

In most machine tools the 3-axis and 5-axis machining gives greater rigidity and allows more accurate machining with less tool vibration and greater speed. However, most engine pipes require a 5-axis machining for some parts of their structure. It automatically optimises the machining sequence allowing to remove a lot of material with the 3-axis or 5-axis strategies, using continuous 5-axis machining only when it is necessary.

This technique reduces overall working time and maintains the required level of finishing. The sequences use a spiral movement for the roughing, but when it comes to finishing, the operator can choose between spiral or plunge machining.

The spiral technique produces crests opposite to the gas flow direction which inevitably cause turbulence, whereas with the plunge technique the crests are generated along the flow direction allowing gases to pass through the pipe much faster.

PowerMILL automatically divides the CAD model so as to create surfaces that will be machined by the pipe ends. The overlap between toolpaths can be accurately managed by the user to ensure a smooth transition where the two operations meet.

PowerMILL is suitable for a complete range of tools, including round tools that are frequently used to reach the most difficult areas of the pipe. The software can be used to machine pipes directly or for the finishing of motors. It is also capable of preventing collisions and hooking to grant a faultless working. The machine tool model specified in the validation module allows to make sure that the movements visualized by the computer are the same as those that take place in the machine. The new strategies of pipe machining take advantage of the precision with which PowerMILL re-distributes the points.

Even with a growing number of points in the toolpath, machining takes place with less vibration and a constant tool load. These improvements give a better finish and enhance the tool’s resistance to wear.

Flash 39

Innovative magnesium anodisation process

In the last ten years, as a result of a significant decrease in the price of magnesium, the use of this material has risen remarkably. Given its excellent lightness and mechanical resistance, magnesium is now appreciated more than other so-called structural metals (aluminium or steel) in many sectors.

It is broadly used in the automotive industry for the manufacturing of wheel rims, car structure parts or car, bike and scooter motor components, especially when weight must be kept low. It is a very reactive metal which is not very resistant to corrosion. That is why it needs a protective treatment when used in exterior applications.

Italfinish, a company that has been dealing with aluminium surface treatments for more than 40 years, has devised a patent pending electrolytic anodisation process, called SweetMag, that forms a composite layer on the magnesium surface protecting it from corrosion.

This anodic layer enhances the adhesion of the finish. In comparison with other treatments for magnesium available on the market, SweetMag stands out for its low energy consumption and simplicity. The treatment takes place in only one step and the anodisation bath does not contain polluting or hazardous substances for the environment and the user.

In September Italfinish will open a new subsidiary in the Chinese province of Guangdong, an area very rich in magnesium as raw material. It will produce anodised magnesium parts with the SweetMag process which will be finished according to the requirements of the end client.

Flash 38

New white anodising treatment for aluminium alloys

Besides granting a high quality finish, the coating of aluminium through electrolysis has a wide range of applications and ensures great protection from corrosion thanks to the porous nature of the oxide films, allowing to produce coloured coatings through the deposit of organic and metallic pigments. Its versatility makes it suitable for various usages in the modern transport industry.

Alumotive, the most important event of the industry running from 18 to 20 October at the Modena fairgrounds and a showcase of innovative solutions, subcontracting, aluminium components and technological materials for the transport industry, will be displaying metal treatments and everything new about them. A new anodisation process for aluminium alloys will be presented that allows to obtain a grey/white opaque finishing that can be also used for alloys with a high silicon content.

The white anodising finishing can stand alone (it grants optimum protection from corrosion) or be used as a pre-treatment for any kind of finishing according to the current techniques. It has been invented by Italfinish, a company with more than 40 years experience in the field of aluminium surface finishing.

Flash 37

Durometers

The ERNST durometer range presented at Alumotive comprises portable, bench instruments and automatic solutions for the control of a line. The ESATEST durometer, patented by ERNST and distributed by C.I.S.A.M., features an innovative measuring principle, capable of controlling areas that would previously have been impossible to access with the ordinary hardness control procedures.

A single measurement is enough to immediately obtain the hardness values, taken on a wide range of loads. This is especially useful for controlling surface treatments of parts and for getting a quick evaluation of the thermal treatment.

The wing of a supersonic jet, the trapezium of a Formula 1 car, the blade of a turbine, the joint of a wheel: these are only some of the difficult areas that can be measured with Esatest. The hardness reading is automatically displayed on the screen.

Electronics offers many possibilities of setting. Measurement system, tolerance fields, load setting, test storage memory, printing of the certificate in five languages, connection to computers through exit RS232, business software for working in Windows environments. ESATEST is available in the motor-powered MTR and portable HANDY variants.

Flash 36

Automatic depth analysis of thermal treatment HTD 900S

A brand new method that brings significant advantages to the determination of hard layer surface thickness. The classic analysis requires much more time and ends up destroying the part. The analysis with HTD 900S does not destroy the piece and can be extended to the entire production batch allowing an efficient control without loss of time and material even in points that were not accessible up to now and without evaluation errors by the operator.

Thanks to an electroconductive drilling device HTD 900S allows to measure surface hardness and treatment thickness up to 1,3 mm immediately and without compromising the part’s integrity. The recording of the load curve of the thickness provides information on the hardness level and thickness of the surface layer.

Flash 35

Motor-powered durometer allows to control large production batches completely automatically

A follow-up of AT200, AT300 DRT-M is a motor-powered durometer which allows to control large production batches (approx. 1,000 parts/hour) completely automatically. Not only the load application, but also the movement of the measuring head is motor-powered, thus streamlining the testing process.

The special shape of the carter’s lower side and the lighting of the testing area allow observation during the test. The control panel is movable to adapt to the various light intensities and can be detached or brought closer to the operator. Operators may store the accessories on board of the machine thanks to a special practical drawer in the crankshaft.

In developing this tool special attention was devoted to design, without neglecting the safety aspects during the moving of mobile parts as the test takes place. On request, it is possible to adapt the length of the measuring head’s stroke according to the customer’s needs.

Flash 34

New solutions for the storing of testing data

Datarec is a new instrument designed and manufactured by Tecna that allows to easily manage manufacturing and testing data. Its 32 megabyte memory allows to record, store and file the testing results in a simpler and faster way than traditional methods. The outcomes of the trials may then be accessed easily through an external support like, for example, a USB memory key.

The greater competitive advantage in comparison with other data storage systems is that data control can be performed remotely through a local network (Ethernet). Users may even choose to program a periodic sending, at a fixed deadline, of the trial data. In this way trial results are constantly monitored. The stored data may even be exported in the most common formats as database or calculation sheets.

Flash 33

New solutions for leak tests up to 6 bar

Provaset 2P is a new electro-pneumatic leak tester available with test pressure up to 6 bar and resolution 0,1mbar. It can be used in various sectors from the medical to the automotive industry and oleodynamics. Its compact size makes it suitable for Quality Management laboratories. This instrument performs both leak tests and multiple obstruction tests.

The equipment contains 16 programmable test parameter charts: each chart includes the parameters that govern one test cycle, therefore it is possible to set different test conditions for different products.

Flash 32

Differential pressure leak testing

Differential pressure leak tests compare one item with one sample having exactly the same features: it is like using a magnifying lens to see the differences between two pieces better. The bedding time is significantly reduced and the pressure reading resolution increases in such a way that even the smallest leak can be detected. For tests up to 6bar the differential method is excellent value for money. Calibrated Leak is the solution that ensures the efficiency of the testing cycle.

With a set pressure, a calibrated leak grants a known leak amount. By inserting the calibrated leak to the test circuit it becomes very easy to check both the control device and the mechanical system that connects the piece to be tested. Tecna Srl, an ISO9001:2000 certified company, has been designing and manufacturing instruments for the control of industrial automatic processes, pressure leak testing and air flow testing since 1983. The DELTA range presented at Alumotive comprises extremely flexible equipment for differential pressure leak tests.

Flash 31

Rapid protoyping machine

The rapid prototyping machine of the Objet Eden series, model 500V ensures 16μ high resolution and top-quality surface finishing. It is presented at Alumotive by Overmach.

Flash 30

New rubber-like resin with an elasticity eight times higher than those available on the market

“Tango Plus”, the new rubber-like resin with elasticity eight times higher than those available on the market is the big news signed by Overmach. The other 10 materials of the Fullcure series will be also displayed at the show.

Flash 29

New ways of surface treatment

Ossidazione Italiana, born in 2006 as a company specialized in aluminium surface treatment, has focused on optimising one part of the aluminium processing (the one that goes from polishing to the finished product).
The company based in Grizzana Morandi (Bologna) will be present at Alumotive 2007 from 18 to 20 October.

In its stand, which it shares with Officine Marconi, a company with which it has established a solid partnership, it will display surface treatments dedicated to the automotive industry.

Steel and aluminium polishing, grinding, buffing of automotive components will be presented by Officine Marconi. Ossidazione Italiana will focus on polishing, grinding, buffing and bright or opaque anodic oxidation or electrocolour again applied to the automotive industry.

The company is committed to environmental protection and safety at work. This led to the decision to invest in an extra-large water/air purifier in compliance with the regulations.

Flash 28

Surface treatments and mechanical working

Nuova In.F.A. S.p.A., a leading company in the field of stainless steel, aluminium and plastic surface treatments, started to produce appealing and functional components for electrical appliances and the automotive industry over 35 years ago.

To cater to the automotive industry, Nuova In.F.A. has invested in new machinery for mechanical working and in an automatic oxidation system equipped with 26 treatment tanks, 2 trolleys for the transportation and the immersion, guided by automatic PLCs, and two motor-powered load stations.

Nuova In.F.A. has also designed high-technology industrial processes in relation to surface treatments, like anti-fingerprint coatings for metal surfaces, satin finish and Scotch Brite, equipped with an automatic load/unload system, rapid cross-linking oven, protective film application with integrated transversal cutting.
A recent investment has to do with the silk-screen field: a last generation machine with completely automatic adjustment and control systems.

Flash 27

Hot pressing for non-ferrous alloys

In September Fonderia Fratelli Maspero moved its production to the new site in Monza, where the technical office and structure of R&S are located as well. Over an area of more than 9,000 sqm the layout of the machining has been redesigned with the aim of rationalising the production flow. All modern systems have been employed so as to reduce the environmental impact of hot pressing to the minimum both in relation to emissions and to noise pollution.

A new rocker arm press built by Comax Technology for the hot pressing of non ferrous metals (screw diameter 580mm and maximum nominal capacity 6,000 tons) will start operating as from October 2007.
This new production line allows Fonderia Fratelli Maspero to hot press large-sized pieces made from aluminium alloys, brass, bronze, copper, copper-nickel and titanium with excellent results. One of the most remarkable products that the foundry has recently created is the special aluminium alloy 6082 mould obtained from a round bar diameter 70.

Being a structural piece, every single detail is tested with penetrating liquids to ensure maximum reliability even in the hardest conditions. The investments made in the last 3 years by R&S in the field of hydroforming allow it to supply special aluminium or steel hydroforms with variable section and without welding.

Flash 26

High-technology leak tests

More than 30 years ago Ateq started to design and manufacture pressure leak testers and air/air leak testers for the worldwide market. The Italian market is managed by Milan-based Ateq Systemes Analytiques Italia that provides sales, technical and metrological assistance to the entire national market. Ateq offers a complete range of instruments for all kinds of control and trial needs, the laboratory and the manual or automatic manufacturing process.

All instruments are equipped with 32 storable programmes, serial port RS232 for connection to PC/printer for the acquisition of trial reports, digital interface in/out and communication protocols modbus, profibus, device net as options.

Ateq provides the following:

• Series F: pressure decay leak tests with 1Pa and 10Pa resolutions and test pressure standard version up to 9 bar. Other test pressures available: 20, 50, 100 and 200 bar.
• Series G: laminar flow pressure tests with 1cc/h and 0,1 cc/min resolutions and test pressures up to 4 bar.
• Series D: laminar flow pressure tests from 5 to 25.000 l/h and pressure up to 6 bar.
• T520: leak detector with tracer gas.
• H2LD: ultrasensible leak detector sniffer with hydrogen mixture.
• Multiple flowmeter, capacity and leak calibrator.
• V570, volume tester – Sample leaks and Sample Nozzles for the calibration check of the instruments.
• TPMS and VT520, tyre pressure control and monitoring systems.
• IONIQ, leak tester with discharge current.
• Filters and compact driers for compressed air transfer.

Flash 25

Adhesives for various purposes

Axson Italia, manufacturer of resins, silicones and composite materials, will be presenting its range of adhesives for various gluing purposes, from the simplest to the more complex, at Alumotive 2007. This range, called Adekit, consists of three product families aimed at the aeronautic, automotive, railway, boating and electronic sectors.

Epoxy adhesives are used in structural gluing. They are famous for their excellent mechanic qualities (rigidity and dimensional stability), the chemical resistance and the resistance to high temperatures. They are typically used for gluing meshed structures, structural elements, railway materials, glass, concrete or steel structures. The newcomer in this family is ADEKIT A180, a rigid epoxy adhesive with excellent mechanic properties and great resistance to high temperature. Polyurethane adhesives are used for flexible gluing. Thanks to their qualities they are suitable for elements that are subject to vibration, shocks and low temperatures.

They are generally used to assemble materials of different kind with a high expansion coefficient. Last but not least metachrylate adhesives: they are characterized by flexibility, mechanic resistance and excellent adhesive qualities suitable for a broad range of plastic materials known for their difficult gluing. These adhesives are meant for the gluing of car-body parts and the assembly of thermoplastic components, but can be also used for the gluing of metals.

Flash 24

Customer-oriented Software

Kubotek Europe srl is the European branch of the multinational group Kubotek Corporation based in Japan. In 2003 Kubotex acquired Cadkey Corporation to enhance the CAD/CAM system presenting it under a new name: Keycreator. Keycreator is a complete CAD/CAM solution giving remarkable operational flexibility to the user. With Keycreator it is the user who decides the right approach for the design, production and analysis of the item.

The software provides all the instruments, the user with his expertise decides the best strategy. At Alumotive Kubotek Europe will be presenting, alongside the updated versions of the Keycreator product line, some new modules like the certification and comparison of models and the interface with arms for 3D digitalisation. The broad range of direct translators from and into other CAD systems makes it possible for this instrument to include high-end products to allow operators to use a flexible and easy-to-use system for the daily design operations.

The Kubotek Europe product line includes a visualization tool for Spectrum files and Realyze, a tool that simplifies business interconnectedness in CAD environments that allows to import, modify and correct CAD models and then to export them to the CAD system employed by the company.

Flash 23

New Fem calculation service

FEM calculation allows to perform structural finite elements calculation developed according to the specific problems faced by the customers, using the best software available on the market. Finite element calculation is a structure calculation technology that has become a must in the field of optimisation and component design granting an efficient and fast re-design. At Alumotive the new Fem calculation service will be presented by Tec Eurolab.

Flash 22

AQUAROLL® EE30 rotational washing system

Alumotive will be featuring aquaroll® a system for washing, removing excess "swarf", passivating and drying metal and non-metal parts manufactured by STS. The system consists of a washing unit that ensures top-quality washing by continuously rotating the load under the combined action of high volume–low pressure spray and dip washing.

The revolving system safely eliminates "swarf" and other metal scrap giving parts/components that are ready to enter the next working step without any further treatment or hand drying.
The chamber, solution tanks, pumps, filters, pipe-work and other parts of the system in touch with the liquids are made from stainless steel. The components may be placed in the machine using plastic or metal baskets.

Main options:

• Standard baskets, plastic containers and special supports, the latter are also cleaned and dried during operation, avoiding the risk of reciprocal contamination.
• Vacuum drying system to remove moisture even from the smallest holes.
• Aerosol and vapour filtering with extraction and closed cycle condensation units.
• Wide selection of moving and positioning devices to perfectly integrate the unit in the production cycle.
• Customised versions according to the needs of the customer.

For information: www.stsitaly.it

Flash 21

AUTOMATIC NUT AND SCREW FEEDER

Alumotive presents special automatic feeders of nuts and screws (drum or vibrating) managed and controlled by the most modern PLCs. Specially manufactured for the automotive industry, they are produced and designed by the technicians of Dengensha based on samples provided by the customers and grant correct selection and feeding right from the start. Through the revolving drum, the vibrating system and an innovative magnetic feeding unit, the Dengensha system can increase productivity ensuring quality and safety. It is presented at Alumotive by CARPANETO & C. Spa.

Flash 20

MEDIUM FREQUENCY WELDING CABINETS

The “EVO ” medium frequency welding cabinets presented at Alumotive by Carpaneto & C. S.p.A., contain all the elements for the adjustment and regulation of electrical power used in resistance welding with Inverter 1000Hz. They allow to use large amount of energy at the weld spot and maintain the size and weight of the transformers. Energy absorption is balanced on three phases and not outphased by the electrical network.

Their use allows to:

• Receive energy for the welding from the three-phase network, transform it through the inverter in AC 1000Hz and send it to a transformer with specific characteristics and capacity.
• Automatically adjust the welding power to the programmed value.
• Interface with Robot or PLC systems for the management of the slot weld in which they should operate.

MFDC RESISTANCE WELDING
Specifications
Application: robotized slots and automatic areas Size: 680x680x430mm Weight:100Kg Protection: IP54 Connection (XS1-XS2) Feeding: grommet wire diameter 32mm (PG36) Input cables section: 35sqmm (three-phase) Output cables section: 35sqmm (max 10 metres), 50sqmm (max 30 metres) Connection (XP1) auxiliary and I/O: Connector 24way F (type ILME CNF24) 77x27mm Connection (XP2) field-bus, TA, proportional valve: Connector 4way bulkhead wire 77x27mm Connection hydraulic plant: hose-end diam.10, water pressure min 2 bar, max 6 bar, capacity 4 l/min 20-40°C Cabinet feeding: 400Vac +/-15%, 50Hz 3-phase
Maximum cabinet capacity: 600kVA 20% duty cycle Auxiliary voltage: 24Vdc 3° General switch (Q1): 250A, magnetic release, minimum voltage coil 24Vdc Security Circuit: differential device Programming unit: remote option, cabinet Inverter type: MFDC EVO 600A and 1200A, feeding 400VAC 50Hz, Air/Water cooling

Flash 19

ALUMOTIVE PRESENTS THE NEW AUTOFORM SOFTWARE – VERSION 4.1 FOR SHEET METAL FORMING

It will be brought at the Modena Exhibition Centre by AutoForm Engineering GmbH from October 18 to 20. The new software offers 200 advanced functions:

• Accurate calculation of springback and springback compensation: with this new option it is possible to modify the die automatically on the basis of an accurate springback calculation. Designers can directly evaluate the effects of springback and adapt the geometry accordingly. The modified geometry will be automatically used as an input for the quick and precise die validation. The result is a more reliable process already during the first phases and thanks to the calculation and recovery of the springback the following adjustment operations can be reduced.
• Precise geometry modelling: the new “morphing” technology allows remarkable improvement in the geometry modelling. Modifying wall angles, developing fins, changing profiles and accurately dealing with the modified surface, the designer can easily attain an optimised geometry.
• Development process of a more efficient die: the die’s development time can be considerably reduced using the new “substitution skin” and “offset skin” tools present in AutoForm 4.1. Defective original surfaces are replaced by very precise skins that can be used for the solid modelling of the die. As a result, the die design takes place much earlier. Moreover, it is possible to create an offset surface that can be used for the foundry model. Therefore, the forming takes place earlier saving several weeks.
• Accurate computing of the deformation stress: AutoForm 4.1 is capable of accurately calculating the deformation stress. Knowing this information precisely, designers may identify the necessary press right from the start.

Flash 18

Alumotive presents the first specialised commercial design software for car manufacturers

AutoForm Engineering GmbH, the leading supplier of software solutions for sheet metal forming, will be presenting the first specialised software of commercial design for the car-making industry at Alumotive 2007. Mr Markus Thomma, AutoForm marketing director, explains: “In the last 10 years our objective has been the development of vertical solutions for the design and production of formed sheet metal parts and the relative equipment. In collaboration with industrial partners, AutoForm has developed a new module that is about to be brought to market. It makes it easier for design divisions to quickly calculate the costs of the equipment pertaining to the manufacturing of car-body parts.

Up to now, equipment cost computing took place mostly using self-developed Microsoft Excel work sheets. This method requires that the user gives a detailed description of the sheet metal part to be cast and all data must be inserted manually. This means lack of transparency and reproducibility in determining costs. Second, the cost calculation for the entire equipment requires much more time, is not flexible and there is no connection between geometry and costs.

The AutoForm equipment cost calculation method is brand new: starting from the product geometry, it automatically identifies the part details and determines the production process and the equipment cost with only little information inserted by the user. Its extraordinary speed allows not only to compute the costs much more quickly, but also, for the first time, to assess multiple and alternative production concepts and attain a cost-effective production process.

The new module is completely integrated with the AutoForm software environment granting excellent performance to the user. It interacts with other AutoForm modules, for example those that determine the minimum slug, material costs and deep drawing feasibility. As a result, a design solution becomes available that allows process and cost computing designers to rapidly obtain complete and reproducible design data.
Moreover, with this integrated solution, it is possible to standardise processes, create transparent and reproducible design data and determine the costs. “We are very happy to cooperate with DaimlerChrysler AG for the development of this new solution (as OEM) and ThyssenKrupp Drauz Nothelfer-Gruppe (as supplier). Both companies have already implemented our software in the pilot phase”, says Markus Thomma.

Flash 17

Development of software and services for business innovation

Altair, a private company established in Michigan in 1985, promotes technological innovation and decision-making processes by offering technologies capable of optimising the analysis, management and visualization of information in relation to business and engineering. Altair collaborates with more than 3,000 customers in the automobile, aerospace, government, military and consumer products sectors.

In Italy the Altair group is made up of four companies with offices in Turin, Milan, Modena and Lecce. The companies focus on research and development activities, engineering and software distribution services for finite element simulation. Altair is also expert in mechatronics and more generally in manufacturing processes.

Altair software technology is encased in the CAE suite called Altair HyperWorks, which allows to bring to market innovative products through a working environment that includes numerical analysis, optimisation, pre- and post-processing and data management instruments. The Altair software range is centred around the development of the product, reduces analysis and manufacturing time and streamlines the design of improved performance products thanks to an integrated multi-disciplinary framework and top-level technical support.

Flash 16

New range of enhanced adhesives for the design and production of plastic and metal components

Something new in the area of structural adhesives at Alumotive 2007: Huntsman Advanced Materials will be presenting Araldite® 2000 PLUS, a new range of structural adhesives specially enhanced for the design and manufacturing of plastic and metal components.

Distributed in Italy by Mascherpa S.p.a-Milano, Araldite® 2000 PLUS is the only product family capable of offering solutions based on three different formulas – epoxic, methacrylic and polyurethane. The range consists of 14 products with optimum performance. Light and capable of granting durable fastening that can stand up to the toughest conditions (cutting, skinning, compression, moisture and temperature changes), Araldite® 2000 PLUS adhesives improve the performance and longevity of the glued materials and can be used with a great variety of materials such as plastic, technopolymers, metals and composites.

The range can be divided into two categories: products for the gluing of metals and those for the gluing of plastic parts. For information: www.mascherpa.it

Flash 15

DRY MASS DEBURRING FOR SMALL ALUMINIUM PARTS

Those of the mechanical industry who deal with aluminium alloys and non ferrous alloys in general making elements that need deburring will certainly have adopted the wet tumbling system, a long-established, very efficient and cost-effective process. The wet tumbling technology has undergone an evolution. It originally entailed the use of acid water solutions or inorganic salts and more or less additivated surfactants like generic antioxidants.

Today specific products are used, capable of treating every single metal alloy. This is specially true for aluminium, a metal with amphoteric characteristics, that behaves as an alkali or as an acid depending on the ph of the solution with which it comes into contact. This means that it falls prey to oxidation, more than other metals.

To preserve the condition of the component surface, it is necessary to use precise formulas and complex substances based on products that are not environmental-friendly at all. Nowadays, the legislation on environmental protection imposes efficient purification systems that neutralize (through other chemical compounds) hazardou substances that should not be discharged into the environment.

The new compounds add up to the sludge generated by the tumbling process and must be disposed of at appointed dumps. All these operations (amortization of the purifier plant and press-filter and their maintenance, consumption of cleaning products, labour demand etc) together with the compliance with extenuating bureaucratic procedures for the management of waste inevitably translate into cost increase and considerable reduction of the wet tumbling process cost-effectiveness.

To overcome these problems and restore the cost-effectiveness of mass deburring today we can use the ECOB dry system. Using special abrasive granules, this new process is based on water (which means it does not produce sludge) and not on chemical products (i.e. it does not pollute). Each detail of the system is approved after a careful analysis of the tumbling needs and thorough testing. It has proved simple, safe and easy to be maintained. It’s the most economical system available on the market today. It will be presented at Alumotive, from October 18 to 20 at the Modena fairgrounds.

Flash 14

NEW MULTISTAGE AND STRUCTURAL STEEL RIVETS ON VIEW AT ALUMOTIVE

Alumotive, the show of Innovative Solutions, Subcontracting, Aluminium Components and Technological Materials for the Transport Industry, taking place in Modena from October 18 to 20 will present a pre-view of everything new as regards rivets.

Visitors will have the opportunity to check the mechanical resistance and the excellent resistance to vibrations of the “TAMP” multistage steel rivets available with diameter 3,2-4-4,8 and self-contained mandrel and also FARBOLT structural rivets in steel with dome heads (6,4x15 – 6,4x20 – 4,8x11 – 4,8x14 mm) or countersunk heads (6,4x17 – 4,8x13 – 4,8x16 mm), suitable for fastening under great loads. They will be presented by FAR, a leading company in the field of tear-off rivets, thread inserts and riveting machines that designs and manufactures semi-automatic and automatic riveting systems. Besides the new steel rivets, Far will be presenting stainless A4 and stainless multistage A2 rivets, M3 FTR for thread inserts, the new riveting machines K35F and RAC171 for structural rivets and FHU05 for tear-off bolts.

The Far tool range has been recently updated replacing M12 mod.KJ40 with M4 KJ45 which offers higher capacity, single switch, commercial tie-rods, ergonomic design, pneumatic adjustment of the stroke and pass valve).

Flash 13

ON DISPLAY AT ALUMOTIVE 2007 THE NEWSOFTGEL PATENT, A THERMOPLASTIC MATERIAL WITH AN EXCELLENT ELASTIC YIELD, LISTED IN THE CATALOGUES OF MATERIAL CONNEXION AND USED IN APPLICATIONS OF DESIGN AND ERGONOMICS

ALUMOTIVE 2007 - the international show for innovative solutions, sub-supply, aluminium components and technological materials for the transport industry – will afford ample room to research on new materials and to the latest frontiers in product innovation.

On show from October 18 to 20 in Modena, the main novelties in the field of polymers will include the NewSoftGel patent, a thermoplastic material with an excellent yield, listed in the catalogues of Material Connexion and used in applications of design and ergonomics. The material is exhibited by Sp Plast.

This company, established in 1995 as an industry involved in the transformation of plastic materials, today has 17 employees, machinery consisting of 20 injection presses for plastic materials, ranging from 6 to 400 tons, a workshop for building and servicing moulds and for quick prototyping and machines for tampography and silk screen printing, high frequency welding. Starting out from the initial production of accessories and minute plastic items for the shoe making industry, Sp Plast has specialised in the field of technical moulding and mould building. It is also engaged in research and development of new materials, and co-operates with universities and research centres (PST - Scientific Park of Tortona). Recently, the technical structure and the quality system of the company have undergone restructuring, thanks to the co-operation of professionals who come from situations with direct experience in the world of technical moulding (testing moulds and materials, gas injection applications, two colour, co-moulding, micro-injection, etc.).

Flash 12

ALUMOTIVE 2007 OPENS UP TO NEW TECHNOLOGIES FOR PRESSURE DIE-CASTING ALUMINIUM AND ZINC

The term pressure die-casting defines the process according to which the molten alloy is poured into a metal form (mould) and then subjected to pressure. One of the quickest and least expensive techniques for transforming metals into manufactured items with a high degree of finish, pressure die-casting finds application in every field of product manufacture and complex equipments which use non-ferrous metal components.

Alumotive, Alumotive - the international show for innovative solutions, sub-supply, aluminium components and technological materials for the transport industry – to be held in Modena between October 18 and 20, hosta an exhibition of a wide range of innovative technologies for pressure die-casting. Like those displayed by Lumpress snc, a company established in 1978 as an individual industrial firm working in the field of pressure die-casting of aluminium and zinc casting, in surface finish and mechanical processing, which works directly with its customers to design and make moulds.

In 1995, Lumpress achieved Iso9002 certification and in the following year became a limited liability company. It specialises in providing products and services for the mechanical, automotive, agriculture and power industries. In 2003, the company obtained the updating of its Quality System to the new international standard ISO 9001- 2000 (Vision 2000).

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Small processing for many different uses

Benozzi, a specialist in medium and small details, will be displaying at Alumotive 2007 Benozzi Angelo, a company based in Piombino Dese (Padova), will be attending the coming edition of Alumotive - the international show for sub-supply, aluminium components and technological materials for the transport industry – to be held in Modena between October 18 and 20.

The company has experience in the following fields: aeronautics, motorcycling, cars, robots, pharmaceutics, eyeglasses, textile and commercial fittings. Benozzi focuses on processing medium-small sized items; the company’s machinery is structured with working range in the order of 600 x 500 x 400 mm with some exceptions: a machine with a working range of 3000 mm and one of 2000 mm.

The output mainly inolves samples, prototypes, spare parts, small and medium series. The orientation is towards items of medium and high complexity, with the possibility of working on 3 and 5 axes, continuously or in positioning, ensuring the utmost accuracy and avoiding unsuitable restarts.

On demand by the customer, with support from outside suppliers, the company may carry out different treatments on the processed items: reclaiming, restoring, hardening, cementing, or else anodising, painting. Specialisation in aluminium alloys goes together with processing of other materials, such as reclamation steel, cementing steel, stainless steel, cast iron, brass, bronze, synthetic materials and so on.

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AIM, THE ITALIAN ASSOCIATION FOR MACRO-MOLECULE SCIENCE AND TECHNOLOGY, IS SPONSORING ALUMOTIVE

Alumotive, the International Show for Innovative Solutions, Sub-supply, Aluminium Components and Technological Materials for the Transport Industry, an event taking place in Modena from October 18 to 20, has obtained the sponsorship of Aim, the Italian association for macro-molecule science and technology.

For the event held in Italy’s Emilia-Romagna region, this is an important acknowledgement, which confirms it to be a prestigious show window for the applications of new materials in the transport business. Aim is a non profit assocation, set up in 1975, in order to promote research and study of macro-molecules in their various aspects, scientific and in terms of technique and application. It organises and promotes conferences, schoows, workshops and seminars on the topic of polymers, publishing such educational material as the periodical AIM Magazine, the Proceedings of Conferences and Schools and the new AIM text, “Foundations of the Science of Polymers”.

At present, the association has about 700 members coming, in almost equal proportion, from the academic world (Universities and National Council of Research) and from the industrial world (including small and medium industry). AIM represents the natural place for meeting and dialogue between two worlds, the university and enterprises, which, though having common interests, often have different experiences, culture, needs and outlooks.

Despite the well known economic situation of Italian industry in the field of plastic materials, and using only the resources contributed by its members, AIM, in its thirty years of life, has managed to support culture and dissemination on a very high level.

A great many national and international scientific Conferences have been organised, as well as “Conference Schools” on general topics of great intertest in the macro-molecular field, as well as the “Technology Days” which, on the other hand, deal specifically with more practical and applicational sectorial issues. Since 1986, AIM has belonged to and been working actively together with the European Polymer Federation (EPF), the European federation which brings together all the national associations for macro-molecule science and technology.

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Insul.tecno, specialising in thermal insulation, will have a stand of its own

The coming edition of Alumotive - the international show for sub-supply, aluminium components and technological materials for the transport industry – to be held in Modena between October 18 and 20 will have space for industrial thermography as well.

There will in fact be a stand of the Insul.tecno Group, a company specialising in thermal insulation which manufactures and markets, in Italy and abroad, insulating materials for the industrial, chemical, petrol-chemical, naval, fire prevention, aeronautics, railway and power production sectors.

The range of insulating and refractory products covers a field of use between -60°C and +1800°C. On items, machines and installations, Insul.Tecno carries out detailed thermographies, special infra-red photos which make it possible to “see” faults even when they are not visible to the human eye.

Insul.Tecno has several departments: a technical and business office, a warehouse and logistics service, a laboratory for making textile items and innovative insulating systems, a service centre for thermographic surveys of the temperatures of thermal installations and a service centre for making complete projects.

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EJOT EXHIBITS AT ALUMOTIVE 2007

The immense competition in the automotive industry and other areas continually demands cost reductions. Most of the time the fasteners, as C-parts, are underestimated in their influence into other areas of design engineering. Despite the low portion of only 15-20% of the total cost of the joint, the application of intelligent fastener solutions can lower the cost considerably.

With thread forming screws the usual process steps “pre-drilling of the hole”, “thread cutting” and “cleaning” can be eliminated. In the area of light metal joints this can be realised with the ALtracs® screw. The ALtracs® is installed directly into the cast hole and can lead to cost savings of up to 30%.

The cost saving does not effect the quality of the joint in any way. The ALtracs® screw shows a high process capability – a large corridor between installation and stripping torques – as well as strength values comparable to a metric 10.9 screw joint. Regarding the pre-tensioning force under thermal and dynamic stress the screw also reaches good values.

The circular thread cross section of the ALtracs® achieves an optimal thread coverage, which enables much higher pretensioning forces in connection with the specifically designed thread geometry. Furthermore circular cross sections are less susceptible to tolerances in the casting.

This allows for a broader use of ovalities and porosities in the cast component. It is beneficial to the manufacturer, to involve an expert in fastening solutions into the design engineering process at the beginning of a project, since 80% of the costs of a product are defined during the development stage. EJOT, with its many years of experience in cooperating with well-known companies, are also available to you. www.ejot.com

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Assomotoracing is born

Technicians, researchers and firms are those who, working behind the scenes, have always allowed to reach important aims in the long history of racing vehicles.

In order to promote this rich legacy of lives, discoveries and development, Assomo-toracing was founded as the first cultural association in Italy dedicated to the his-tory of racing motor-sports techniques. This 'onlus' association, founded last Janu-ary in Bologna thanks to a group of technicians and fans, aims at promoting and spreading the themes connected with the past and current history of racing motor-sports by means of popular initiatives and conventions, events and cultural ex-changes with universities, technical institutes, museums and topical exhibitions in Italy and abroad.

Assomotoracing wants to promote a methodical activity of research and collection of documents concerning the world of racing motor-sports. Among the most demanding prospective projects there is the creation of a data-base collecting the data of all the suppliers of materials, subcontractors, and train-ers in the sector of the professional races. The Committee of Honour of Assomotoracing, which has already achieved wide-spread success and membership, includes: Ermanno Bonfiglioli; Mauro Forghieri; Francesco Stanguellini; Gualtiero Valeri; Enrico Costa; the teachers Mr Giovanni Barozzi, Mr Cantore, Prof. Strozzi of the Faculty of Engineering at the University of Modena and Reggio Emilia, Prof. Marino of the Polytechnic of Milan, Prof. Tomesani of the University of Bologna, Prof. Garagnani of the University of Ferrara, Prof. Bonollo of the University of Padua, Prof. Renzi of the University of Rome; the sports photographer Franco Zagari. www.assomotoracing.it

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Competence and technology: the EnginSoft virtual experimentation

EnginSoft, established in 1984, is now a major partner of the most important Italian industrial groups in the field of virtual experimentation, with a staff of more than 80 experts and various specializations, more than 1000 licenses for the main business software and a steady growth that make it the first Italian and the second European company in this field. A distinguishing feature of EnginSoft is the great variety of specific technical skills that allows it to establish exclusive business relations with other companies for all sorts of problems regarding CAE and virtual experimentation, both in relation to the use of business software and the development of custom-made solutions. The variety of services offered includes complementary software technologies (among them modeFRONTIER, proprietary) and the relative applications but also a variety of training initiatives and the ability to coordinate and implement industrial research projects funded by the public sector. EnginSoft also offers a CAE assessment service to identify the intervention context and establish the scope of the CAE development plan. EnginSoft is present in 5 Italian cities: Trento, Padova, Bergamo, Florence and Mesagne (BR). In Europe it promotes the modeFRONTIER distribution network through its subsidiaries in Germany, Sweden, France, the United Kingdom, Greece and Turkey.

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Textile fibre metallization. Soliani Emc

A considerable amount of technological research was conducted to find solutions that combine the shielding value with weight reduction thanks to the employment of composites to replace conventional metal. Besides composites, also non impregnated fabrics are being increasingly used as electrically shielding materials for flexible solutions. The shielding effectiveness ratio (SE) in dB with a frequency range from 100 KHz to 18 GHz has made it possible to reach interesting ratios in laminated composites with carbon fibre fabrics featuring Reinforced Polymer (CFRP). Other interesting applications have been made with Sadwich, i.e. carbon fabrics coupled with electroless nickel plating. The electroless plating creates an electrically conductive coating on each fibre of the fabric structure. Inside the structure it achieves a coating that extends the metallization surface offering shielding and resistance to radiant heat. The possibility to coat fabrics of various types has been successfully tested according to MIL G 285 and an efficient contribution is connected with the new fibres to be used for the composite. Superficial electrical resistivity with values around 0,5-0,03 Ohm/square has already given interesting results with one or more overlapping layers with or without dielectric. The shielding effectiveness (SE) is defined as the ratio between the size of the electrical field without a shield, in this case a fabric, and the size of the field that is transmitted through the shield. The fabrics are covered with pure nickel as it offers more advantages than copper. This 100% Italian processing is a test bed for new developments required by new potential customers.

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Bett Sistemi: safety and automation systems

Bett Sistemi deals with the design and production of components, accident prevention guards and automation systems for the packaging and bottling industry. The accident prevention guards of Bett Sistemi include the following ranges: Roboframe pack, safety guards with aluminium profiles and joints from thermoplastic material for packaging machines; Roboframe food, safety guards with stainless steel profiles and joints from thermoplastic material with reinforced steel core for food processing machinery. The modular system of standard components Robomec, a product for making aluminium structures for the industrial automation, comprises two important series: A.S. (Assembly System) and P.S.M.S. (Standard Modular Protection System). A.S. is a modular system of standard components for the manufacturing of mechanical constructions, ergonomic workstations, partition and communication walls. It is applicable to many industrial sectors and allows a huge number of workbench types. P.S.M.S. is a system for creating perimeter safety barriers fixed to the ground around work islands, palletizers, automatic machines and robots that allows a quick and problem-free assembly of the guards. In addition to P.S.M.S. Round (round profiles) and P.S.M.S. Square (square profiles), Bett Sistemi has enriched its range with a solution specially designed for the food and chemical sector: P.S.M.S. Inox Glass.

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X-ray technology for Bosello High Technology

Bosello High Technology, a company working in the field of non destructive testing since more than 30 years, has presented the new industrial X-ray equipment SRE M@X, designed for inspection programs easily developed by the operator and featuring the highest technology. The new brushless motors with integrated electronic control do not need to search for the zero point, can move quickly and work silently. The image, coming from a Mega-pixel digital camera is displayed on a high resolution touch screen monitor together with the user interface that incorporates all the processing software developed to improve the image quality and help the operator find out the defects. The new control unit is totally integrated in the x-ray generator. A new generation of master controllers allows to check castings with size up to 700x1200 mm and maximum weight of 80kg in a relatively compact cabin. The mobile and ergonomic console connected to the cabin contains all the electronics and reduces the installation time. Safety is granted by the safety barriers located in front of the door that moves with decelerated movements.

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The new TOX® technology for the freddo delle lamiere

TOX® Pressotechnik is specialized in the cold-forming process through sheet metal deformation. The TOX® sheet metal joining system using a punch and a 2 matrix (or 3 in some cases) delivers plates of varying thickness and different materials, even high tensile steel. The sheet metal is not cut thus preserving the surface coating. Joining with adhesives is also possible. The procedure is extremely simple and the equipment pneumatically or electrically driven. The electrical powering allows a great variety of usages avoiding manual settings of the machine and helps optimise the time and control the procedure. This translates into a significant growth in productivity. TOX® Pressotechnik has recently expanded its product range by introducing the TOX® rivet. Its simple geometrical form makes it inexpensive, easy to use and increases the resistance of the joint. The static and dynamic resistance is greater than other similar systems. It has been successfully tested and has undergone crash tests.

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Alufin vibrofinishing for deburring of automotive products

The automotive sector is very familiar with problems associated with aluminium pressure die casting and the deburring of items even large-sized ones. Rollwasch has dealt with these problems and found interesting and inexpensive technical solutions. The Alufin treatment for example can carry out quick vibrofinishing cycles on aluminium items with small burrs, approx. in 5-6 minutes time. Of course, each case is different but according to the experiences made up to now, satisfaction is guaranteed. The photo shows the result on an item for cylinder heads meant for PSA. Another version of this kind of treatment is that of employing, in special cases with complex geometries that need thorough treatment, the so-called “polytropic” systems that can solve two aspects: cover particularly delicate areas or subject to possibile joining and at the same time remove burrs in very short time and with successful results. Through the Alufin treatment with vibrofinishing machines or hypertropic frame it is possibile to solve a wide range of problems of the automotive sector with aluminium pressure die castings and light alloys in general.