24 SHEET METAL - St. Joseph's Preparatory School...The Sheet Metal Skills Competition Provides a great opportunity for young people to measure their skills against others in the sheet

the complete range for the forging industry

Oststrasse 1D-77694 KehlGermany

Phone +49 7851 93 76-0Fax +49 7851 93 [email protected]

www.presstrade.com

24FASTENERSFASTENERSPSM InternationalOverviewPage 12

FORGINGFORGINGDecoupled analysis of die loads:Helpful tool in forging processoptimization?Page 13

STEELSTEELPlatts SBB update: Activity levels on the northwestEuropean coil market remainedmuted towards the end of MarchPage 19

SHEET METALSHEET METALSpaceClaim Engineer: a New Approach to 3D Sheet MetalPage 16

24

WIN

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2

£7.50ISSN 1759-5975

ISSUE

C o n f e d e r a t i o n o f B r i t i s h M e t a l f o r m i n g

MACH is owned and organised by The Manufacturing Technologies Association

The Confederation of British Metalforming pavilion at MACH 2012 is the ideal platform toshowcase your manufacturing capability and capacity to tens of thousands of decision makersand buyers looking to expand their metalforming processes.

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THE PRESIDENT’S REVIEW

1www.britishmetalforming.com

“I must admit, although I always try to take a positive andupbeat view on life, it’s been increasingly hard in recentmonths, largely because the national media seem todelight in finding negative news, and making pessimisticpredictions.

“Eventually, this drip-drip effect makes people believe oureconomy is doomed to enter a second phase of whateconomists call ‘negative growth’, and such a mindsetthen begins to affect business decisions; especially aboutinvestment.

“I work for Hadley Group - the UK’s largest cold roll-forming business - and we’re feeling very positive, notbecause we’re naïve about the present economicchallenges, but because we see them as hurdles to beovercome, not impossible obstacles.

“The rising cost of raw materials is certainly a challenge,but if you take the long view, such increases are cyclical,and after a period of rising prices, there is always a fall -even if not quite back to the previous level.

“I think we all need to adopt a more positive mindset, toignore the gloomy headlines, and to focus with renewedenergy and tenacity on what we can do to make thingsbetter.

“Take apprenticeships, for example. We know we need toattract the brightest and the best youngsters to ourindustry, but so many people seem to considerrecruitment as a negative cost.

“I believe we should see apprentices as an investment -in the future of our own companies, and in the future ofBritain’s manufacturing and engineering sectors.

www.britishmetalforming.com for the latest news, events & features

METAL MATTERS ISSUE 24 ONLINE NOW!

CBM STAFFPresident

Barry Yeomans president@@britishmetalforming.com

Chief Executive Dennis Kent [email protected]

Company Secretary / OperationsGeraldine Bolton MCMI, Dip.OCR, MAAT, [email protected]

Forging Sector SpecialistDr Ken Campbell [email protected]

Fastener Sector SpecialistDr John [email protected]

Sheet Metal Sector SpecialistAdrian Nicklin [email protected]

AccountsChris Smith [email protected]

AdministratorDebbie [email protected]

Marketing & Communications ManagerKirsi Lintula BA(Hons), [email protected]

IGNORE THE doom-mongersand focus on theFUTURE

“Of course, youngsters who arrive fresh from school or higher education can not have a significant immediateimpact as they acquire new skills and expertise, but the pendulum soon swings, and they move from being acost to being a contributor.

“Even during their apprenticeships, they can approach issues with fresh eyes, and minds uncluttered by decadesof baggage about how things ‘should be done’.

“I well understand - especially for the smallest firms - that it is a brave decision to commit to taking a youngsteron for four or five years, but if an employer can not afford the cost of an apprentice, perhaps two companies couldset up a joint training programme or perhaps through a trade association such as CBM.

“It may sound radical, and it wouldn’t be easy to create such a structure, but if we don’t look to seek such innovativesolutions, then we will stagnate as an industry.

“Since Abraham Darby’s Coalbrookdale furnaces heralded the start of the Industrial Revolution, Britain’smetalforming sector has been famed worldwide for innovative products, craft skills and its remarkable ability tosurvive.

“Now more than ever, we need to bring those qualities to bear, not just to devise new products, and win newcustomers, but to address the biggest challenge of all - persuading talented and enthusiastic youngsters that wecan offer them interesting, enjoyable and satisfying careers.”

Barry Yeomans

CBM president

CONTENTS

2 www.britishmetalforming.com

•The President’s review•CBM staff

•CBM membershipNEWS•Businesses in the Black

Country can bid for £1bn•Engineering business up

with the arrival of 2012

NEWS•Members news

1 4 5 6 7

ENERGY•Innovation Award

for MAX

FASTENERS•EC terminates anti-

dumping action onstainless fastenersfrom India

FASTENERS•Changes on the way to

ISO nut property standard•The Steel Index launches wire

rod price change index

FASTENERS•PSM Overview

FORGING•Decoupled analysis of

die loads: Helpful tool in forging processoptimization?

8 10 11 12 13

SHEET METAL•SpaceClaim Engineer:

a new approach to 3D sheet metal

SHEET METAL•CBM Event:

Resistance weldingtraining courses for CBM Members

STEEL•Platts SBB update

COLD ROLLED•The need of advanced

material testing methods with respect to the accuratefem simulation of bendingprocesses

BUSINESS SUPPORT•CBM has appointed

Wolverhampton based R and D tax reclaim specialists R&D Tax Claims Ltd to act on its behalf in respect of R and Dclaims for CBM members.

16 18 19 20 23

Confederation of British MetalformingNational Metalforming Centre, 47 Birmingham Road, West Bromwich, West Midlands B70 6PY.

Telephone: 0121 601 6350 Enquiries: Kirsi Lintula, Marketing & Communications ManagerEmail: [email protected]: www.britishmetalforming.com

Designed by: Pineapple Comminication LimitedTelephone: 0845 177 1820Web: www.pineapplecommunication.co.ukTel: 0845 177 1820Email: [email protected]

All rights reserved. No part of this publication may be reproduced in any form or by any means, electronic or mechanical including photocopying, recording or any information storage or retrieval system without the express prior written consent of thePublisher. ISSN 1759-5975 Metal Matters Magazine is published by The Confederation of British Metalforming and designed by Pineapple Communication Limited.Every effort has been made to ensure the accuracy and reliability of material published in this magazine. The Confederation of British Metalforming, Pineapple Communication Limited and its agents do not accept any responsibility for the views or claimsmade by contributors in the advertising or editorial content. © The Confederation of British Metalforming 2010 © Pineapple Communication Limited 2010

NEWS•Advanced Manufacturing

Supply Chain Initiative

HEALTH & SAFETY•RWG Safety & Environmental•REACH Update,

February 2012

CONTENTS


INSURANCE•Reviewing the relationship

MEMBERSHIP DIRECTORY•Manufacturer members•Supplier members•Commercial suppliers

25 27 2824

DIARY

DATES

• IOSH Safety for Senior Executives 15 March The IOSH Safety for Senior Executivescourse is a one day course aimed atDirectors and Senior Executives (notmanagers).

• Euroforge Meeting22-23 March

• CBM Sheet Metal Sector Meeting29 MarchCBM Sheet Metal Sector meetings provide members and associates with the opportunity to meet and talk to seniormanagers and directors from other similarmanufacturing companies, and at the same time receive presentations on topics of current interest.

• MACH 201216 - 20 AprilMACH 2012 takes place at the NEC, Birmingham.

• SBB Green Steel Strategies Conference19 AprilDefining a common perspective for a future sustainable steel industry

• CBM Forging Sector Meeting24 April Forging Sector meetings provide membersand associates with the opportunity to meet and talk to senior managers anddirectors from other similar manufacturingcompanies, and at the same time receivepresentations on topics of current interest.

• Fastener Fair Hannover 24-26 April

• CBM H,S,&E Group Meeting09 May The CBM H,S,&E Group meet quarterly to discuss relevant H&S issues. The recent Accident Reduction inMetalforming Sector (ARMS) initiative has embarked on a strategy to reduce the accidents in the sector andsubsequently reduce insurance premia.

• Eifi Congress - 01 June • IOSH Managing Safely

06 June 'Managing Safely' is the nationally recognised H&S qualification for managers, supervisors and team leaders in any sector or organisation.

• IOSH Safety for Senior Executives07 June The IOSH Safety for Senior Executivescourse is a one day course aimed at Directors and Senior Executives (not managers).

• Subcon 201212 - 14 JuneThe next Subcon will take on June 12-14, 2012 at the NEC, Birmingham

• ISME Sheet Metal Skills Competition14 JuneThe Sheet Metal Skills CompetitionProvides a great opportunity for youngpeople to measure their skills againstothers in the sheet metal industry.

• IOSH Safety for Senior Executives06 September The IOSH Safety for Senior Executivescourse is a one day course aimed at Directors and Senior Executives (not managers).

• IOSH Managing Safely12 September 'Managing Safely' is the nationallyrecognised H&S qualification for managers,supervisors and team leaders in any sectoror organisation.

• International Trade Fair for Metal Working18 September Fully booked halls are again expected atAMB 2012, with over 1300 exhibitors on anexhibition area of 105 000 square meters.

• EuroBLECH 2012: Booking statusreflects recovery of sheet metal working industry23 - 17 October 2012The 22nd International Sheet MetalWorking Technology Exhibition,EuroBLECH 2012, in Hanover, Germany.

• IOSH Safety for Senior Executives29 November The IOSH Safety for Senior Executivescourse is a one day course aimed at Directors and Senior Executives (not managers).

• Fastener Fair Russia12 March 2013Fastener Fair Russia to be launched in St Petersburg, Russia.

For further informationor to book a place please visit:

www.britishmetalforming.com/events.aspx

BUSINESS SUPPORT•Diamond Jubilee•Workplace pensions...

Changes ahead from 1 October 2012

HEALTH & SAFETY•CBM Event:

IOSH managing safely•CBM Event:

IOSH safety for senior executives

CBM is THE leading trade association for UK manufacturers of fasteners, forgings andpressings; the very building blocks of UK manufacturing

Contact CBM now for a freesubscription to our membership

magazine - Metal Matters

CBM MEMBERSHIP….What’s in it for you?

Confederation of British Metalforming • National Metalforming Centre • 47 Birmingham Road • West Bromwich • West Midlands B70 6PY

0121 601 6350 [email protected] www.britishmetalforming.comtt ee ww

CBM members provide high quality components to key industry sectors;indeed virtually every manufacturing sector buys components from a CBMmember company.Working with members, and the UK government CBM creates a world classmetalforming supply base for UK manufacturing.Maintaining close links with UK Department for Business, Innovation andSkills (BIS), Transport and the Regions, and the Health & Safety Executive,CBM ensures that the members' interests are represented in theconsultative processes which precede legislative or regulatory initiatives.

Membership of the CBM includes a wide and growing range of free anddiscounted services, designed to save you money and help your businessoperate more efficiently:

•REBATES on your Climate Change Levy•FREE employment law helpline•Monthly market reports•FREE technical helpline•Health and safety officer service•FREE publications•And many more….

CBM MEMBERSHIP


To be part of the wider picture and be masters of your own identity…

contact CBMNOW!

NEWS


T here was a big increase in the number of firms reporting orders up in Januaryaccording to the EAMA Business Monitor.

Martin Walder, EAMA chairman: “Following the downbeat news on export ordersrecorded in the Monitor at the end of last year, January’s bounce-back producedpositive balances on export orders as well as UK business.” (UK +18% and +24%on export orders).

“Compared to November, our previous reporting period, the export numbers are reallyencouraging with gainers up by a third and fallers down from one in three to one in six.”

There’s also better news on jobs and investment in the Monitor.

Getting on for a third (29%) of firms say they have more job openings giving anoverall balance (between firms offering more jobs and those cutting numbers) of+21%, which is the highest it’s been since September 2011.

January also saw a big increase in investment intentions with 42% saying they areinvesting in all areas of their business, which is up 6% on November and the highestsince June 2011.

This increase occurred at the same time as an apparently similar decrease inavailability of finance as significantly more companies recorded difficulties inaccessing finance (21% for working capital and 27% on investment capital).

Martin Walder again: “The inferences here may be that companies are using theirown funds or perhaps what they consider to be unconventional sources.

“It’s certainly a surprise to see such high investment figures counterbalanced by thebiggest increase in difficulties we’ve recorded in accessing finance since 2009.

“Despite the disappointing off-colour financial context, confidence is returning tofirms in the sector, which is good news with MACH 2012 scheduled at theBirmingham NEC April 16-20th.

Black Country businesses are being invited toapply for a slice of a £1 billion governmentfund aimed at creating private sector jobs.

There is a deadline of June 13 for bids for the third round of theRegional Growth Fund.

The Black Country Local Enterprise Partnership is encouragingcompanies to apply for funding after other local firms weresuccessful in previous rounds.

Black Country companies have been allocated £9.6 million to allowthem to expand their business operations, with a further £54.7 millionof investment provided by the companies themselves. The projectswill create and safeguard 700 jobs.

Companies can visit the LEP website at www.blackcountrylep.co.ukto download a RGF factsheet which contains further details of theeligibility criteria of the fund and provides contact details of theBlack Country RGF team.

Stewart Towe, chairman of the Black Country LEP, said:

‘The Regional Growth Fund presents another fantastic opportunityfor Black Country businesses to bid into a fund that could bringforward their growth plans. This growth will of course provide jobopportunities for the people of the Black Country and improve theBlack Country as a place to do business.’

Businesses in the Black Countrycan bid for £1bn

The Regional Growth Fund aims to stimulate private sector invest-ment by providing support for projects that offer significant potentialfor long-term economic growth and the creation of private sector jobs.

Bids are competitive and must be made for a minimum of £1 millionunless the application is part of a package of projects.

Source: Express and Star – 28 February 2012

2012Engineering business up w

ith the

arr

ival

of 2012

January export orders up according to the

EAMA Business Monitor

NEWS


members newsBarrett Strip and Alloys new printing technology torevolutionise spiral wound gasket traceability Barrett Steel’s Strips & Alloys business has developed andproduced new printing technology that revolutionises the spiralwound gasket industry by giving it a level of traceability neverseen before.

As well as allowing full traceability from completed gasket all the way back tothe producing mill, this new state of the art printing technology can assist withlicensee auditing to ensure only approved materials are being used. The technologyassists in detecting and preventing fraudulently manufactured gaskets, and byproviding clear identification of material grade and heat number helps to preventcross contamination. Manufacturers using the strip will have a major qualityadvantage over their competitors.

The new technology represents a huge improvement on the general standard, whichis to put a sticky label onto a plastic spool or pancake. This label can fall off orbecome unreadable, completely removing all traceability. Similarly, the higheststandard available, which involves colour coding the strip before adding a stickylabel, can lose traceability if the label is lost or unreadable, even if the colour codestill identifies the grade of material.

With Barrett Strip and Alloys new development a finished gasket retains its identityand traceability.

Initially the technology will be available to an exclusive selection of customers inappreciation for their support during the development phase, while plans are inplace to introduce the technology to the open market later this year.

More information on the benefits of Barrett Steel’s new printing technology isavailable from Paul Massey, t: +44 (0)1274 260820, e: [email protected]

www.barrettstripandalloys.com

A hat trick of award nominations! Professional Polishing Services Ltd the UK’s market leader in stainlesssteel surface finishing, are finalists in not one, but two, regional business awards and their Managing Director, Kirsty Davies-Chinnock has also beennominated for the regional IOD SME Director of the Year.They have been chosen as finalists in the categories –Manufacturing Champion and Green Business in the Expressand Star Business of the Year Awards.

In the category of Manufacturing Champion it was the passionexhibited by their MD, Kirsty Davies-Chinnock that impressedthe judges. “Manufacturing is not a dirty word!” said Kirsty “AndUK Manufacturing is proving to be the bright light in a fog offinancial doom and gloom.”

PPS are also finalists in the category for Green Business andexplained that manufacturing can be Green and that it bringspractical and financial benefits for the Company. From investing in energy efficientcompressor systems with the help of the Carbon Trust, to re-cycling everythingfrom notepaper to strapping, the company take their green credentials very seriously.

Kirsty was the recipient of the Attwood Award in 2009 for services to manufacturing.www.professionalpolishing.co.uk

FOR GENERAL ENQUIRIES OR TO ADVERTISE ON THIS PAGE PLEASE CONTACT

KIRSI LINTULA [email protected]

• Barrett Steel’s new printing technology provides full traceability of spiral wound gaskets.

LOOKING FOR EMPLOYMENT -

If you are looking for employment you can advertise

in the Metal Matters and/or CBM website

A candidate with a strong forgings background which includesproduction/ operations management and account management/sales is seeking employment.

Ideally looking for an account management type role althoughoperations or general management positions would also beconsidered especially in the forging sectors.

An extensive manufacturing and a sales background gained in the metals andengineering industries around the world has enabled a unique insight into bestpractice, modern production process routes, commercial awareness and globalcompetition. Results have always been achieved by strong management ofpeople and situations.

Sales and production management experience stems from 12 years in theforging industry followed by a further 10 years in the metals and metalprocessing sectors. Starting off on the shopfloor and progressing through tosenior management has enabled a unique insight into processing routes, qualitysystems, sales processes and business development.

For further information please call Kirsi Lintula at CBM on 0121 601 6350 or email: [email protected].

EMPLOYMENT WANTED


NEWS

You may be aware that the Technology Strategy Board has released advance notice of a £125m AdvancedManufacturing Supply Chain Initiative. Details are available online:

http://www.innovateuk.org/content/competition/advance-notice-advanced-manufacturing-supply-chain.ashx

T he fund will support applications that deliver economic growth in the advanced or high valuemanufacturing sectors, or in newer growth areas where the UK is well placed to takea global lead, such as energy renewables and other low carbon sectors. It provides

a flexible approach to funding (grants and loans) and is designed to promote closercollaboration within the supply chain and to address market failures. In practicalterms funding will be available to support the following areas, subject to the normalState Aid rules:

- The purchase of capital equipment

- R&D activity which improves manufacturing equipment, systems or processes

- Specific training and skills development to support the project.

Information on opening and closing dates, the competition brief and guidance forapplicants will be available on the TSB website shortly. Briefing(s) will be held forpotential participants and will take place once the application process timetable hasbeen confirmed.

Advanced Manufacturing Supply Chain Initiative


ENERGY

Powerstar MAX, the innovative new voltageoptimisation solution from the UK’s leadingmanufacturer of energy saving solutions EMS, has

won the Innovation of the Year award at the Yorkshire PostExcellence in Business Awards.

Powerstar MAX, which is specifically designed for siteswith high levels of voltage fluctuation and volatility, wonthe prestigious award ahead of entries from fellow finalistsQ8 Oils and Premier Farnell.

In addition to the energy savings, carbon reduction, phasebalancing, harmonic filtration and transient protectionoffered by EMS’s standard Powerstar system, thePowerstar MAX offers electronic-dynamic optimisationto ensure the optimum voltage is always supplied to a site.

Manufactured in the UK, all the components for thesystem are sourced in the UK. Powerstar MAX is alsothe only voltage optimisation system in the world to be granted a patent on its design.

The new technology does not supersede the original Powerstar system but offers analternative solution to businesses whose site characteristics are unsuited to fixedvoltage optimisation.

EMS is the UK’s most experienced manufacturer of voltage optimisation systems,having already successfully installed solutions for Whitbread, Asda, the NHS,Transport for London, Holiday Inn and Mothercare, amongst others.

UK MADE, HIGHEST EFFICIENCY PATENTED DESIGN

100% British Engineered. 100% Guaranteed Results.

Suppliers to Whitbread

100% B i i h E i d 100% G d R l100% British Enginneered. 100% Guaranteed Results.

• Dr. Alex Mardapittas, managing directorEMS receiving the Yorkshire PostExcellence in Business Innovation of the Year Award for Powerstar MAXfrom Nick Clegg, deputy prime ministerand Jon Culshaw, comedian.

Innovation Awardfor MAX

Gas and power prices increased by about 20% in 2011 and are continuing to rise in 2012. Manufacturers therefore need to be proactiveand start planning now in order to renew their 2012/13 energy contracts at the most competitive price. Whether following a fixedor flexible procurement strategy, businesses need to monitor the energy market on a regular basis to be able to identify the right

time to buy.

Energy Market Tracker service

CBM is offering all members access to a FREE Bespoke Market Tracker service from ENER-G, to monitor the wholesale market and providean estimate of their next contract renewal price.

An intelligent tool

Intelligent energy buyers will begin to watch the energy market and plan to secure a newcontract well before termination of the current one. The Bespoke Market Tracker report

will inform manufacturers about how the current wholesale market prices will affecttheir future contract renewal price, providing an insight into when to take action. It

also helps them budget and forecast for the coming year.

How it works

The Bespoke Market Tracker service is a simple, one-page report that provides an estimated view on how much higher or lower an organisation’s nextenergy contract will be - making a direct comparison between the cost of theircurrent one and the probable cost of their next renewal, using current wholesale market prices.

To sign up to the Bespoke Market Tracker Service please [email protected] or call 01527 855072.

How to beat rising energy prices in 2012

FASTENERS


O n 16th January 2012, the European Commission issued aGeneral Disclosure Document stating that it intends toterminate its anti-dumping proceeding against imports into

the EU of stainless steel fasteners originating in India. This actionwas originally initiated following a complaint lodged by the EuropeanIndustrial Fasteners Institute (EIFI).

The EC document gives the details of the reasoning behind thedecision. The investigation, which took place between April 2010and March 2011, found that for 87% of Indian imports, which theyclaim come from a single company, they could find no evidence ofdumping. For those companies where evidence of dumping wasfound, the dumping margin was calculated as 24.6%. But thesedumped imports had a market share of only 2% during the period ofthe investigation, and their prices were 12% higher than those of thenon-dumped Indian imports. For these reasons, the Commissiondecided that it was not appropriate to impose anti-dumpingmeasures.

The Commission conducted a parallel anti-subsidy investigation, andissued the results in Regulation 115/2012 on 9th February. Importduties have been imposed against all the specified stainless steelfasteners imported from India, the default rate being 16.5%. Butagainst the main producer the rate is only 3.2%, which is unlikely tohave any significant effect.

Imports from India into the EU have shown a spectacular increasein recent years, as shown in the chart below. Products from Chinaand Taiwan showed a large rate of growth between 2002 and 2004,but since anti-dumping tariffs were applied against them by the EC

in 2005 there has been significant shrinkage of their imports.Meanwhile the rate of growth of Indian imports since 2005 has beenspectacular, and the EC found that India’s market share during itsinvestigation period was now 18.3%. In contrast the market share ofproducers in the EU is reported as falling from 46.5% in 2008 to36.6% in the investigation period, and the employment in theindustry has fallen by 24%. Unfortunately, since average prices forstainless steel fasteners from India are about 30% lower than thoseproduced in the EU, there seems little to stop these adverse trendsfrom continuing. Certainly the EC decisions reported above will haveno effect on the continuing devastation of the stainless fastenersindustry in the EU.

EC terminates anti-dumping action on stainless fasteners from India

Stainless steel fastener imports into EUNB. 2010 data is from the EC investigation period

FASTENERS


Changes on the way to ISO nutproperty standard

The final draft of what will become the new ISO 898-2 has beencirculated by ISO and has been approved by the BSI fastenerstandards committee. This is the basic mechanical property

standard for nuts with metric threads, and there are some significantchanges.

The most obvious change is that it replaces two existing standards.BS EN 20898-2:1994, ISO898-2:1992 which covers nuts with coarsemetric threads is rewritten, and also BS EN ISO 898-6:1996 for nutswith fine pitch thread is now incorporated into the same standard.So this document will cover standard nuts with coarse threads ofdiameters M5 to M39, and fine threads from M8 to M39.

ISO/FDIS 898-2 Mechanical properties of fasteners madeof carbon steel and alloy steel – Part 2 Nuts with specifiedproperty classes – Coarse thread and fine pitch thread.

The Steel Index launches wire rod price change index

In January, The Steel Index (TSI) announcedthe launch of a price change index forEuropean cold heading boron alloyed steel wire rod, a material widely used in the

manufacture of fasteners for automotive and other industrial applications. This newindex will extend TSI’s existing range of steel, scrap and iron ore reference prices,widely used by industrial companies and financial markets around the world.This index is based on the data developed by the Deutscher Schraubenverband (DSV),the German fastener manufacturer’s trade association, which has been published onthe DSV website and is widely used in the UK, not only by fastener manufacturersbut also by their customers. The increment of price is captured rather than the priceitself, since different manufacturers may experience significant variation in actualprices because of volume and other requirements. TSI states that boron alloyed wirerod can account for up to 70% of the sales price of some fasteners, so the index willsignificantly increase the efficiency of the purchasing process for fastener buyers andtheir suppliers. From the point of view of the manufacturer, because the data isadministered by a respected third party (not a fastener trade association) it has thepotential to facilitate the process of price increase negotiation that has always beenso difficult.The index is compiled and published monthly, expressed in Euro per metric tonneand reflects the delivered price change from October 2010 (base period). Initially itis intended to base the index on data submitted by German, Italian and French steelmills and fastener manufacturers, with the intention to extend the scope in the futureto include transactions in other European countries.CBM believes that DSV will eventually withdraw the freely available price change datafrom its website.Further information on the new index can be obtained on TSI’s website at:www.thesteelindex.com/wire-rod/ or by contacting Virginia Mainwaring at The SteelIndex on 020 7176 7658.

This is a comprehensive revision of the existing standards and there are several technical changes. Style 0, for thin nuts of heightsbetween 0.45D and 0.8D, has been introduced (D being the nominaldiameter) alongside style 1 for regular nuts and style 2 for high nuts. There have been changes to the ranges of nominal diametersin relation to nut style and property classes, and the guidance for matching nut designs and property classes with those of ISOmetric bolts has been enlargedand clarified.

The material compositions tablefor the various grades and styleshas been enlarged, with changesto the minimum manganese, and maximum phosphorus andsulphur in some grades. Mech-anical property tables have beenrearranged and are easier tounderstand, and the hardness tables now include Brinell andRockwell values rather than referring to a conversion standard. Thesection on property test methods has been amended and expanded,and there are now requirements for dimensions and hardness of testtooling which did not appear previously.

The modifications to the existing two standards appear to be sensibleand logical, but manufacturers will need to ensure that they complywith the adjustments to steel chemistry and modifications to testrequirements. There is also the possibility that some parts in stockmay not totally comply with the changes. But since the basic propertyrequirements of the nuts have not been modified, there should besome confidence that any nuts in stock that complied with themechanicals in the previous standards should also comply with this one.

AMC (UK) Fasteners LtdUnits 3 & 4 Darwin Road, Willowbrook Industrial Estate,

Corby, Northamptonshire NN17 5XZTel: 01536 271920 Fax: 01536 271929

[email protected]

AMC are a UK nut manufacturer, producing Hexagon, Square & Round Parts.

Quality approved to BS EN ISO 9001 and TUV AD2000 Merkblatt WO TRD 100

Supplying PPAP Level 3 and full ISIR assurance.

• Weld Nuts• All Metal Locknuts• Wheel Nuts• Flange Nuts• Lock, Castle & Slotted Nuts

• Petrochemical Nuts ingrade 2, 2H, 4, 7 8 & 8m

• Heavy Series Nuts• HSFG Nuts• Customer Specials

To name just a few.Produced in Carbon & Stainless Steels

All normal accepted finishesPlease visit our website for further details

www.amcukfasteners.co.uk

PARTS INCLUDE:


FASTENERS

rofilePompany

Following the acquisition of BAS Components Limited byPSM International in December 2010 the business haveoperated largely autonomously throughout 2011 however

a full integration of the BAS entity into the PSM entity took place1st January 2012. The integration provides a great opportunity tostrengthen the two key ingredients of business performance,these being people and processes. Under the new leadership of CEO Paul DeMand (joined May 21011) the key focusfor the business globally is sustainable and profitable growth in both establishedmarkets of North America, Europe and Asia through a combination of competent andmotivated direct technical sales staff, established and respected Joint Ventures andcore distribution partners. To support its organic growth PSM International is activelyseeking to expand its route to market by engaging new partners in all 3 areas as wellas exploring opportunities to enter key emerging markets.

The key focus for the group is being prioritised to ‘manufactured/designed in’applications which effectively translates to PSM working closely with design engin-eering as well as manufacturing and purchasing resources at the OEM and tiercustomers to ensure it maximises the utilisation of the groups global manufacturingfacilities.

PSM has a newly structured Leadership Team with defined regional ManagingDirectors who have full P&L responsibility for the region and are supported by localand global technical and management teams. One of PSM’s core competencies andUSP’s is undeniably the technical strength of its people and product offering. Theextensive product range of Inserts for Plastics (IFP), Sheet Metal Fasteners (SMF),precision turned parts and cold forming technology combined with effective feed-system and in-die technology offers customers around the globe a real valueproposition in fastening technology.

by

Lee Timbrell,Managing DirectorEurope

PSM InternationalOVERVIEW

PSM is continually driving improvement in all areas of its business with some veryencouraging results being experienced. R&D into new materials and fasteningsolutions remains a high priority and is headed up by the Global Technical DirectorPaul Martin. Paul who is based at the Technical Centre in Bilston, UK has decadesof extensive and highly valued experience in the fastener field. The latest developmentis a range of aluminium inserts which provide ‘light weight cost effective processsavings’ when compared to the more traditional brass inserts. PSM is excited aboutits customers’ reaction to this latest technology offering and rapid growth is expectedacross several market sectors including automotive.

The global footprint of PSM is a key advantage for similarly structured OEM and tiercustomers who require local support for all their operation. The business’ future islooking very bright despite the general economic doom and gloom predictionsemanating from the global media with each PSM region predicting significant growththroughout 2012 stemming mainly from nominated and secured business and the teams globally are motivated and focused to execute the opportunities that are being presented.

www.psminternational.com

• Manufacturing team


FORGING

Decoupled analysis of die loads: Helpful tool inforging process optimization?By: Michael Wohlmuth, simufact engineering gmbh, Hamburg, Germany

Dr. Hendrik Schafstall, simufact engingeering gmbh, Hamburg, GermanyAndreas Hagen, simufact engineering gmbh, Hamburg, Germany

1. General differences in tool analysis

A tool analysis via finite element simulation can generally be effected in two ways.On the one hand, there is the coupled analysis, on the other hand there is thedecoupled analysis.

Within the coupled simulation, the component as well as the tools to be examinedare discretized. As a rule, this concerns only those tools which you want to checkwith regard to stress, strains and other process factors, and not all tools of the formingprocess. All other tools can also be modeled as rigid bodies in a coupled analysis. Itis therefore possible to get a mixture of deformable and rigid tools, which makessense regarding an increased performance.

The other approach, the decoupled analysis, is featured by effecting a primary formingsimulation (material flow simulation) with solely rigid tools. The physical conditionin the contact area (normal tension, shear stress as well as other variables) is“preserved”, i.e. saved for each increment.

A separate (decoupled) simulation, which does not view the material flow any morebut merely bases on tools being a model for structure analysis with alternate boundaryconditions, considers only the dies. The selected and saved physical conditions ofthe contact area serve as boundary loads at the moment you view the increment.

Both approaches have advantages and disadvantages. The decoupled simulationdefinitely is the faster variant because a material flow simulation with rigid tools (andthus without a so-called “deformable-deformable” contact) shows significantly lessvariability and calculates more robust in contact.

On the other hand, the coupled analysis considers the elastic flexibility in everyincrement, so that this approach has to be regarded to be the more realistic one.

Due to the advantages and disadvantages - “speed of calculation versus precision” -it turned out that the coupled analysis, which does not have important influence onthe calculation speed, was good for 2D and axial symmetrical models, while thedecoupled analysis is chosen for 3D models only, because in these cases, calculationtime has the first priority.

This will be qualified within short when the new parallel functionality based on the‘Domain-Decomposition-Method’ (DDM) will be available with Simufact.forming10.0. Here, different tools can be written in separate domains as ‘deformable bodies’.This approach will show a minimum increase of calculation time only. Exact resultson this aspect will be published later on.

2. Configuration of a decoupled tool analysis

Prerequisite for the tool analysis is a forming simulation of the forging process atfirst. This should be effected with the same discretization for tool surfaces which willafterwards be used for tool analysis. To do so, the tools have to be imported into theforming process with the option “Quality-Facets”. This happens by reading in the

geometry data by means of the CADfix-interface and thus guarantees a sufficientprovision of facet nodes on the tool surface for a posterior volume mesh. A geometryimport with the standard STL faceting as exported by most of the CAD systems is notenough to meet the necessary demands for quality (Fig. 1 and 2).

(a) (b)

Fig. 1: Tool import with quality-facets

(a) (b)

Fig. 2: STL-tool import

Tools in bulk metal forming processes evidently are under considerable stress. Due to these high loads, die failure may arise.

Rupture and failure of dies often burst all previously calculated production costs. After such an incident, a profitable manufacturing of forgingparts is partially not guaranteed any more. Moreover, the customer has to be confronted with a delayed delivery of parts.

Process optimization to reduce the tool load is most difficult in practice, requires dedicated experts knowledge and can typically be realizedthrough many physical try-outs with several optimized tool variants only.

Forming simulation is able to indicate the peak stress within the forming process, to contrast the existing conditions with optimized variantsand thus to reduce the number of trials on the forging aggregate.

In this paper, we want to present the approach of decoupled die load analysis with Simufact.forming and to give some useful hints.

continued on page 14 ●●●●>

FORGING


After completion of the forming simulation using the “Quality-Facet” tools, a toolanalysis is effected by copying the forging process without results. The properties of the copied process then have to be converted from the original process type, e.g. “die-forging”, to “tool analysis”. Results of the forming simulation which shalllater be applied for the tool within the tool analysis, can now be selected. Allincrements of the process simulation can be selected e.g. in order to study thecontinuous tool behaviour under load; but is it also possible to make an individualselection of increments in case a single critical process stage hast o be optimized.

Afterwards, all no longer required components will be deleted from the tool analysis.

The remaining tool to be calculated is converted from “rigid body” type to“deformable” type. Now, material parameters have to be assigned to the deformabletool from the standard material data base “Tool-Steel”.

It is mandatory to insert a constraint to the tool in order to define the conditions ofinstallation (similar to the fixation at the forming aggregate) in order to clamp the dieand to prevent a translation when applying the forming loads. Activation of the contacttype “Glued” between tool and constraint in the contact table quasi effects a "screwing"of the tool. After thus fixing the tool, the analysis can be started.

3. Meshing of the tools

With the option “quality facets”, geometry data will be read in by means of the CADfix-interface. The number of generated triangle elements on the surface should not exceed100.000. This value is on the one hand sufficient for an adequately precise descriptionof the tool geometry and the necessary number of sampling values, on the other handis ensures a subsequent fast tool analysis. Higher values would lead to unnecessarybig model sizes in the volume meshing.

The input of the facet-sag value when importing with CADfix is decisive for the numberof facets. Fig. 3 shows the different number of facets using the parameter ‘Facet sag’0,2 and 0,05 mm” of the imported drive rod tools.

(a) (b)

Fig. 3: Tool import with different parameter setting(a) 76.690 Facets with Facet sag 0,2

(b) 275.240 Facets with Facet sag 0,05

The suitable import parameter setting can interactively be tested in a very fast andsimple way. The tool designer will very quickly find a value which he should generallyand ideally use for his tools.

Sometimes, complex tool geometries show faulty transitions between the facets. Thesefaults which can be attributed to the modeling within and the export from the CAD-system can be corrected and mended with an STL-repair program (e.g. CADfix,netfabb, Magics) before their use in forming simulation. After insertion of the toolsinto the model, the forming simulation can be started as usual. The automatic volumemesh is effected immediately after starting the simulation. Also, the boundaryconditions (clamping) are checked before the real tool analysis starts to finish theselected increments resp. results of the forming simulation.

4. Examples of use

In the following, some results of the decoupled tool analysis are shown using theexample of forging a drive rod. The process is effected after several rollreduceoperations which are not illustrated here. The results are demonstrated at the lowerdie of the pre and final forging operation.

(a)

(b)

Fig. 4: Pre forging of a connecting rod, shown here: tool contact (grey) (a) start and (b) end of forming

Fig. 5: Tool analysis of lower die with 88% forming of the pre forging operation, shown here: maximum principal stresses (red = tension stresses; blue = compression stresses)

<●●●● continued from page 13


www.britishmetalforming.com 15

(a)

(b)

Fig. 6: Final forging of a connecting rod, shown here: tool contact (grey)(a) start and (b) end of forming

Fig. 7: Tool analysis of the lower die with 97% forming of final forging operation, shown here: maximum principal stresses (red = tension stresses; blue = compression stresses)

In another example of hot forging processes, the results of the decoupled tool analysisare confronted with a real picture of cracking belonging to a final forging lower die.

The final forging process is effected after a pre forging operation, which is notillustrated here. In a two-stage production the lower die of the final forging operationbroke after having produced a very low number of pieces.

Fig. 8:Maximum principal stresses of the lower die/final forging operation

(red = tension stresses; blue = compression stresses)

Fig. 9:Real rupture course of the final forging lower die

The calculation results of the decoupled tool analysis clearly show the complianceof simulation with reality.

5. Summary and perspectives

The decoupled tool analysis brilliantly shows the weak spots of the engravings withregard to arising peak tensions. In several projects it was possible to quickly optimizesome critical forging parts with tool ruptures. It is very important to import the tooldata correctly - this enables a suitable volume mesh for the tool analysis.

The actual state of software development offers a very good and suitable tool for asystematic tool optimization. There will however be further improvements here. Sowe bear in mind to integrate a utility into Simufact.forming to check the possibility of volume meshing before starting the proper forming and tool simulation. We alsosee a potential to optimize complex reinforcement toolsets in hot forging operations,which makes the design of these sophisticated tool concepts as easy as possible to model.


FORGING


SHEET METAL

SpaceClaim Engineer: a new approach to 3D sheet metal

By Dr Ihsan A Al-Zanki CEng, MRAes, Technical Director, CPI Technologies Ltd

Imagine a CAD tool that can read parts from any CAD system,

fixes dirty geometry, and won’t cost you a penny for training.

Okay, you can stop laughing now.

Actually, it does exist, and it’s called SpaceClaim. It’s a new CAD tool that’s becoming

the Metal Forming Industry’s secret weapon.

Well perhaps not so secret..............because in just a few years it has gone from zero to 20,000 users.

• A typical sheetmetal design as created by design engineers (right) and optimised formanufacturing in SpaceClaim (left).

• The full chassis for the design, nested in the Aptia Solutions Plug-In for SpaceClaim.

D edicated sheet metal manufacturers have traditionally had a mixed relationshipwith CAD systems. 2D flat pattern layouts are reliable and work well withmachine programming tools, but they are error-prone and time-consuming

to construct. On the other hand, current 3D solid modeling software leaves a lot to be desired for modern sheet metal businesses. Historically, solid modelingapplications could barely work with models from other CAD systems; they madeexploring flattening options difficult, and often lagged behind production capabilities.These systems were created for design engineers, not manufacturing engineers.

SpaceClaim have taken a different approach. They’ve come up with a morestraightforward way of doing sheet metal that caters to the needs of peoplewhose job it is to get parts out the door. We think they’ve made a tool that willdelight those who may have already looked at 3D but correctly decided that it wastoo frustrating or not cost effective. Here’s what they’ve done that’s different:

• They’ve learned that one of the hardest tasks is getting parts flattened. TypicallyCAD designers don’t know how to build great sheet metal designs. All too often,the models need to be completely rebuilt for manufacturing. SpaceClaim canread parts from CAD systems and turn them into viable sheet metal. It can turnsolids into thin-walled parts and turn thin parts into proper sheet metal. In canclean up and repair dirty geometry and heal the problems. It can recognizebends, forms, joggles, hems, beads, notches, gussets, and tabs. It’s the fastestpath to flat pattern.

• SpaceClaim can explore different bend options, turning bends to rips and vice versa while showing you the flat pattern in real-time, to create the lowest-cost pattern.

• It has tools for double walls, hinges, and other features modern machines canform. These capabilities can help you reduce part count and lower costs.

• Rather than being developed by people who’ve never seen a press brake,SpaceClaim’s sheet metal has been developed in partnership with and underthe watchful eye of the world-leading German Sheetmetal cutting and preparingequipment supplier Trumpf.

If you’ve tried to do sheet metal in 3D and found it wasn’t for you, you need to lookagain. No longer are high costs, and long and arduous learning curves involved.

A number of highly respected software development companies, having recognisedthe uniqueness of the SpaceClaim system within the manufacturing space, havedeveloped low cost software “plug-ins” to extend the functionality of SpaceClaim.One such company is Aptia Solutions Limited. A technology spin-off from theUniversity of Nottingham, Aptia have made their new generation Parts Nestingalgorithms available for SpaceClaim generated parts. Fast and efficient optimisationof sheet-usage has proven over and over again to be a key weapon in increasing profitmargins on jobs.

Aptia have also added further value to the SpaceClaim environment by looking at thefront end of the Sheetmetal process. Their SpaceClaim integrated “Fast Quote”solution offers easy, accurate, and most importantly, consistent job quotes that canhelp win profitable business. Not an easy task in the current economic climate!

On the broader front, SpaceClaim is also proving a success in other manufacturingarenas. The key drivers don’t vary; skip the complexity of traditional CAD systems;take in files from your customer in all popular formats and prepare the part/s for themanufacturing process in record time.

Use SpaceClaim’s simple but effective 3D Direct Modeling tools to: quickly createtooling and fixtures, create 2D cross-sections, de-feature and simplify models, plugholes, repair incomplete CAD data, clearly articulate machining steps with notes anddimensions, add/change fillets and rib dimensions on the fly (with or without draft),split parts, slice models and add joining features quickly and easily.

CPI Technologies Limited is a Midlands based partner for SpaceClaimin the UK and we would be delighted to show you just how productivethese solutions could be for your environment.

www.cpitech.co.uk

ACCREDITATIONS:ISO 9001:2008 • ISO/TS 16949:2009 • ISO 14001:2004 • BS OHSAS 18001:2007

Ryeland Toolmakers Ltdwww.ryelandtoolmakers.co.uk

Manufacturers ofhigh and low volume

components to all industriesMetal pressings: sheet metal: tube manipulation:

Welded assemblies: manual assembly and powder coating.

Tel: +44 (0) 1908 271940

(mkp) Maine Office Ltdwww.maine.co.uk

Milton Keynes Pressings Ltdwww.mkp.co.uk

MKP GROUP:

SHEET METAL


FOWLERS OF BRISTOL (ENGINEERS) LTD.

Electrical Enclosures,Aerospace & Automotive Components,

Decorative St. Steel Products,Welded Fabrications, Brackets, Clips & Tabwashers

STAINLESS STEEL & GALVANISED HANGING SYSTEMSFOR PVC STRIP CURTAINS AND DOORS

CNC SHEET METALWORKPRESSWORK

PRECISION MACHINING

TEL: 0117 9422563

FAX: 0117 9424770

www.fowlers-eng.com • [email protected]

In the current busy climate with sheet and pressedmetal companies we appear to have lost the basicskills and expertise in the assembly joining processmaking quality spot welds using the correct settingsand machines.After a successful training programme with a CBM member company, resistancewelding expert Bauromat have put together a Training Course Syllabus to suittechnicians and operators.

These training programmes can be completed at your company or at theBauromat Plant in Malvern. The choice is yours if you send one person or agroup of up to 5 personnel.

These will be a 1 day courses partly in the training room with course notes givenfollowed by a practical session around a spot weld machine.

Training programmes available:

• Practical Spot Welding.

• Practical Projection Welding.

• Practical Arc Welding / Robot Programming.

• Weld Monitoring.

• Fault Diagnostics.

• Optimum Tooling Materials.

• Basic Welding Technology.

• Quality Assurance.

• Good Operator Practice.

• Health and Safety.

• Equipment Maintenance.

• Equipment Familiarisation.

• Resistance and Arc Welding Process Practice and Theory.

• Destructive Testing of Welds.

• Electronic Control and Programme Setting.

Resistance welding trainingcourses for CBM Members

If you are interested in participating please contact Adrian Nicklin on 07774 260126 or email [email protected].

CBM EVENT


STEEL

www.steelbb.com

Activity levels on the northwest European coil marketremained muted towards the end of March, with buyersdeferring purchases despite the best efforts of producersto pass price increases.

Platts SBB Update

M argins for producers of hot rolled coil are still coming under pressure, despite a recentsoftening in spot raw material prices, as they are working through material bought in the fourthquarter. Spot prices from local mills were around €545-550/tonne ex-works base in mid-

March, while sales for May delivery are slightly higher at €560-580/t ex-works base.

The euro:dollar exchange rate has helped to keep third country imports out of the market, but uncertaintyabout the outlook for the second half of the year is also preventing traders and end-users fromcommitting to cargoes. New orders for Asian material were placed in early March at €550-560/t cfrAntwerp.

Southern European mills were offering HRC into the region at around €550/t delivered base. Inventorylevels among stockists and traders remain low, with little evidence of a hoped-for bout of restockingafter January. The ready availability of material from producers and some risk-aversion amongdistributors is also encouraging back-to-back trades.

Outsell HRC prices from some northwest European mill-tied distributors also equated to base prices of€620/t ex-works, traders suggested. Local cold reduced transactions were at €630-640/tonne baseex-works, with offers at €630-680/t. Imports at €600/t effective for delivery in May.

The outlook for steel prices in the second quarter is for further price increases – although end-usersare refusing to accept increases. Prices for cold reduced coil could reach €550/t ex-works base in Q1,producers suggested.

Raw materials costs have begun to trend down, underlining concerns about the impact of weaker Chinesedemand. By the middle of March spot prices for 62% Fe iron ore fines were around $143/dry metrictonne (dmt) cfr China.

The outlook for steel demand remains broadly unchanged from the second half of 2011. The prospectsfor domestic consumption in the euro-zone remain divided, with austerity programmes in southernEurope affecting already weak demand. In northern Europe, with the exception of France and Belgium,the situation is somewhat better, but outside Germany and Scandinavia signs of recovery are fragile.

Real European end-demand was seen to be relatively stable, particularly towards the start of the month.However, mills were reporting lower sales with buyers favouring small tonnages on very quick leadtimes from service centres. European car producers expect to lower production as EU sales are underpressure. There is little prospect of an upsurge in the construction sector, with lower governmentinvestment weighing on steel-intensive infrastructure projects.

COLD ROLLED

www.britishmetalforming.com20

Abstract:

A uni-axial tensile test cannot be used to identify the gradients ofmaterial properties throughout the thickness of sheet metal.However, particularly for the Finite Element Simulation of thebending process, it has to be considered that the outer parts of sheetmetal behave in a different way compared to the core of thematerial. Therefore an advanced test-setup has to be devised,whereby gradients of Material Properties are not ignored. data Mhas performed bending tests together with an inverse routine toachieve the appropriate material properties for an accurate FEMsimulation of the roll forming Process.

Introduction:

Investigations have illustrated, that the use of material parametersfrom tensile testing leads to important behavioral differencesbetween the FEM simulation results and that of the actual behaviorof the sheet metal.

This noted difference increases along with the ratio of bendingradius and sheet thickness. In such cases only a very small area onthe surfaces of the sheet is plastically deformed. Due to the factthat the outer zones of the sheet have a higher value of Rp than theinner parts, the amount of spring back is therefore underestimatedby the FEM simulation compared with material parametersidentified from standard tensile tests.

In the following, the influence of the material parameters used forthe FEM simulation of a roll forming process is studied.Furthermore the concept of a new bend-test in combination withan inverse routine to investigate the material properties of sheetmetals is introduced.

Procedures, results and discussion:

To increase the accuracy of the FEM simulation of a channelproduced by roll forming, it was necessary to perform a uniquebending test. The used material was aluminum 3105 H16 with aspecial thermal coating which was applied prior to forming. Due tothe thermal treatment during the coating, the sheet has a highgradient of Rp in throughout its thickness.

The performed bending test was a rolling operation. The specimenwas bent between a silicon pad and steel cylinders with varyingdiameter. The resultant radii following spring back was subse-quently measured. The used specimens were cut out of the sheet in0° and 90° orientation with respect to the direction of rolling. Thetest results are shown in Fig. 1.

To define the material properties, the test setup was modeled andsimulated with the Finite Element program COPRA® FEA RF. Thematerial parameters were indentified in multiple simulation runswith the help of the optimization module COPRA® FEA RF OPT.Three parameters were varied during the optimization: the Young

modulus E, and the work hardening parameters K and ε0 of theSwift-Law (σy = K · (ε0 + εpl)n). While the exponent n was keptconstant at a value of n = 0.04879. The objective was theminimization of the variance between the final radius in thesimulation and that of the one measured in the actual test.

The results for the 90° orientation to rolling direction were used, asthis corresponded to the sheet's orientation of the producedchannel. In Table 1 the material parameters obtained from a tensiletest are compared with that one identified from the bend tests.

Figure 1: Results of the Bend Test

Figure 2: FEM Simulation

Table 1: Material Parameters

Test Young modulus Swift Parameter Swift Parameter E [N/mm2] K [N/mm2] ε0 [-]

Tensile test 69 234.8 0.001230

Bending test 72 328.5 0.000108

Nonlinear FEM simulations (see Fig. 2) of the roll forming Processwere performed with both sets of material parameters. For thoseresults from the tensile test, a bending radius of 50mm wasdetermined, which lead to an irregular geometry in reality. By using the parameters obtained from the bend tests, a bending radiusof 30mm was thus calculated and subsequently it was this, radiiwhich then provided a channel within tolerance.

data M bend test:

To ensure this increase in accuracy of the roll forming FEMsimulation became accessible for the users of the simulationsoftware COPRA® FEA RF (Sedlmaier [2008]), a stand alone Bend-testing device was thus developed by data M. Now in combinationwith an inverse routine to calculate the material parameters, theuser is now therefore able to acquire adequate input for hissimulations automatically. The test device is based on the DEAKINBend test (Weiss et al [2009]) and is shown in Fig. 3.

The need of advanced material testing methods with respect to theaccurate FEM simulation of bending processesBy: Stefan Freitag, Albert Sedlmaier. data M Sheet Metal Solutions GmbH, Am Marschallfeld 17, D-83626 Valley / Oberlaindern, Germany,

[email protected], [email protected]


During the test process the specimen is clampedat the end of the bending arms, thus “free bending” without anyfriction influences is possible. Both bending arms are able to rotate,while the rotation center of one bending arm is moved towards theother. During the movement of the bending arms, the actual positionas well as the force is measured.

The resulting measured position/force curve is then the input of theoptimization performed by the inverse routine, where the position/force curve from the simulation is compared to the test results. For the optimization of the material parameters a Nelder-Mead-Simplex-algorithm (Nelder [1965]) is used. The flowchart and apicture of the FEM model for the inverse Routine are shown in Fig. 4.

The described test setup also allows cyclic loading paths which can beused to determine the kinematic hardening properties of the material.

Figure 3: Setup of data M Bend Test

Figure 4: Inverse Routine

Conclusions:Within roll forming processes with deformations near to the yieldpoint, the material parameters identified from bend test dataprovide a much better description than uniaxial tensile tests in thearea of elastic plastic transition, as material in homogeneitiesthrough the thickness due to residual stresses or grain sizevariations are taken into account. It has been shown that the qualityof Finite Element simulation results for a roll forming process hasbeen significantly improved by using these material parameters.Recovery related shape defects could be minimized.

References: Weiss, M. et al, 2009, "Measurement of bending properties in strip for roll forming",International Deep Drawing Research Group Meeting, Golden 2009, pp. 521-532.Nelder, John A.; R. Mead,1965, "A simplex method for function minimization".Computer Journal 7: 308–313.Sedlmaier, A., 2008, “High quality tubes require high quality tooling – ways tooptimize a roll tool design. Pipe Dream India 2008 - International Conferenceorganised by the International Tube Association ITA, 13 February 2008, NewDelhi, India.

FEM simulation of theBend test

Update of thematerial

Comparison of the experimental andthe simulated position/force curve

Output of the materialparameters

Test data(position/force)

www.britishmetalforming.com 21


TEL 01262 400088FAX 01262 401110EMAIL [email protected] www.bw-industries.co.uk

BW INDUSTRIES LTDCarnaby Industrial Estate,Carnaby, Bridlington,East Yorkshire. YO15 3QY

PRESS RELEASE March 2012

As part of a £1.6 million pound investment programmeBW Industries Ltd; have completed the installation of a new heavy duty roll forming line for the production ofsteel sections. This new facility increases existing capacityand adds new section sizes to the company’s alreadyextensive range.

The new installation will produce 2mm to 6mm thicklipped (C) and plain (U) channel sections, web (base) rangeof 100mm to 500mm, and flange (upstand) range of50mm to 150mm, with a maximum length to 18 metres,and also incorporates a flying shear and punching to bothweb and flange.

Also, simultaneously launching the ‘SurebuildTM’ lightgauge steel framing system up to 2mm thick for interiorand exterior, load bearing and non - load bearing wallsand structures.

Managing Director, Mike Pugh, said; ‘Completion of thisdevelopment is another significant step in the continuingprogramme of modernisation and product developmenttowards achieving the companies ambitious targets, andreflects the forward thinking and positive attitude of its staff.’

BW are a premier supplier of press formed (to 7.2 metres)and roll formed sections to the construction, industrial,commercial and agricultural sectors, with a 9 metre longlaser facility and an extensive fabrication and assembly plant.

Further information at www.bw-industries.co.uk

COLD ROLLED

Headline sponsors & supporters

For more information about exhibiting call Jon Clark on 020 7970 6742 or email [email protected]

Subcon 2012sponsors British metalformingin association with CBM

It is your best opportunity to:

Make new contacts Forge new partnershipsWin new business

Take advantage of the 10% discount available to CBM members

The National Contract Manufacturing and Technology Show

Be a part of the only UK show dedicated to contract and subcontract manufacturing.

BUSINESS SUPPORT


“The tax relief for Research and Development (R and D) tax relief scheme allows SMEscarrying out R and D the opportunity to claim back extra tax relief from HMRC onrevenue expenditure on every pound spent on developing new products or introducingnew or improved processes. Any activity must meet the definitions set out by theDepartment of Business, Innovation and Skills (BIS) and can include costs spent onstaff, materials and sub contractors. The HMRC website gives a complete guide towho can apply.

“An SME carrying out qualifying R and D up to 31 March 2011 in the last two yearscan enhance their relevant expenditure for tax purposes by 75 per cent. This increasesto 100 per cent up to 31 March 2012 and 125 per cent from 1 April 2012.

“An R and D claims expert can save a manufacturing company thousands of poundsby netting a successful reclaim of corporation tax for that year, in addition to annualreductions on future corporation tax bills. “Manufacturing” covers a wide spectrumand can encompass engineering, electronics, pharmaceutical, transport andcommunication systems. Occasionally, a company that has improved the methodof manufacturing a fairly standard product can qualify for R and D tax relief.

“There are around 150,000 SMEs in the UK alone that could benefit from the scheme.However, compared with the rest of Europe, the UK has been slow to take advantageof it and Government statistics show that less than 10,000 SMEs are claiming. Manybusinesses are not aware that what they do qualifies as R and D, because theyconsider problem solving and innovation as essential for growth or simply survival.Also, many accountancy firms acting for SMEs do not have the resources or expertiseto adequately manage a successful R&D tax claim from outset to completion.

“Many companies are reluctant to apply because they assume it will be timeconsuming, but a good R and D tax claim specialist will operate on a no win, no feebasis, can quickly identify if a business is carrying out quantifiable R and D and willliaise directly with HMRC to ensure a positive outcome. The process can take as littleas two months from the initial visit to obtaining the refund and requires relativelylittle input from the management team. In most cases 1-2 days with the relevantsenior staff is sufficient and a good claims expert can produce the necessarypaperwork in just two weeks. Any queries raised by HMRC prior to agreeing the claimare dealt with by the tax claims specialist.

“Over the last three years the team at R&D Tax Claims have gained a 100 per centsuccess rate in submitting over 90 successful claims to HMRC with a value of £6million, including recently helping a Birmingham manufacturer net £134,000. It’svital to use a specialist with a good reputation with HMRC. The skill is in presentinga watertight case to them that proves without doubt the existence of R and D activities.”

For further information: www.hmrc.gov.uk

For further information on R and D tax relief or the services providedby R&D Tax Claims Limited, visit www.rdtaxclaims.co.uk, call

Mark Evans on 01902 783172 or email [email protected]

• (L to R) Richard Whincup, R and D tax consultant;Mark Evans, managing director; Paul Sherborne,tax consultant, all of R&D Tax Claims Ltd

The Confederation of British

Metalforming (CBM) has

appointed Wolverhampton

based R and D tax reclaim

specialists R&D Tax Claims Ltd

to act on its behalf in respect of

R and D claims for CBM members.

Here, managing director Mark Evans discusses why it’s vital to claim back R and D expenditure.

• Mark Evans, managingdirector, R&D tax Claims Ltd

www.britishmetalforming.com24

A n extra public holiday has been confirmed to celebrate the DiamondJubilee. Are we obliged to give all staff the additional holiday even if

the contracts of employment only state that employees will receive eightpublic holidays?

Whether or not there is a legal obligation to pay employees for bank andpublic holidays will depend on the wording of the employee’s contract ofemployment. Where the contract specifically provides for eight bankholidays, there will be no obligation on an employer to increase this toreflect the additional bank holiday on 5 June 2012.

If the organisation is open on this day and staff wish to take the day off,then they can elect to book a day’s annual leave. This request should beconsidered in line with business needs on a first-come, first-served basis.If the business closes on this day and staff do not want to take this day asone of the eight days to which they are entitled, then the employer can givenotice to insist that they take the leave. The notice required will be twice thelength of the leave, eg two days’ notice to take one day off (unless theircontract requires greater notice to be served).

Employers can, of course, decide to be generous and give the additionalbank holiday in 2012 even if the contract does not provide for it.

WORKPLACE PENSIONS.. Changes ahead from 1 October 2012

Changes being introduced from April 2010 mean that the StatePension will be fairer and available to more people. The StatePension will be a foundation for retirement but most people

will want to build up their own savings on top of this. To encouragemore people to save in a private pension the government is planningto introduce workplace pension reforms from 2012.

From 2012 employers will be required to automatically enroll alleligible job holders into a qualifying

workplace pension and to make mini

mum contributions into it.

Three parties are working together to imp-lement these workplace pension reforms:

• Department for Work and Pensions

(DWP) is responsible for the policyand legislation

• The Pensions Regulator (TPR) isresponsible for maximising employers'compliance with their new duties

• National Employment Savings Trust

(NEST) Corporation is the trusteebody responsible for overseeing NEST

Start dates for enrolment depend onnumbers employed.

BUSINESS SUPPORT

CBM members can access Croner’s Business Support Helpline FREEPlease call CBM for details on:0121 601 6350

HEALTH & SAFETY

CBM EVENT

IOSH managing safely

Who is it for?Directors, Vice Presidents, Senior Exec-utives and other senior managers whohave the responsibility for policy makingand strategic planning for health andsafety within the organisationAims and ObjectivesTo provide top-level decision-makerswithin the organisation, with a highly inter-active workshop, using case studies todemonstrate the moral, financial and legalissues relating to health and safety.

The course will highlight delegate'sresponsibilities and liabilities with regardsthe HSE Guidance on ‘Safety Leadership’,as well as providing guidance on thesteps required to promote safety culture.

How is it delivered?In one day at the National MetalformingCentre in West Bromwich.

When is the Course?7 June, 6 September, 29 November 2012How much does it cost?CBM members - £175Non-CBM members - £225All prices attract VAT at the current rate, andare inclusive of course materials, certificatefees, excellent buffet lunch, morning & after-noon refreshments.How do I book a place?Please email [email protected] tosecure your place on the course. Placesare limited to 12 delegates per course.

IOSH safety forsenior executives

CBM EVENT

Who is it for?“Managing safely” is the nationally recog-nised health and safety qualification formanagers, supervisors and team leadersin any sector or organisation. It's des-igned to get your people up to speed onthe practical actions they need to take tohandle health and safety in their teams, andalso includes environmental awareness.Why should people attend?The course will elevate the profile of safetyand environmental issues at managementlevel within your organisation, allowingyou to reduce accidents, costs and mini-mise your legal liabilities. With increasedemphasis on corporate liability, you mustensure your staff are adequately trained,and this course is ideal to meet these needs.

How is it delivered?It’s inspirational training, based on 4 daystraining (on a one day per week basis), atthe National Metalforming Centre in WestBromwich. When is the Course?6, 13, 20 & 27 June 201212, 19, 26 September & 3 October 2012 How much does it cost?CBM members - £395Non-CBM members - £495All prices attract VAT at the current rate, andare inclusive of course materials, certificatefees, excellent buffet lunch, morning & after-noon refreshments.How do I book a place?Please email [email protected] tosecure your place on the course. Placesare limited to 12 delegates per course.


HEALTH & SAFETY

RIDDOR Guidance – In line with the forthcoming changes to the Reporting ofInjuries, Diseases and Dangerous Occurrences Regulations 1995 (RIDDOR), dueto come in to force from 6 April 2012, the Health and Safety Executive has issuedan updated version of L73 – the detailed guide to the reporting regulations.

The main changes include:

• An increase from more than three consecutivedays to more than seven consecutive daysbefore the occupational accident or injury(which results in incapacitation of a worker),has to be reported to the enforcing authorities;

• Reporting the incident within 15 days(previously 10 days) by employers andthose responsible for health and safety.

Employers and others with responsibilities underRIDDOR must continue to keep a record of allover-three-day injuries, and if the employer has to keep an accident book, this record will be sufficient.

The detailed guide to RIDDOR can be found at:

www.hse.gov.uk/pubns/priced/l73.pdf

The brief guide to RIDDOR can be found at:

www.hse.gov.uk/pubns/indg453.pdf

The RIDDOR amending legislation (which is subject to parliamentary approval) canbe found at:

www.legislation.gov.uk/uksi/2012/199/pdfs/uksi_20120199_en.pdf

Pros & Cons of Climate Change - The UK is set to be amongst the bestprepared nations for the implications of climate change following publication ofa groundbreaking study into the threats the country faces.

The Climate Change Risk Assessment (CCRA) highlights the top 100 challenges tothe UK and our economy of a changing climate and provides the most compellingevidence yet of the need to increase our resilience. The research confirms the UK asa world-leader in understanding climate risk to ensure we can make robust plans todeal with these threats. Read more:

www.defra.gov.uk/environment/climate/government/risk-assessment/

For further information please contact:

Rob Wright LLB (Hons) CChem CFIOSH CEnv, OHSCR Registered Consultant at

WG Safety & Environmental on 07832 228 661 or email: [email protected]

www.wg-safety.co.uk

HEALTH AND SAFETY MANAGEMENT ENVIRONMENTAL MANAGEMENT

Annex XIV, Authorisation List for Substances of Very High Concern

There are now fourteen substances listed in the Authorisation List,Annex XIV, most of them organic chemicals apparently withoutapplications in the metalforming industry. There are five inorganic

compounds, two being oxides of arsenic, and three are chromates used inthe past as dying agents. They all have ‘sunset dates’ between August 2014and August 2015, and three of the organic chemicals have some exemptedcategories of use in the packaging of medicinal products.

On 20th December 2012, 13 more chemicals were recommended for theAuthorisation List, bringing the total that have been recommended, in threeseparate packages, to 36. The newly added substances are seven chromium(VI) compounds, five cobalt (II) compounds, and trichloroethylene. Many ofthese substances are still in use, and will affect the manufacturers offorming products, in particular suppliers to the aerospace industry.According to an article last December in Aviation Week on chromates, nosubstitutes are currently available for many applications in aerospace, andthe industry may be relying on having exemptions from authorisation.

There is an expectation that the European Commission will include these13 chemicals in Annex XIV in February 2013, and ECHA has givenrecommendations for the ‘sunset dates’ for the chemicals which would beat various dates in 2016 if the EC confirms their inclusion in Annex XIV.After this, no unauthorised use would be allowed.

Candidate List

The 20 new substances proposed as SVHCs in August 2011 have now beenadded to the Candidate List, bringing the total number on the list to 73.

For further information please contact Kirsi Lintula at the CBM offices on 0121 601 6350

or email: [email protected].

UPDATE FEBRUARY 2012

Announcing the UK’s onlydedicated automotive supplychain engineering event

AutomotiveEngineering 2012

www.ukautoengineering.com

The UK Vehicle Engineering Supply Chain Event

7-8 November - NEC Birmingham - UK

Hosted as part ofAdvanced Engineering UK group of events

www.advancedengineeringuk.comMedia and industry Partners include

CALL US ABOUTEXHIBITING ON+44 (0)20 8783 3573

________________

Automotive Engineering provides a unique new annualforum for UK based volume production & specialist vehicledesign, development, manufacturing & supply chain teams.

� Meet customers & partners across automotive design,development, test, production, quality and more . . .

� Invited from all the UK’s volume car and commercial vehiclemanufacturers, including: Jaguar Land Rover, Nissan UK,Honda UK, Aston Martin, Bentley Motors, BMW Mini . . .. . .through to niche vehicle and engine manufacturers andsupply chain companies

� Attend co locating briefings and technology forumshighlighting opportunities for developing business in the UKautomotive supply chain


For most CBM members, their insurance

programme is one of their biggest yearly

purchases. But for many, taking a ‘better

the devil you know’ approach is the simpler

option so they automatically renew with their

current broker. This decision can be taken

without fully understanding whether:

• the right insurance programme is in place for their business

• the broker is regularly testing the market to secure the best pricing for them

• their insurance programme has kept pace with any changes to thebusiness/risk profile.

Insurance is often described as a “relationship business” and many clients have builtup long-term relationships with their current broker. There is much to be said for this,but as with any service provider it is entirely reasonable and indeed good corporatepractice that a second view is obtained. A ‘fresh pair of eyes’ can often highlight areasthat may be uninsured or inadequately insured as well as identifying areas in whichpremium savings could be made.

Charlie Thomas, Divisional Director at R K Harrison Insurance Services says “it’s notuncommon when reviewing a client’s insurance position to come across criticaldiscrepancies and questions. The most common query will involve the adequacy ofthe sums insured: do the building(s) and contents levels represent current values?Does the business interruption cover allow enough time for repair and recoveryfollowing an incident? Are there additional policy covers required by the businesswhich are not currently insured?

By tendering their insurances every three to five years with another reputable brokerthat provides alternative options, the business can be more confident that it has aprogramme in place that best reflects their business. It may well obtain premiumsavings as well”.

R K Harrison Insurance Services are the approved insurance providerto CBM members. To find out more go to www.rkhis.com/cbm or call01234 305 555.

INSURANCE

reviewingthe relationship


MANUFACTURER MEMBERS

A.M.C. UK Fasteners Ltd (: 01536 271 920Northamptonshire NN17 5XZ www.amcukfasteners.co.uk

Alcoa Fastening Systems (: 01527 525 719Worcestershire B98 7TD www.mckechnieaerospace.com

Alcoa Fastening Systems (: 01952 290 011Shropshire TF3 3BQ www.alcoa.com

Avdel UK Ltd (: 01925 811 243Cheshire WA1 4RF www.acument.com

Barton Cold-Form (UK) Ltd (: 01905 772 021Worcestershire WR9 0LP www.coldform.it

Brooks Forgings Ltd (: 01384 563 356West Midlands B64 5QJ www.brooksforgings.co.uk

Caparo Atlas Fastenings Ltd (: 0121 224 2000West Midlands WS10 8UL www.atlasfastenings.com

Cirteq Ltd (: 01535 633 333West Yorkshire BD20 8QP www.cirteq.com

Clevedon Fasteners (: 0121 378 0619West Midlands B75 7DG www.clevedon-fasteners.co.uk

Clyde Fasteners Ltd (: 01355 225 451Lanarkshire G74 5ET www.clydefasteners.com

Cooper & Turner Ltd (: 01142 560 057Yorkshire S9 1RS www.cooperandturner.com

Gesipa Blind Riveting Systems Ltd (: 01535 212 200West Yorkshire BD21 4JU www.gesipa.co.uk

Griff Chains Ltd (: 01384 569 415West Midlands DY2 0ED www.griffchains.co.uk

Henrob Ltd (: 01244 837 220Flintshire CH5 2NX www.henrob.com

Leggett & Platt Components Europe Ltd (: 01282 811 232Lancashire BB18 6JA www.leggetteurope.com

PSM Interantional (: 01646 623 569Pembrokeshire SA71 4RE www.bas-components.co.uk

RCF Bolt + Nut Ltd (: 0121 522 2353West Midlands DY4 8RF www.rcfboltnut.co.uk

Smith Bullough (: 01942 520 250Lancashire WN2 4HD www.smithbullough.com

SPS Technologies (T.J. Brooks Div.) (: 0116 276 8261Leicestershire LE4 9HX www.spstech.com

ThyssenKrupp Woodhead Ltd (: 01132 441 202Yorkshire LS4 2AQ www.thyssenkrupp.com

Tucker Fasteners Ltd (: 0121 356 4811West Midlands B42 1BP www.emhart.com

Vaughan Jones Socket Screws Ltd (: 01937 843 298Yorkshire LS23 7FT www.vaughanjones.co.uk

FASTENERS

Abbey Forged Products Ltd (: 0114 231 2271Yorkshire S6 1ND www.theabbeygroupuk.com

AKS Precision Ball Europe Ltd (: 0191 587 0000Co Durham SR8 2PP www.aksball.com

Bedford Steels (: 0114 276 9643Yorkshire S4 7YS www.bedfordsteels.co.uk

Bifrangi UK Ltd (: 0152 258 5812Lincolnshire LN2 5DT

Brockhouse Group Ltd (: 0121 556 1241West Midlands B70 0SN www.brockhouse.co.uk

Brooks Forgings Ltd (: 01384 563 356West Midlands B64 5QJ www.brooksforgings.co.uk

Caparo Forging: Europe (: 01384 252 587West Midlands DY2 0LA www.caparo.com

Cascade (UK) Ltd (: 0161 438 4021Greater Manchester M11 2DD www.cascorp.com

Cerro EMS (: 0121 772 6515West Midlands B9 4DS www.cerro-ems.com

Chapmans Agricultural Ltd (: 0114 285 6000Yorkshire S6 2FH www.chapmans-uk.com

Cramlington Precision Forge Ltd (: 01670 716 811Northumberland NE23 1WA www.cpfl-tvs.com

Crosby Premier Stampings Ltd (: 01384 353 100West Midlands B64 6AJ www.premierstampings.co.uk

Doncasters Blaenavon Ltd (: 01495 790 345Gwent, Wales NP4 9XG www.doncasters.com

Doncasters Precision Forgings Ltd (: 0114 285 8100Yorkshire S6 2FR www.doncasters.com

Firth Rixson - River Don (: 0114 219 3694Yorkshire S9 2LD www.firthrixson.com

Firth Rixson Forgings Ltd (: 0114 219 3740Yorkshire S9 1HD www.firthrixson.com

Firth Rixson Forgings Ltd (: 0114 219 3694Derbyshire DE4 2JB www.firthrixson.com

Firth Rixson Metals (: 0114 219 3740Yorkshire S35 9XH www.firthrixson.com

George Dyke Ltd (: 0121 526 7138West Midlands WS10 8LP www.george-dyke.co.uk

Henry Williams Ltd (: 01325 462 722Co. Durham DL1 2NJ www.hwilliams.co.uk

Hull Forgings Ltd (: 01482 323 089Yorkshire HU9 1LL www.wp-forging.co.uk

Independent Forgings & Alloys Ltd (: 0114 234 3000Yorkshire S6 2BL www.forgedinsheffield.com

Integriti (: 0191 263 8686Yorkshire S63 6BJ www.integriti.co.uk

FORGING

MEMBERSHIPDIRECTORY

FASTENERS

FORGING

SHEET METAL

COLD ROLLED

COMMERCIAL SUPPLIERS



Kimber Drop Forgings Ltd (: 01384 414 500West Midlands B64 5QZ www.kimberdropforgings.co.uk

Koyo Bearings (Europe) Ltd (: 01226 733 200Yorkshire S75 3TA

Mettis Aerospace Ltd (: 01527 406 400Worcestershire B97 6EF www.mettis-aerospace.com

Mills Forgings Ltd (: 024 7622 4985Warwickshire CV1 2BJ www.millsforgings.co.uk

MSI-Forging Division (: 01302 366 961Yorkshire DN4 8DH www.msi-forge.com

Padley & Venables Ltd (: 01246 299 100Yorkshire S18 2XT www.padley-venables.com

Pandrol UK Ltd (: 01909 476 101Nottinghamshire S81 7AX www.pandroluk.com

Rollins Bulldog Tools (: 01942 244 281Lancashire WN1 3DD www.bulldogtools.co.uk

Schaeffler (UK) Ltd (: 01554 747 748Carmarthenshire S14 9TG www.schaeffler.co.uk

Shakespeare Forgings Ltd (: 01384 632 420West Midlands B64 7RB www.shakespeareforgings.com

Smethwick Drop Forge Kidderminster (: 01562 823 451Worcestershire DY11 7QE www.sdf-auto.co.uk

Solid Stampings Ltd (: 01384 636 421West Midlands B64 7BL www.solidswivel.co.uk

Somers Forge Ltd (: 0121 585 5959West Midlands B62 8DZ www.somersforge.com

South Wales Forgemasters (: 029 2081 0341Wales CF15 7YF www.swforgemasters.co.uk

Special Forged Products (: 0114 2560 914Yorkshire S9 3XL www.specialforgedproducts.com

Spromak Ltd (: 0151 480 0592Merseyside L36 6AN www.spromak.co.uk

Stokes Forgings Dudley Ltd (: 01384 342 550West Midlands DY2 0SE www.stokesforgings.com

Symmetry Medical Inc (: 0114 285 5881Yorkshire S6 2AN www.symmetrymedical.com


Tinsley Bridge Ltd (: 0114 2211 111Yorkshire S9 2DZ www.tinsleybridge.co.uk

TSL Turton Ltd (: 0114 273 0966Yorkshire S4 7YP www.tslturton.com

VTL Precision (Huddersfield) Limited (: 01422 882 561West Yorkshire HX2 6EL www.vtl-automotive.com

W. H. Tildesley Ltd (: 01902 366 440West Midlands WV13 2AN www.whtildesley.com

Wyman Gordon Lincoln Ltd (: 01522 525 492Lincolnshire LN2 5XY www.wyman-gordon.com

Wyman Gordon Ltd (: 01506 446 200West Lothian, Scotland EH54 5BZ www.wyman-gordon.com

Yorkshire Fittings Ltd (: 0113 270 1104Yorkshire LS10 1RT www.pegleryorkshire.co.uk

SHEET METAL

3M Healthcare (: 01200 421 140Lancashire BB7 1NX www.3M.com/uk

AGA Rangemaster Ltd (: 01926 457 400Warwickshire CV31 2AD www.rangemaster.co.uk

Aisin Europe Manufacturing (UK) Ltd (: 0121 421 5688West Midlands B32 3BZ www.aisin.com

ArcelorMittal Tailored Blanks Birmingham Ltd (: 0121 558 8464West Midlands B66 2BA www.arcelormittal.com

Ash & Lacy Perforators Ltd (: 0121 558 8921West Midlands B66 2RP www.ashlacyperf.co.uk

Berck Ltd (: 0121 553 2726West Midlands B70 7DP www.bercklimited.co.uk

Bird Stevens & Co Ltd (: 01384 567 381West Midlands DY5 2JE www.birdstevens.co.uk

Calsonic Kansei (: 0191 417 0084Tyne & Wear NE37 3JD www.ckeurope.com

Carlton Laser Services Ltd (: 0116 233 9990Leicestershire LE4 9LN www.carltonlaser.co.uk

Cooper B-Line (: 01278 783 371Somerset TA9 4AQ www.cooperbline.co.uk

Cooper Crouse-Hinds (UK) Ltd (: 01795 889 146Kent ME12 1LP www.enclosures-crouse-hinds.uk.com

Cooper Lighting and Safety (: 01302 321 541South Yorkshire DN2 4NB www.cooperindustries.com

Covpress Holdings (: 024 7669 1000Warwickshire CV5 6RT www.covpress.com

Doncasters Bramah (: 0114 251 2102Yorkshire S20 3GB www.doncasters.com

DPE Automotive Ltd (: 01325 300 777Co Durham DL16 6UJ www.dpe-automotive.co.uk

DPE Automotive Ltd (: 07919 044 355West Midlands B11 2BF www.dpe-automotive.co.uk

DRB Engineering Ltd (: 0121 359 4566West Midlands B19 3TE www.drbengineering.com

Eu-Matic Div. of Multimatic Ltd (: 024 7667 3333Warwickshire CV5 6UB www.multimatic.com

Fellows (Rical Group Div.) (: 01902 576 400West Midlands WV2 4HL

Ford Component Manufacturing Ltd (: 0191 428 6600Tyne & Wear NE33 5ST www.fordcomps.co.uk

Fowlers of Bristol (Engineers) Ltd (: 0117 942 2563Avon BS6 5PT www.fowlers-eng.com

Futaba-Tenneco UK Ltd (: 01282 433 171Lancashire BB12 6HJ

Genex UK Ltd (: 01922 710 050West Midlands WS2 7NA www.genexuk.co.uk

Glen Dimplex Home Appliances (: 08442 484 466Merseyside L35 2XW www.gdha.com

Grorud Group Ltd (: 01207 590 471County Durham DH8 8JA www.grorud.com

Grove Metal Sections Ltd (: 01902 601 697West Midlands WV13 3RN www.grovems.com

G-TEKT Europe Manufacturing Ltd (: 01452 610 022 / 01452 632 129Gloucestershire GL3 4AJ www.takao.co.uk

G-TEKT Europe Manufacturing Ltd (: 01495 307 190Gwent, Wales NP23 5SD www.takao.co.uk



Guala Closures UK (: 0141 777 2000Lanarkshire, Scotland G66 1ST

H V Wooding Ltd (: 01303 264 471Kent CT21 6HG www.hvwooding.co.uk

Hadley Industries Plc (: 0121 555 1300West Midlands B66 2PA www.hadleygroup.co.uk

JCS Hi-Torque Ltd (: 01787 376 212Suffolk CO10 2YH www.jcshi-torque.co.uk

Kiyokuni Europe Ltd (: 01952 292 920Shropshire TF2 9TY www.kiyokuni.co.uk

Krupp Camford Pressings Ltd (: 01554 772 233Carmarthenshire SA14 8EU www.thyssenkrupp.com

Laser Process Ltd (: 01543 495 000Staffordshire WS12 2GI www.laserprocess.co.uk

Leonardt Ltd (: 01746 861 203Shropshire WV16 6NN www.leonardt.com

Metsec Plc (: 0121 601 6000West Midlands B69 4HE www.metsec.com

Miking Ltd (: 0191 415 5919Tyne & Wear NE37 3JD www.mi-king.co.uk

Milton Keynes Pressings Ltd (: 01908 271 940Bedfordshire MK2 3EF www.mkp.co.uk

Mitchell Grieve (Rical Group Div.) (: 0116 235 0512Leicestershire LE4 0HZ www.mitchell-grieve.co.uk

Northern Automotive Systems Ltd (: 01873 832 263Wales NP7 0EB

Portola Packaging Ltd (: 01302 552 400Yorkshire DN4 5NT www.portola-europe.com

Presspart Manufacturing Ltd (: 01254 584 126Lancashire BB1 5RF www.presspart.com

Rical Group (: 0121 555 4807West Midlands B66 1NY www.ricalltd.com

Rical Group (: 01384 569 283West Midlands B64 7AL www.ricalltd.com

Rittal-CSM Ltd (: 01752 207 600Devon PL6 7EZ www.rittal-csm.co.uk

RSM Industries Ltd (: 024 7636 2082West Midlands CV7 9NN www.rsmindustries.co.uk

Sankey Laminations Ltd T/A Kienle + Spiess (: 01902 693 000West Midlands WV14 9NE www.kienle-spiess.com

Sertec Ltd (: 01675 463 361West Midlands B46 1JU www.sertec.co.uk

SPS Aerostructures Ltd (: 0115 988 0000Nottinghamshire NG15 0DP www.spstech.com

SSAB Swedish Steel Ltd (: 01905 795 794Worcestershire WR9 0QE www.ssab.com

Stadco Castle Bromwich (: 0121 382 3120West Midlands B24 9GZ www.stadco.co.uk

Stadco Powys (: 01691 648 561Powys, Wales SY22 5DH www.stadco.co.uk

Stadco Shrewsbury (: 01743 445 541Shropshire SY1 3AS www.stadco.co.uk

Steel Service Centre Ltd (: 01889 270 241Staffordshire ST18 0PJ www.steelservicecentre.co.uk

Swann-Morton Ltd (: 0114 234 4231Yorkshire S6 2BJ www.swann-morton.com

Tallent Automotive Ltd (: 01325 313 232County Durham DL5 6EP www.thyssenkrupp.com

Tallent Automotive Ltd (: 01543 466 664West Midlands WS11 1LY www.thyssenkrupp.com

Tata Steel (: 01902 698 635West Midlands WV11 3SR www.tatasteel.com

Taurus Engineering (Rical Group Div.) (: 01903 761 188West Sussex BN15 8TA www.taurusengineering.co.uk

The Regent Engineering Co (Walsall) Ltd (: 0121 526 6060West Midlands WS10 8XB www.regenteng.com


TKA Body Stampings Ltd (: 01543 466 664Staffordshire WS11 1LY www.thyssenkrupp.com

UYS Ltd (: 01865 334 860Oxon OX4 2BW www.uys.ltd.uk

UYT Ltd (: 024 7667 1400West Midlands CV5 6UF www.uyt.ltd.uk

Waites Pressings Ltd (: 01229 582 046Cumbria LA14 4EQ www.waitespressings.com

Walsall Pressings Co Ltd (: 01922 721 152West Midlands WS1 4JW www.walpres.co.uk

Whittan Storage (: 01952 682 251Shropshire TF7 4LN www.whittan-storage.com

William King Ltd (: 0121 500 4100West Midlands B70 9DR www.williamking.co.uk

William Mitchell (Rical Group Div.) (: 0121 558 2694West Midlands B66 1NY www.william-mitchell.co.uk

Wrekin Sheetmetal Ltd (: 01952 587 387Shropshire TF7 4JR www.wrekinsheetmetal.co.uk

X-met Fabrication & Finishing Ltd (: 01698 733 533Lanarkshire ML1 5RX www.x-met.com

COLD ROLLED

Aisin Europe Manufacturing (UK) Ltd (: 0121 421 5688West Midlands B32 3BZ www.aisin.com

Hadley Industries Plc (: 0121 555 1300West Midlands B66 2PA www.hadleygroup.co.uk

Metsec Plc (: 0121 601 6000West Midlands B69 4HE www.metsec.com

Stewart Fraser Ltd (: 01233 625 911Kent TN24 8DR www.stewartfraser.com


SUPPLIER MEMBERS

FASTENERS

Ajax Tocco International Ltd (: 0121 322 8000West Midlands B8 1BG www.ajaxtocco.co.uk/ajaxtocco.com

Broder Metals Group Ltd (: 0114 243 1206Yorkshire S9 3WL www.broder-metals-group.com

Deepak Fasteners (Shannon) Ltd (: 00 353 6171 6500County Clare, Ireland www.unbrako.com

FNsteel Ltd (: 01384 213 940West Midlands DY2 8UL www.fnsteel.com

National Machinery UK Ltd (: 0121 585 9846West MidlandsB63 3HY www.nationalmachinery.eu

PEM Europe - Penn Engineering (: 00 353 9175 1714County Galway, Ireland www.pemnet.com

Tata Steel (: 01724 404 040LincolnshireDN16 1BP www.tatasteel.com

The Bifurcated & Tubular Rivet Company (: 01296 314 300Buckinghamshire HP20 1DQ www.bifandtub.co.uk

FORGING

Ajax Tocco International Ltd (: 0121 322 8000West Midlands B8 1BG www.ajaxtocco.co.uk/ajaxtocco.com

Barrett Nickel Alloys Ltd (Barrett Steel Div.) (: 01709 386 690South Yorkshire S60 1FB www.barrettnickelalloys.com

Barrett Steel Ltd (: 01274 654 212West Yorkshire BD4 9HU www.barrettsteel.co.uk

Barrett Steel Ltd (: 01709 789 201South Yorkshire S65 1SU www.barrettsteel.co.uk

Barrett Steel Ltd (: 01274 474 372West Yorkshire BD4 9HU www.barrettsteel.co.uk

Barrett Strip & Alloys Ltd (Barrett Steel Div.) (: 01274 654 229West Yorkshire BD4 9HU www.barrettstripandalloys.com

CMT Steel Services Ltd (Barrett Steel Div.) (: 01384 565 166West Midlands B64 7DD www.cmt-steel.co.uk

Deritend Induction Services (: 01922 621 664West Midlands WV2 4PB www.deritend.co.uk

Dielife Limited (: 01642 221 133North Yorkshire TS2 1JW www.dielife.com

Euromarch Ltd (: 01452 525 259Gloucestershire GL2 5EU

Fabreeka International Inc. (: 01274 531 333West Yorkshire BD18 1QG www.fabreeka.com

Forge Tech Services (SA) Ltd (: 01922 612 192West Midlands WS2 8NG www.forgetechservices.com

Fuchs Lubritech (UK) Ltd (: 020 8345 5566London N18 3DB www.fuchs-lubritech.com

Henkel - Acheson ASM (: 07768 477 310Worcestershire B61 8LG www.achesonindustries.com

Henkel Loctite Adhesives (: 01823 430 034Somerset TA4 3UD www.henkel.com

HKB Steel Ltd (Barrett Steel Div.) (: 0121 601 5075West Midlands B69 3HU www.hkb-steel.co.uk

HKB Steel Ltd (Barrett Steel Div.) (: 0121 601 5062West Midlands B69 3HU www.hkb-steel.co.uk

Interpower Induction Europe (: 01675 477 700/07746 976 232West Midlands B76 9EB www.interpowereurope.com

J Boyd Laurie & Son Ltd (Barrett Steel Div.) (: 01274 474 335West Yorkshire BD4 9HU www.boyd-laurie.co.uk

Jobweld Fabrications (: 01902 408 055(A Div. of Kespar Engineering Ltd)West Midlands WV14 7EG www.kespar.co.uk

Kespar Engineering Ltd (: 01902 353 848West Midlands WV14 7EG www.kespar.co.uk

Lasco UK Agent (: 01902 672 491West Midlands DY3 3RF

Locum Fine Steels Ltd (Barrett Steel Div.) (: 01709 789 273South Yorkshire S65 1SU www.locumfinesteels.com

Micas Simulations Ltd (: 01299 822 522Worcestershire DY13 0WU www.micassimulations.co.uk

Pearson Panke Ltd (: 020 8959 3232London NW7 3LR www.pearsonpanke.co.uk

Primary Steels & Alloys (Barrett Steel Div.) (: 01709 789 263South Yorkshire S65 1SU www.primary-steel.co.uk

Schmolz Bickenbach (: 0121 544 1923West Midlands B69 2NY www.schmolz-bickenbach.com

SMS Mevac UK Ltd (: 01606 551 421Cheshire CW7 3RS www.sms-mevac.co.uk

Staniforth-HKB Steel Ltd (Barrett Steel Div.) (: 01709 789 227South Yorkshire S65 1SU www.staniforth-hkb-steel.co.uk

Steel Supplies (Scotland) Ltd (Barrett Steel Div.) (: 01674 674 009Angus, Scotland DD10 9PA www.steelsuppliesltd.com

Tata Steel (: 01709 371 234Yorkshire S60 1DW www.tatasteel.com

Taylorsteel (North East) Ltd (Barrett Steel Div.) (: 01207 599 226County Durham DH8 6HG www.taylor-steel-northeast.co.uk

Taylorsteel (North West) Ltd (Barrett Steel Div.) (: 0161 621 9848Lancashire OL1 4AD www.taylor-steel-northwest.co.uk

Taylorsteel (North West) Ltd (Barrett Steel Div.) (: 0161 621 9840Lancashire OL1 4AD www.taylor-steel-northwest.co.uk

Timet UK Ltd (: 0121 356 1155West Midlands B6 7UR www.timet.com

Tubes (UK) Ltd (Barrett Steel Div.) (: 0121 601 5006West Midlands B69 3HU www.tubes-uk-steel.co.uk

Woodberry Chillcott & Co Ltd (Barrett Steel Div.) (: 0117 316 5410Avon BS11 8AF www.woodberrychillcott.co.uk

Woodberry Chillcott & Co Ltd (Barrett Steel Div.) (: 01752 343 421Devon PL7 5ET www.woodberrychillcott-plymouth.co.uk


SUPPLIER MEMBERS

Bauromat UK Ltd (: 01684 575 757Worcestershire WR14 1GL www.bauromat.co.uk

Dayton Progress Ltd (: 01926 484 192Warwickshire CV8 1NP www.daytonprogress.co.uk

Institute of Sheet Metal Engineering (: 0789 149 9146West Midlands WV6 7UQ www.isme.org.uk

Oerlikon Balzers Coating Ltd (: 01908 377 277Buckinghamshire MK7 8AT www.balzers.co.uk

Pearson Panke Ltd (: 020 8959 3232London NW7 3LR www.pearsonpanke.co.uk

Professional Polishing Services Ltd (: 0121 555 6569West Midlands B66 2DZ www.professionalpolishing.co.uk

QCI Group (: 01543 677 792Staffordshire WS11 9SS www.qci-group.com

Ross UK Ltd (: 0121 559 4900West Midlands B65 0QW www.rosscontrols.com

Sims Metal Management (: 0121 565 5666West Midlands B66 2LF www.dunnbros.co.uk

Tata Steel Strip Products UK (: 01633 755 113Gwent, Wales NP19 4XN www.tatasteel.com

The Bifurcated & Tubular Rivet Company (: 01296 314 300Buckinghamshire HP20 1DQ www.bifandtub.co.uk

TTI Group Ltd (: 0121 327 2020West Midlands B6 7EE www.ttigroup.co.uk

Whiston Industries Ltd (: 01384 560 606West Midlands B64 5JY www.whistonindustries.com

OVERSEAS

Bharat Forge Ltd (: 00 91 212 671 666India

China Forging Industry Association (: 00 86 10 6846 5045P.R. China

CPM (: 00 49 2407 95940Germany

Ewald Dorken AG (: 00 49 2330 630Germany www.doerken.de

Forging Industry Association (: 00 1 216 781 6260USA

Japan Forging Industry Association (: 00 81 3 3241 7661Japan

Lasco Umformtechnik GmbH (: 00 49 9561 6420Germany www.lasco.com

Pietro Rimoldi & C SRL (: 00 39 0 331 504 449Italy

Presstrade GmbH (: 01788 890 055Northamptonshire www.presstrade.com

SHEET METAL COMMERCIAL SUPPLIERS

ENER-G Procurement Ltd (: 0844 225 1161Warwickshire B80 7AS www.energ.co.uk

Imperial College London (: 0207 594 7082London SW7 2AZ www.imperial.ac.uk

Interactive Ward Lovett (: 01543 501 111Staffordshire WS11 8JB www.i-wl.co.uk

Lean Education (: 01562 720 596and Development Group of CompaniesWest Midlands DY6 0NW www.leadlimited.co.uk

Pertemps Recruitment Partnership Ltd (: 01676 525 000Warwickshire CV7 7PT www.pertemps.co.uk

Pro Enviro Ltd (: 01788 538 150Warwickshire CV23 0UZ www.proenviro.co.uk

R & D Tax Claims Ltd (: 01902 783 172West Midlands WV9 5HD www.taxandgrants.co.uk

R K Harrison Group Ltd (: 01234 305 555London EC3V 1LE www.rkhgroup.com

SEMTA (: 01923 238 441Hertfordshire WD18 0JT www.semta.org.uk

TEK Recruitment Solutions (: 0114 252 5730Yorkshire S1 2FY www.tekpersonnel.co.uk

TEK Recruitment Solutions (: 01902 810 010West Midlands WV1 4EG www.tekpersonnel.co.uk

WG Safety & Environmental (: 01543 670 067Staffordshire WS7 1AG www.wg-safety.co.uk

MACH is owned and organised by The Manufacturing Technologies Association

The Confederation of British Metalforming pavilion at MACH 2012 is the ideal platform toshowcase your manufacturing capability and capacity to tens of thousands of decision makersand buyers looking to expand their metalforming processes.

MACH is the ONE event where you can make new contacts, generate business enquiries fromnew sectors and meet face to face with existing customers and contacts.

MACH Easy Exhibiting packages start from just £456 per day and include everything youneed to showcase your company - a shell scheme stand, stand lighting, seating, a productdisplay cabinet and graphics. You just need to turn up and display your products. Also available,Space Only packages, from as little as £399 per day.

To find out more and to book your stand, contact Adrian Sell at the MTA on 020 7298 6401 orvisit www.machexhibition.com

EVENTBe part of the

for manufacturing- from only £399 per day

The UK’s premier manufacturing technologies event

Sponsored by

the complete range for the forging industry

Oststrasse 1D-77694 KehlGermany

Phone +49 7851 93 76-0Fax +49 7851 93 [email protected]

www.presstrade.com

24FASTENERSFASTENERSPSM InternationalOverviewPage 12

FORGINGFORGINGDecoupled analysis of die loads:Helpful tool in forging processoptimization?Page 13

STEELSTEELPlatts SBB update: Activity levels on the northwestEuropean coil market remainedmuted towards the end of MarchPage 19

SHEET METALSHEET METALSpaceClaim Engineer: a New Approach to 3D Sheet MetalPage 16

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£7.50ISSN 1759-5975

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C o n f e d e r a t i o n o f B r i t i s h M e t a l f o r m i n g

24 SHEET METAL - St. Joseph's Preparatory School...The Sheet Metal Skills Competition Provides a great opportunity for young people to measure their skills against others in the sheet

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