PRIMO™ revolutionises automatic setting of parts and tools...
Y
X
• Simple to learn and use • Faster to payback and increase profits • Easy to justify compared to manual alternatives
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20 6674 6200 or visit www.renishaw.co.in/primo
Renishaw India [Pune] S.No.282, Hissa No.3, Raisoni Industrial Estate, Village Mann, Tal:Mulshi, Pune 411057 T +91 20 6674 6200 F +91 20 6674 6211 E india@renishaw.com
www.renishaw.co.in
www.mtwmag.com
Volume 1 Issue 1
Editor’s note
Publisher Shirish Dongre
CEO Shekhar Dongre
Editor
Welcome to the inaugural edition of MTW
Shilpa Dongre
Marketing Team Ladoji Pendurkar, Amol Powle, Bhavin Shah, Bharat Shah, A.Purohit, Vinod Surve, Kavita Chaudhari
Designer & Layout Arun P. Shinde, Pradeep M. Pillalamarri, Nandan Moghe, Dinesh S. Gawade
Circulation Executive Satish Kadam, Amol Ranshur Branch Offices (Zonal)
NORTH
(Delhi & NCR regions) Sandesh Jain : 09810837877 / 09871602777
SOUTH
(Chennai & Coimbatore) Y. V. Raghu : 09566141224 Bangalore Vaman : 09686721340 Kochi Sanjeev Nair : 09846249568
EAST
(Kolkata & Other regions) S. Roy - 09433097806
Dear Readers, With ‘Make In India’ gaining ground as the national agenda, the manufacturing sector gets a new fillip. The machine tool industry, making mother machines, has once again begun to flex its muscle. Quality has become the watchword in the industry which is chiselling out sophisticated machines to meet new benchmarks in quality, precision and reliability. Breakthroughs in precision and cutting toolings and tool changing mechanism have enhanced productivity. Robotics are making Machine tending and Automation viable. One segment of the industry is scaling new heights in import substitution of high end machines, saving precious foreign exchange for the country. Lean manufacturing has weeded frills and slashed material wastage to make the products cost-effective and competitive. MACHINE TOOLS WORLD stands an eloquent testimony to these developments and innovations in the machine tool world. DIVYA MEDIA PUBLICATIONS – India’s leading publishers since last 15 years having leading magazine brands like ENGINEERING REVIEW & INDUSTRIAL SAFETY REVIEW is pleased to present this publication which will play vital role of information source of latest business news, technology trends & industry insight of machine tools & allied industry.
WEST
(Maharashtra & Gujarat) Pune S.Kadam - 09833373371
Happy Reading! Editor
Gujarat Dinesh Shah - 09327344559 Rajkot (Saurashtra) Swapnil Bhatia: 09227909005
Head Office : Divya Media Publications Pvt. Ltd., 3rd Floor, Harmony Tower, N.S. Road, Thane-400 602. Maharashtra Tel: +91 22-25380574/75, Telefax: +91-22-25418254 E-mail: shekhar@divyamediaonline.com, Website: www.mtwmag.com.
Printed & Published by Shirish Dongre on behalf of DIVYA MEDIA PUBLICATIONS PVT LTD., Printed at Anitha Art Printers 29/30, Oasis, Next to Vakola Market, Santacruz(E), Mumbai-400055, published from 303/304, Harmony Tower, N.S.Road, Court Naka, Thane West, Thane-400601. Editor : Shilpa Dongre
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MTW JUNE 2015
MTW Overseas Associates USA Nancy TARTAGLIONE, Mepax USA n.tartaglione@mepax.com / usa@mepax.com
ITALY Valeria VILLANI Tel.: +39 339 8610117, Via Firenze, Milano, Italia
GERMANY Sebastian OLLIER Mepax Deutschland, Tel: +49 711 222 54 456, deutschland@mepax.com
FRANCE MEPAX SA, Romain CLASS Tel.: +33 1 39 02 77 78, FRANCE
RUSSIA Garri ZALTS Mepax Russia Tel: +7 495 576-7666 / gizalec@yandex.ru
SPAIN Sofiane JEDIDI Mepax España Tel : +34 963 255 886, spain@mepax.com
UK Liz Jones Tel: +44 (0)1227 276016 , l.jones@mepax.com CHINA/South Korea/ Taiwan Mepax - Konaxis Shanghai Julien PENARD Tel : (+86) 21 6252 2731/ china@mepax.com
Our Lean Selection speed reflects our own core values. Speed, high performance, efficiency.
JUNKER Lean Selection speed High-speed cylindrical grinding.
The Lean Selection speed grinds shaft-type components and cutting tool blanks at impressive speeds. One or two high-performance grinding spindles mounted at the swivel-action wheelhead (B axis) work using both the plunge-cut and QUICKPOINT grinding methods. This facility makes the grinding machine extremely flexible and capable of implementing several grinding operations in a single clamping. The Lean Selection speed cylindrical grinding machine is ideally suited for the grinding of small and medium-sized series: It not only operates with outstanding cost efficiency, but also benefits from operating simplicity and fast retooling.
Erwin Junker Maschinenfabrik GmbH India Branch Office Office No. 104, City Square 29-2, K.M. Gandhi Path, Bhamburda Shivaji Nagar, Pune 411 005
Phone: +91 20 255 33 896 E-Mail: info@junker.in
www.junker.in
A member of JUNKER Group
Editorial Board
Mr. A.P. Jayanthram Managing Director Heidenhain Optics & Electronics India Pvt. Ltd
Mr. GK Pillai Managing Director & CEO
Mrs. Mohini Kelkar Managing Director
Mr. Yogin Chhaniara President – Machine Tools Manufacturers Association - Rajkot
Mr. Ayaz Qazi Director
Grind Master Machines Pvt. Ltd
Walchandnagar Industries Ltd.
Mr. MIHIR Baxi President – Global Sales Jyoti CNC Automation LTD
Ms.Samina Khalid Marketing Expert
Mr. Arjun Prakash Managing Director
Precihole Machine Tools Pvt. Ltd.
Effica Automation Ltd.
Renishaw Metrology Systems Ltd.
Mr. Suhas Belapurkar Director - Sales & Marketing ( Industrial Products)
Mr. P.K. Balasubbramaniian President VBS Corporate Support
Sanjay Tools & Adhesives
Editorial Index A
GmbH
38
9
8
Ace Designers Limited
30
E
Ador Welding Limited
53
Effica Autiomation Ltd.
34
G
CNC Software, Inc.
8
Grind Master Machines
Concept Laser
9
Pvt. Ltd.
D
H
DMG MORI Microset
Haas Factory Outlet
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10
Pvt. Ltd.
32
K Kennametal
S Sanjay Tools &
P
Electronics India
PcVue solution
36
Adhesives
52
Stratasys
46
Supra Industries
54
R 12
31
M
4
MathWorks
Heidenhain Optics &
Accelerator Group LLC
C
Haimer Group
T
Renishaw Metrology Systems Ltd.
22
TAL Manufacturing
Roots Multiclean Ltd
52
Solutions Ltd.
MARPOSS INDIA 14, 42
Pvt Ltd
53, 54
For editorial contribution contact editor@divyamediaonline.com
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Contents BUSINESS NEWS
Vol 1 Issue 1 | June 2015
CASE STUDY
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08
The Primo™ From hours to seconds
CNC Software, Inc. Continues to Partner up with Edge Factor in 2015
TREND SETTER
09
26
10
TECH UPDATE
TAL Manufacturing Solutions takes giant strides in high-tech fields
Concept Laser’s redesigned M2 cusing Multilaser system
MathWorks Introduces Pixel-Streaming Algorithms on FPGAs and ASICS
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®
INDUSTRY FOCUS
18
Automation leads the way for Indian machine tool industry
Automotive Industry Bouncing Back: Good Opportunity For Machine Tool Industry 6
MTW JUNE 2015
Innovative features for monitoring and controlling distributed assets & IP networks
COVER STORY
KENNAMETAL Launches New ToolBOSS™ Vending Solution Connecting ToolBOSS with NOVO™
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36
14 38 HAAS : It’s all about More efficient simplicity & innovation production thanks to tool Mr. Terrence Miranda - Managing Director Haas Factory Outlet Mumbai, India
FACE TO FACE
30
Machine Tools Industry Eyeing the prospects
31
Make in India The booster of machine tools industry
32
Machine Tools Milieu
34
Effica unleashes robotic automation in India
presetting
42
HAAS: Full control
46
3D Printing helps Swany Reinvent Itself
48 PROJECTS 52 PRODUCTS
Details make a difference
WRI World Radio Interface
WRP World Radio Probe Ø45 mm
WRP World Radio Probe Ø60 mm
WORLD RADIO SYSTEM
MARPOSS RADIO FREQUENCY TRANSMISSION TOUCH PROBE SYSTEM ...reliable, highly versatile and available for worldwide use
Marposs India Pvt. Ltd. 147, Sector 7, IMT Manesar - 122050 Tel: +91 124 4735700 sales@in.marposs.com
Your global Metrology par tner
•
www.marposs.com
BUSINESS NEWS
CNC Software, Inc. Continues to Partner up with Edge Factor in 2015 CNC Software, Inc. is proud to announce that they will again be partnering with Edge Factor throughout 2015. Edge Factor produces inspiring, high impact media that tell the stories of innovative teams who design and build incredible products with Mastercam that impact lives and ultimately... the future of the country. Each show is designed to be an integral part of the foundation used in multiple platforms to reach a large demographic through TV shows, educational curriculum, and events.
Edge Factor eduTAINMENT: The Edge Factor Show
and LaunchPoint stories bring to screen the innovative manufacturing teams working together to design and build incredible products that impact lives. In each production, extraordinary stories are being told about the people who are redefining what is possible through manufacturing, as well as their pathway to success.
eduFACTOR: All the media produced by Edge Factor is the foundation of eduFACTOR, a membership¬ based, online suite of multimedia resources for educators and business leaders to inspire the next generation of advanced manufacturers. edu-
FACTOR empowers STEM teachers to use real-life stories that make learning concepts relevant to students. Media and tools developed from the Edge Factor Show and LaunchPoint episodes deliver a variety of educational opportunities, from school year plans to one day projects in the machine shop with Maker Projects. You can see Mastercam’s influence throughout the site, even some media developed by corporate CNC Software employees. See for yourself at eduFACTOR.org
are joining forces for the best Manufacturing Day yet. Manufacturing Day is a celebration of modern manufacturing meant to inspire the next generation of manufacturers. Manufacturers across the world open up their facilities to the public to get a tour of their shops and businesses. CNC Software is dedicated to getting today’s youth interested in manufacturing, and together with Edge Factor, hopes to inspire students to look at manufacturing as a rewarding and exciting career path.
Manufacturing Day:
For more information, visit www.edgefactor.com
Edge Factor and CNC Software
Accelerator Group joins hand with Spark Minda, India Accelerator Group LLC (“Accelerator”) is pleased to announce that its client, global automotive component manufacturer, Spark Minda, Ashok Minda Group”(“Minda”) has entered has entered into a Joint Venture partnership with Vehicle Access Systems Technology LLC. (“VAST”) USA. This joint venture entity between two groups is Minda VAST Access Systems Private Limited (“Minda VAST”) and has operations in Pune, India and Delhi-NCR, India. Accelerator was the exclusive advisor to Spark Minda, Ashok Minda Group for this transaction. Mr. Ashok Minda, Group CEO, Spark Minda, Ashok Minda Group commented: “We are delighted to have partnered with VAST. The strategic alliance is a step towards ensuring support to meet the expectation of targeted and strategic customers. VAST’s global presence will help us to reach out to more areas and expand our base & offer new technology with latest products to our Customers. Mr. Sanjay Thapar, Group Chief Strategy Officer, Spark Minda, Ashok Minda Group remarked: “Accelerator proved to be an invaluable adviser for this deal and contributed
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significantly in terms of the deal construct and consummation of the deal through creative solutions leading to a win - win for both Minda and VAST. They leveraged industry access, deep domain knowledge and experience to conduct a well-tailored and confidential process.” Frank Krejci, President & CEO of STRATTEC and a board member of VAST LLC observed: “This is a very important step forward in the strategic strengthening of VAST. India is projected to be one of the fastest growing economies globally. In addition to the growth opportunities, it is important that VAST is able to properly support the global needs of our automotive customers as they expand both their manufacturing and marketing. We are very excited to join a partner with the history of success and capabilities of Minda and its affiliates. We appreciate the work that Accelerator did in facilitating this opportunity. Their demonstrated understanding of the cross-border deal making, businesses, processes, and market was critical in allowing for a seamless transaction.”
BUSINESS NEWS www.mtwmag.com
Concept Laser’s redesigned M2 cusing Multilaser system “From our inception, Faustson Tool has committed to being a pioneer in the industry by utilizing new leap-frog technology and pushing the bounds of a traditional machine shop,” said Alicia Svaldi, President, Faustson Tool. “While conducting our indepth research on additive manufacturing processes available on the market, the LaserCUSING® technology from Concept Laser was the best fit.” “Staying at the forefront of technology is critical, not only to stay competitive, but to provide our customers with the best manufacturing solutions available on the market. Concept Laser’s M2 cusing Multilaser system with 2 x 400 W lasers provides another depth to our manufacturing services,” said Heidi Hostetter, Vice President, Faustson Tool. “There is a tremendous emphasis on UAV and defense in Colorado,” continued Hostetter. “As new technologies, such as metal additive manufacturing came on to the market, our customers began requesting
services that could only be produced on an additive manufacturing system. The technology we found from Concept Laser was stronger then other metal additive manufacturing technology available, offered flexible parameters, and fit into our current process seamlessly. The multilaser technology offers throughput similar to higher-powered systems (e.g. 1kW), while maintaining the high-precision and superior finish available with lower power settings.” Concept Laser introduced the redesign of the M2 cusing with multilaser option at the end of 2014. With a new look and fully integrated structure, the M2 is equipped with a new filter design and increased surface area of 20 square meters. The M2 cusing Multilaser is available with 2 x 200 W lasers, or alternatively with 2 x 400 W lasers, and makes use of Concept Laser’s improved segmented exposure strategy for laser melting of metals. The dual-laser configuration increases the machine’s throughput by up to 1.8 times over that of its single-laser counterpart. The increase is dependent on the geometry of the corresponding component. These solutions with multilaser technology are interesting to digital service centers with a tendency to industrial mass production.
OSG cutting tools ties up with the HAIMER Safe-Lock™ System
Jiro Osawa, Managing Director of Technology with the OSG headquarters in Japan & North American CEO, is convinced of the Haimer Safe-Lock™ System: “In addition to the absolute technical superiority of Safe-Lock™ compared to alternative systems, it is the only system that is actually in high demand globally and also available in various clamping methods.”
The OSG-Group, Japanese market leader for solid carbide endmills, has begun offering their high quality cutting tools with the HAIMER Safe-Lock™ system worldwide. The unique Safe-Lock™ design in cutting tools and toolholders combines a high precision press fit clamping with a positive form locking mechanism. This prevents round cutting tools from being rotated or completely pulled out from its tool holder during heavy machining. The combination of symmetrical pull out protection, highest concentricity and excellent balance of the Safe-Lock™ system, results in a vibration free machining process. This leads to a more efficient metal removal rate, that is superior when compared to conventional Milling chucks or
Weldon shanked cutting tools and toolholders. OSG has been testing various systems for pull out security over the past several months. Only the technology of the Safe-Lock™ system could convince the high-tech Japanese company. Jiro Osawa, Technical Managing Director at OSG headquarters and CEO for North America, explains: “Our field testing proved that the combination of our endmills with Safe-Lock™ resulted in higher RPMs and feed rates even with difficult-to-machine materials. This enables our customers to obtain a significant increase in their current metal removal rates, while at the same time having a higher security in their machining processes. Safe-Lock™ also has a very positive effect on tool wear.” For the globally oriented corporation that is represented in 29 countries with 52 subsidiaries, over 5,000 employees and
As a licensed partner, OSG will begin offering their cutting tool shanks with the patented pull out protection system, Safe-Lock™ from Haimer
MTW JUNE 2015
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BUSINESS NEWS
Andreas Haimer, President of the Haimer Group, on the licensing agreement with OSG: “We are very proud & happy to have reached a strong partnership with OSG, one of the largest and leading producers of tools in the world.”
annual sales of approx. one billion US dollars, there was one further crucial factor, as Jiro Osawa argues: “In addition to the absolute technical superiority of Safe-Lock™ compared to alternative systems, it is the only
system that is actually in high demand globally and also available in various clamping methods. Since we are not only in Japan but also well represented in North America and in Europe, we have decided to sign this li-
cense agreement and integrate the Safe-Lock™ design into our tools worldwide.” OSG is headquartered in Toyokawa, south east from Tokyo, where it has its solid carbide endmill production, coating facilities and production halls with the most modern CNC grinding machines. Due to these manufacturing capabilities, the company is able to insure the highest level of quality and availability of their tools. An additional global production network enables the demands of local markets and customer needs to be met with fast delivery and the highest of service and support. Andreas Haimer, President of the Haimer Group, explains: “We have established SafeLock™ as a standard in rough-
ing and heavy machining for which a variety of tools are available worldwide. We are very proud and happy to have reached a strong partnership with OSG, one of the largest and leading producers of tools in the world.” Since its launch in 2007, the Safe-Lock™ System has developed very successfully and excited many international customers. Last year alone, the growth was four times higher compared to previous years. This boom can be attributed to recognizing that the productivity increases resulting from the pull out protection is not restricted to typical aerospace applications but the cost and time savings can also be used in any typical milling application.
MathWorks Introduces Pixel-Streaming Algorithms on FPGAs and ASICS MathWorks introduced Vision HDL Toolbox, a new product now available in the company’s Release 2015a. Vision HDL Toolbox provides pixel-streaming algorithms for the design and implementation of vision systems on FPGAs and ASICs. The toolbox also includes a design framework that supports a diverse set of interface types, frame sizes, and frame rates, including high-definition (1080p) video. The image processing, video, and computer vision algorithms in the toolbox use an architecture appropriate for HDL implementations. Vision algorithm developers are challenged by the combination of increasing video frame sizes, frame rates, and the complexity of prototyping or implementing the v ision algorithms on FPGA and ASIC platforms. Vision HDL Toolbox helps developers overcome these challenges by providing a library of image processing and computer vision algorithms specifically designed for FPGA and ASIC implementation, as well as automatic conversion between frames of various sizes and pixels. In addition, when used with HDL Coder, designers can generate readable and vendor-independent HDL code from these algorithms. And, with HDL Verifier, designers can connect the algorithms running on the FPGA or ASIC with frame-based
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MTW JUNE 2015
test models running in MATLAB or Simulink. “FPGAs in particular are an increasingly popular platform for image processing and computer vision systems,” said John Zhao, marketing manager at MathWorks. “The new Vision HDL Toolbox has been created to help developers prototype and implement systems faster, with shortened design cycles, and more efficiently, through the ability to identify design errors early in the workflow and minimize the time needed for writng HDL code.”
Key Vision HDL Toolbox Features • Image processing, video, and computer vision algorithms with a pixel-streaming architecture, including image enhancement, filtering, morphology, and statistics • Frame-to-pixel and pixel-to-frame conversions to integrate with frame-based processing capabilities in MATLAB and Simulink • Video synchronization signals for handling nonideal timing and resolution variations • Configurable frame rates and frame sizes, including 60FPS for high-definition (1080p) video • Support for HDL code generation and real-time verification
BUSINESS NEWS
KENNAMETAL® Launches New ToolBOSS™ Vending Solution Connecting ToolBOSS with NOVO™ Driven by “Different Thinking is Better Thinking,” Kennametal continues to seize the productivity-building potential of NOVO™ by launching a new service offering combining its premium vending solution, ToolBOSS™ and its cloud-enabled digital tooling and process knowledge vehicle NOVO™.
Market-Driven Solution Manufacturing’s unrelenting pressure to remain competitive and control costs combined with the widening skills gap are shaping the present and future of how customers operate and manage machine shops today. Kennametal’s ToolBOSS with NOVO was inspired by the needs of machining customers seeking seamless real-time integration of their enterprise engineering systems (CAD/
CAM systems) with their production floor. Recent research indicates up to 70% of manufacturing executives are focusing on plant-floor data initiatives to drive operational and business excellence, faster time to market, and immediate access to data from machines on the factory floor. ToolBOSS users on the cloud with the latest software version can now use NOVO™ to see if an item proposed for a process plan is already available in their ToolBOSS inventory. This makes plans and budgets more timeand cost-efficient. “By adding ToolBOSS credentials to their user profile, customers easily check the inventory in their local ToolBOSS units with their developing process plans,” says Daniel Gillig, Global Services ToolBOSS Manager at Kennametal. “They’re better able to visualize items already in their shop.”
Powerful Solutions Linked The unique ToolBOSS – NOVO linkage will provide customers the ability to quickly ID the optimal tool (selecting from the industry’s latest technology), and assess corresponding tool availability; moving customers from design to shop floor in the shortest time possible with the most efficient cutting tool option. This linkage also makes it easier to order new tools, provide secure back up of data and conduct proactive diagnostic checks and updates
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to the ToolBOSS. “With these powerful solutions linked together”, explains John Jacko, Kennametal vice president and chief marketing officer, “our customers should expect a 20-50% time savings in quoting, programming, set-up, and machining processes compared to traditional fragmented approaches requiring high levels of skill in the areas of tool selection, application, and data integration.”
Industry Leading Partners The connection of ToolBOSS and NOVO is enabled through partnership with the Machining Cloud GmbH and ToolBOSS Vending Solutions supply chain partner, Supply Point Systems (SPS). SPS is a world leader in the design and manufacture of secure, point-of-use inventory management systems, while Machining Cloud is a leader in the global manufacturing
community providing a singlesource of access to complete and up-to-date product data from leading manufacturers of cutting tools, machine tools and workholding. Kennametal ToolBOSS Vending Solutions is planning a staged rollout of ToolBOSS – NOVO beginning in the United States, expanding to other world regions within the next 18 months. “This innovation builds on our premium vending solution, ToolBOSS, and provides the type of valueadded service our customers demand – allowing them to be more efficient programing new jobs, as well as running those same jobs on the shop floor. Our vision is to leverage these types of digital solutions more and more to help our customers fully optimize their operations,” commented Jeswant Gill, Kennametal vice president and executive vice president, industrial segment.
MACHINE TOOLS WORLD |
13 | June 2015
COVER STORY
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COVER STORY www.mtwmag.com
HAAS : It’s all about simplicity & innovation Q. How did machine tool industry performed in 2014 ? The machine tool industry in India witnessed a high in 2011 but in 2012 and 2013 the pace of growth was relatively slow. In 2014 there has been steady growth and the momentum is building towards a strong performance in 2015. This growth has fuelled the demand for quality CNC machine tools. The Indian Machine Tool Industry has been able to meet this demand with a mix of local made CNC Machine Tools and imports. Global Machine Tool Builders have set up offices and manufacturing bases in India and this influx of technology and investment is driving the industry to newer heights. The business environment in India is also being simplified with a clear focus from the government to reduce duties and taxes and bring these in line with global norms. This is also helping both Indian and foreign machine tool builders looking to grow in the Indian market.
Q. What are the future technology trend of the industry ? CNC Machine Tools: Machining Centers and Turning Centers are becoming faster, more accurate and capable of more complex machining tasks every day. The extensive use of automation: robots loading / unloading parts or automatic pallet systems or barfeeding systems is a clear trend that is being seen in India. The need to machine a complex component in a single setup is also growing. HAAS offers a range of high performance 5 axis machining centers in vertical or horizontal configurations to machine a range of complex components such as impellers,
Mr. Terrence Miranda
Managing Director Haas Factory Outlet Mumbai, India
MTW JUNE 2015
15
COVER STORY blades, cylinder heads, cylinder blocks etc in a single setup. The new ST series from HAAS offers high end options such dual spindles, C axis, Y axis and powerful live tooling, all at an affordable price.
Q. What are initiatives carried out by your company ? Simple Innovation and providing true value to our customers is a mantra at HAAS. We at HAAS truly believe that the HAAS VALUE Proposition: a wide range of high performance, quality products, backed by a strong HFO HAAS FACTORY OUTLET network providing service, applications and parts support within 24 hours: all of this at an affordable price, is designed to do exactly this. In line with this philosophy HAAS has launched a number of new products recently which provide simple, innovative solutions to the machining needs of our customers. HAAS offers a range of high performance 5 axis machining centers in vertical or horizontal configurations to machine a range of complex components such as impellers, blades, cylinder heads, cylinder blocks etc in a single setup. The new UMC-750 five-axis Vertical Machining Centre offers a generous capacity of 762 x 508 x 508 mm in the X, Y and Z axes respectively. It features a twoaxis, 630 x 500 mm integrated trunnion rotary table with +110 and -35 degrees of tilt and 360 degrees of rotation to provide excellent tool clearance and large part capacity up to 300 kg. Also featured is a 40+1 side mount tool changer and a 40-taper, 22.4 kW, 12000 rpm direct drive spindle. The new ST series CNC Turning Centre from HAAS set the standard for quality and affordability in complex CNC Turn Mill applications and provide high end options such dual spindles, C axis, Y axis and powerful live tooling, all at an affordable price. HAAS has also been at the forefront of automation technology, creating products such as the EC-400PP Horizontal Machining Center with 6 station Pallet Pool System and its unique RRI Robot Ready Interface which makes interfacing part
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Although therapeutic hypothermia has proven to be the only medical intervention beneficial for perinatal asphyxia; it is not practiced widely. The standard cooling equipment available in the market are very expensive, costing approximately `10-15 lakh ($15,000-$25,000). It cannot be afforded by most of the hospitals in India or other low and middle income countries.
loading robots on a HAAS, simple and cost effective.
Q. What will be the future of the industry ? The machine tool market in India is poised to grow rapidly as the emphasis on manufacturing in India grows. There are several industry sectors which provide tremendous opportunity for business for machine tool builders. The construction equipment industry is one of the fastest growing sectors and as infrastructure growth peaks this will definitely
creating lot of demand for machine tools. One more sector to look for is the aerospace industry, which is growing at a fast pace in India. Apart from these, medical, defense, telecommunication, precision export components etc, too, are generating demand for machine tools. The automobile and auto component industry remains the biggest customer of machine tools. I think in next 2 years these industries will provide impetus to machine tool builders and will drive demand for the latest generation of CNC machine tools.
INDUSTRY FOCUS
Automation leads the way for Indian machine tool industry Partner Industries The partner industries for automation technology are mainly automotive, food and packing, textile and machine tools industries. Industry enthusiasts believe that automotive industry will drive the use of automation. They believe that with the rise in cost and regulatory pressure, the automotive sector is increasingly turning to automation to deliver quality products, cut costs and raise productivity. As auto component manufacturers look to raise adhere to international standards, automation, especially robotics, is fast gaining prominence.
Going Ahead
Compiled by Ms. Nishi Rath
I
n the past, the machine tool industy in India saw a very little need for automation. But it is all a passĂŠ now, the market is fast growing and the demand is fast changing. The Indian consumers are demanding high-quality products to increase their efficiency and cut down on time. According to TechNavio, the Automation market in India will grow at a CAGR of 7.94% over the period 20122016. One of the key factors contributing to this market growth is the need to improve the decision-making system. The automation market in India has also been witnessing the development of customised automation solutions. Automation is not only removing the human intervention but also improving speed and efficiency. This clearly indicates that India is maturing in automated
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solution. Automation can be divided into process automation, factory automation and electrical automation. Process automation is well-matured in India and as labour is becoming more expensive, factory automation is also gaining ground. Manufacturers recognise the need to automate their processes, and now robotics is also making its way into the industry. However, electrical automation has not caught up in India like the other two. Experts feel there there is lot of growth scope when it comes to electrical automation, factory automation and robotics. According to Markets & Markets, the Industrial Controls and Factory Automation market is projected to reach $301.9 Billion by 2020, from $171.2 Billion in 2013, with a CAGR of 8.53%.
Competitiveness of India’s manufacturing sector, especially the machine tool industry, also known as the backbone industry is critical for sustaining the growth of the Indian economy. Thus, to develop the manufacturing sector further, the Government has announced the National Manufacturing Policy, which aims at increasing the share of manufacturing in GDP to 25% by 2022, from the current level of 15%. Today, it is seen that more and more Indian companies and CNC builders are coming up with automated CNC machine where robots and measuring devices are mounted on it. This is not only cutting down human intervention, but also providing speed and efficiency. This clearly indicates that India is maturing in automated solution. According to Frost & Sullivan, National Manufacturing Policy will lead to creation of national investment and manufacturing zones along with increasing manufacturing activity in the automation sector that will boost the demand for automation products.
INDUSTRY FOCUS www.mtwmag.com
Automotive Industry Bouncing Back: Good Opportunity For Machine Tool Industry Compiled by Ms. Nishi Rath
A
utomotive industry has been known as the key driver of any growing economy. Experts believe that due to its deep forward and backward connections with almost every segment of the economy, the industry has a strong and positive multiplier effect on the progress of a nation. Growth in demand driven by the country’s economic performance, growing middle class and low levels of vehicle ownership helped the growth of the Indian automobile industry during 2009 and 2010. The passenger vehicle industry was largely contributed to the growth of the industry. “Automotive and automotive component industry segments have slowed down in last couple of years. Although there are good signs of upsurge in requirements, still capacities which have been created are not getting filled-up completely. This might take some more time than we envisaged. Once capacities are filed to their designated outputs, real investments will happen. Until that time, investments will be fragmented. On other side , India is poised to be among top five global auto producers. Automobile Sector contributes for about 20 % GDP,” said B.P.Poddar, Vice President, Sales & Marketing, Fatty Tuna India Pvt. Ltd..
industry was not able to grow as expected during last two years due to the slowdown in the economy. Analysts believe that the Government’s thrust on manufacturing sector and reduction of excise duty on auto industry will help regain its sheen. Looking at the strong connection between automobile industry and machine tools, demand for machine tools is likely to witness a healthy rise. “Earlier we were talking about domestic & export markets. However, global boundaries are vanishing faster than we imagined.. It means the whole world is a market place. This gives rise to a lot of opportunities coupled with global challenges such as very high quality demands, delivery commitments and cost pressures. This is a paradigm shift in thinking, approach and implementation in shortest possible time with lot of flexibility,” added Poddar. He also added that the result of all these positive aspects will get translated into sizable demand of machine tools. Machine tool builders must embrace innovation, collaboration, efficient supply chain and shortest possible time to deliver. According to Frost & Sullivan, the demand for machine tools and cutting tools is expected to grow in emerging economies such as China, India, Brazil and Russia.
User Industries & Growing Demand Winds of Change This change will create lot of opportunities for the machine tool players. As we all know, there exists a strong relationship between the machine tool industry and the automotive industry. Performance of automotive industry affect the performance of the machine tool industry. Automobile
The machine tool industry mainly depends on the growth of the engineering sector. Some of the sectors that impact the machine tool players are automotive, auto ancillaries, railways, defense, electrical & electronics, telecommunication and textile machinery among others. With India emerging as a key
sourcing destination for vehicles and components, exports have also hit the right note. This growth has had a positive impact on the machine tools sector, as automotive manufacturers have been looking to upgrade and expand capacities.
Government Initiatives The Government announced the Automotive Mission Plan (AMP) in 2006 with an aim to lead India to become an international hub for designing and manufacturing of automobiles and auto components with output reaching $145 billion and accounting for more than 10% of the country’s GDP. According to reports, the government will announce details of the second AMP like investment and employment targets to be achieved by 2026 in September this year. “The details of the second phase of AMP (2016-26) would be announced in September this year. Through this plan, we are aiming for the automotive sector to account for 10% of the country’s GDP by 2026,” Ambuj Sharma, Ministry of Heavy Industries Additional Secretary said recently.
A Global Giant in the making The production volume of vehicles is rising in India due to increasing domestic demand. Further, as a production hub for global markets, the volume of vehicles for export is also increasing. Within the rising production volume is an expansion of global engine platform production for global vehicle manufacturers. Against this backdrop of increasing production, India is projected to become the world’s fourth-largest vehicle producer after China, the U.S., and Japan by the year 2020, raising its presence in the global automotive industry. MTW JUNE 2015
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CASE STUDY
The Primo™
From
hours to seconds
The Primo™ system reduces part set-up Time for Victory Precisions from hours to seconds, eliminates scrap and maintains tight tolerances Victory Precisions Pvt. Ltd., Pune, India, manufactures aluminium die-castings and large machined engineering components for companies in the oil and gas, automobile, agricultural, infrastructure, and other sectors. It is critical to maintain an accuracy of 15-20 microns on these components and reduce non-productive time while machining. The Primo™ twin probe system, developed by Renishaw, has helped Victory Precisions to achieve this accuracy, reduce part setting time and increase productivity.
MR SAGAR KAUSHIK, Director of Victory Precisions.
Victory – the one-stop solution company Victory Precisions was established in 2006 and supplies components to wellknown companies such as ABB, Alfa Laval, Atlas Copco, Cummins, and many others across the globe. The company has a workforce of
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MTW JUNE 2015
165 people consisting of engineers, designers, operators, and other staff. It registered a turnover of INR 250 million in the financial year 2013–2014. The well equipped aluminium die-casting foundry has an E6 heat treatment plant, a drop quench facility, core shooters and shot blasting machines providing the ca-
pacity to produce 100 tonnes of castings every month. The machine shop has 14 twin pallet horizontal machining centres (HMCs), three vertical machining centres (VMCs), two CNC vertical turning lathes machines (VTLs), turning centres, coordinate measuring machines (CMMs)
CASE STUDY www.mtwmag.com
and comprehensive inspection facilities. It is an ISO-TS certified company and a proud Zero PPM supplier to all of its customers. The company is a one-stop solution for its customers as it has the facilities for making dies, patterns, castings, and extensive machining capacity.
The Primo system – a big saver for Victory Victory Precisions was incurring huge losses in terms of time and material until it started using Renishaw’s Primo system. The Primo system which consists of a Radio Part Setter and a Radio 3D Tool Setter, is available at a competitive price, and is aimed at delivering a fast return on investment. It enables automated on-machine part setting, part inspection and tool setting, helps to eliminate manual setting errors, and improves accuracy and part conformance whilst reducing non-productivetime and scrap. This helps to increase productivity, improve quality, andincrease profits. The Primo system is easy to use, simple to install and represents a low initial financial outlay. Additionally, its exclusive, enhanced warranty offers users peace of mind. The innovative Primo credit token system offers users the flexibility to ‘pay-as-you-probe’. Its 6-month renewable tokens allow unlimited use of the Primo Radio Part Setter and the Primo Radio 3D Tool Setter within this period of time. The credit tokens are also available as an upgrade to enable unrestricted continuous use.
A key benefit is the elimination of the need for extensive G-code knowledge. The system is supplied with GoProbe, an innovative ‘all-in-one’ software package that simplifies part setting, tool setting and calibration. Simple, single-line commands are used instead of multiple lines of code which further eliminates the need for any special training.
Going with the best
GoProbe quick user tool and Primo Radio Part Setter
“We were introduced to Renishaw in 2007, when we decided to install probes in our manufacturing unit. The selection parameter was to go with the best supplier and Renishaw, being best in class and category, was a natural choice for us. Today, we have seven different probing systems from Renishaw,” said Mr Sagar Kaushik, the Director of the Victory Precisions. The company felt that the Primo system suited various applications and installed it on one of its HMCs. “While it is revolutionary, installing the Primo system is also very easy. Renishaw installed it within one and a half hours at Victory Precisions and the operators were trained to operate the probe in just three hours using Go Probe. This combination of software, self learning material and reference tools is standard with the Primo system. Requiring no previous experience of probing, GoProbe makes the probe system easy to understand and use.”
scrap. When machining a crankcase – a critical product for any engine – some casting process variations are often present. At Victory Precisions, in order to get equal wall thickness and avoid future failures, the component would be set up on the machine and bore alignment would be performed manually using dial gauges. Before the Primo system was installed this part setting process took two and a half hours and caused machine downtime. With the Primo system, the on-machine alignment of a crankcase takes just 5 to 10 seconds, saving time and costs. In addition, scrap is eliminated – a saving of INR 45,000 per component – and precision is guaranteed. When machining a cylinder – an engine component and a high-performance part – concentricity is critical. Once the boring operation is performed, checking of concentricity is essential and previously it was necessary to take the product to another inspection facility, which led to a delay in the machining cycle. This entire process took one and a half hours. The Primo system enabled the inspection of this parameter to take place on the machine itself, and in just 30 seconds, without a gap in the machining cycle. A bonnet – an oil and gas industry component – is very heavy and the cost of the raw forging is high. After machining the diameter and other operations are performed on a VTL, the component is set to within an accuracy of ±10 microns of the centre axis on an HMC,
Time saved is money earned The Primo System locating positions on an endbell component.
At Victory Precisions, the Primo system has helped to save time and eliminate
Machined crankcase casting.
MTW JUNE 2015
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CASE STUDY About Renishaw
of dental structures
Renishaw is an established world leader in engineering technologies, with a strong history of innovation in product development and manufacturing. Since its formation in 1973, the company has supplied leading-edge products that increase process productivity, improve product quality and deliver costeffective automation solutions. A worldwide network of subsidiary companies and distributors provides exceptional service and support for its customers. •
Products include
• Advanced material technologies with a variety of applications in multiple fields • Dental CAD/CAM scanning and milling systems and supply
for middle hole boring, PCD holes and threading operations. This alignment was previously carried out by using a dial gauge and it took around two hours. After installing the Primo system, it took
The Primo system: Radio Part Setter, Radio 3D Tool Setter and Interface
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• Fixturing for CMMs (co-ordinate measuring machines) and gauging systems • Gauging systems for comparative measurement of machined parts • High speed laser measurement and surveying systems for use in extreme environments • Laser and ballbar systems for performance measurement and calibration of machines • Medical devices for neurosurgical applications
Additive manufacturing, vacuum casting, and injection moulding technologies for design, prototyping, and production applications
Bonnet, a component used in the oil and gas industry
• Encoder systems for high accuracy linear, angle and rotary position feedback
• Probe systems and software for job set-up, tool setting and inspection on CNC machine tools • Raman spectroscopy systems for non-destructive material analysis • Sensor systems and software for measurement on CMMs • Styli for CMM and machine tool probe applications
A machined endbell as used in genset engines.
a minute to perform this alignment, resulting in a significant time-saving and confidence in the alignment. The Primo twin probe system also saves time when machining endbells, used in genset engines. The casting itself comes with a notch, which is used for locating positions of the holes for drilling and tapping operations. Failure by an operator to locate this particular notch for further machining can lead to many rejected parts. The Primo system has been useful to operators as it can correctly probe the notch and allows the machine to locate other features using this data. Previously this process took 5 to 7 minutes and there was a possibility of rejections; now, it is a matter of just 20 seconds, with guaranteed results. Another critical component where the
Primo system has helped in maintaining accuracy and reducing rejections is the air intake manifold used in automobile engines. This component comes in different sizes and can be very long. When a manifold is cast, there is normally a distortion of 1 mm to 2 mm. Correct alignment is very important when machining, so that bored and clamping holes are machined as per the drawing. The Primo system probes port holes on the casting and aligns the component perfectly. It takes wall thickness variations into account, leading to a total time saving of ten minutes and the elimination of scrap.
Unique Mr Kaushik is clearly impressed with the Primo system: “The software is very simple: the operators using the Primo system can be trained in 30 minutes and find it very easy to use this product. The advantage is its probe-on-probe calibration and the credit token system, which is a unique payment system that Renishaw has offered. We do not have to pay everything at one time and as such, higher initial investment is avoided. We can buy credit tokens as and when we want to use Primo. It is like a prepaid system that is a low cost solution for SMEs.”
MACHINE TOOLS WORLD |
25 | June 2015
TREND SETTER
TAL Manufacturing Solutions takes giant strides in high-tech fields TAL Manufacturing Solutions Ltd. was formed by the merger of the resources of the Machine Tool Div. and Growth Div. of Tata Motors, Pune in March 2000. What was started as an arm for providing automation solutions to the industry has, over the years, metamorphosed into a multi-faceted engineering entity with core competencies in making high-end machines, tooled up solutions, assembly, testing & handling systems, painting systems, hydraulic solutions, and materials handling & conveying including robotized ASRS. Working on its core strength of offering comprehensive manufacturing solutions, TAL has recently forayed into the development, manufacture and assembly of precision aerospace components, aero structures and tooling. Mr. P.K. Balasubbramaniian converses with Mr. Rajesh Khatri, Executive Director and CEO, TAL to get an update on the dynamics and the path-breaking initiatives of this innovator who is exploring exciting business lines to take a slice of the untapped global market. Excerpts:
Q. TAL was formed in 2000 by the merger of two Divisions of Tata Motors. Has the new entity served the purpose it was founded for and the vision set out in the charter? Yes. TAL was started in 2000 by merging the resources of the Machine Tool and Growth Divisions of Tata Motors (then known as Telco), at Pune. Earlier it was named TelcoAutomation Ltd. Telco / Tata Motors was our major customer at that time. Slowly we added new dimensions to our activities and added quite a few new customers for special purpose machines, tooled up solutions, materials handling and automation. We also changed our positioning from a provider of ‘automation solutions’ to ‘manufacturing solutions’. Our new
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Mr. Rajesh Khatri, Executive Director and CEO, TAL Manufacturing Solutions Ltd.
name goes well with the activities we are currently into and the lines of products and services we want to add up to our portfolio in the future.Business from Tata Motors is to the extent of 35% of our sales turnover-the rest comes from external clients.
Q. Could you elucidate the manufacturing solutions you offer? Today we offer integrated manufacturing solutions for the industry. We continue to offer sophisticated machine tools and special purpose machines with tooled up solutions. Integration of Robotics & Automation is another area where we contribute significantly. Manufacture of precision aerospace components and aerospace tooling is
our new focus area. Our fluid power solutions are also adding value to our offerings.We have even provided facility planning and execution services to several group companies. The thrust is on improving quality and productivity through cost effective automation and innovation.
Q. If you see the machine tool scene, the players are many and the competition is fierce. What’s TAL’s niche and positioning? The size of the machine tool industry in India is to the order of Rs.6,800 crores. In an industry that is expected to grow @8-10% annually over the next five years, almost 55% of the country’s machine tool requirements are met by imports. With a depreciating rupee, it offers a good opportunity for the local manufacturers to grow their market share. TAL produces Machining Centers, Vertical Turning Lathes and Special Purpose Machines (SPMs) and 5-axis MachiningCenters based on PKM technology.When it comes to SPMs, TAL is always a preferred supplier.
TREND SETTER www.mtwmag.com
We have now come up with a 5-axis machining center with PKM technology from Exechon, Sweden. PKM (parallel kinematic mechanism) enables an articulated robot like movement of the machining head against a linear movement of the axes in the conventional machines. Along with a wider machining envelope, it offers a highly flexible and productive solution. With a thrust on flexibility, our PKM technology is timely and makes us future ready. These machining centers will be a boon for automotive, aerospace and defence applications. We offer quality plus cost-effective tooled up solutions and value added services for machine tending requirements. We have also tied up with Maus of Italy with exclusive rights formarketing their products (VTL) in India.
Q. Let’s take machining centers for instance. What’s your differentiated offer to the end user? Our machining centers are highly reliable, while being economical. We offer them with tooled up solutions to the MSME segment. Of late, we have supplied tooled up machines to industry majors like Cummins, L&T, Bongfiglioli and others. We have recently supplied a VTL to Bonfiglioli, India, for machining the inside profile of a hardened (54Rc) bearing ring to very close tolerances, thereby eliminating the need for grinding. The VTL (with MAUS design) is very robust and highly reliable and has been well received by the industry. We have supplied SPMs for machining large engine cylinder blocks for Railways and turbine blade machining.
Q. Over the years, you have added quite a few new dimensions to your own capabilities and value additions. Could you elaborate this? We have set-up a greenfield worldclass facility at MIHAN-SEZ Nagpur for manufacturing precision parts and assemblies for Aero-structures and Aero-engines in the Aerospace domain. The facility is equipped with latest technology equipment and a one- lac class clean room for manufacturing advanced composite parts. Leveraging our own capabilities, we have also manufactured and supplied large assembly tooling for Aerospace Industry. TAL has partnered Tata Motors (TML) for the fabrication activities of defence vehicles like Mine Protected Vehicle and Wheel Armored Platform - and is well poised to support TML in its efforts to exploit the emerging opportunities in Defence. Over the years, TAL has acquired the credibility of being the most preferred supplier to address the emergent needs of our customers.
Q. What are the various solutions you offer for assembly, testing and handling of end products? We offer integrated solutions in Material Handling, Paint Systems and Tooling for welding/assembly including Robotics & Automation. Our integrated manufacturing systems have a proven track record of facilitating processes in the automobile and heavy engineering sectors. We offer systems for welding wagons, robots for welding or assembly, testing facilities, painting systems and so on. We have designed and manufactured test-rigs / dynamometers.
Q. What are the various products and systems you offer from the Fluid Power Div? Our Fluid Power Division offers Telescopic Cylinders, Control Valves, Axial Piston Pumps and Gear Pumps for Hydraulic Tippers. We cater to OEM’s like Tata Motors.
Q. Are you also into materials handling? In materials handling, we are already offering solutions for floor conveying and overhead conveying. We are also developing & supplying Automated Storage & Retrieval Systems required for modern warehouses.
Q. What are the painting solutions you offer? We provide cost-effective and environment friendly complete painting solutions to our customers. This includes facility for pre-treatment, primer coating, painting and drying, as also handling, control and automation.
Q. What are your growth plans? What we are doing currently for the aerospace industry is just a tip of the iceberg. The estimated global requirement of commercial aircrafts is to a tune of ~30, 000 numbers per annum. This throws up a business opportunity of more than USD.25 billion annually in Aero-structures and tooling. Several leading Aircraft manufacturers have large Offset obligations to fulfil. India also offers a cost arbitrage in labor intensive parts and assemblies. With the relaxation in FDI norms in Defence, the opportunity is only expected to grow. TAL is gearing up to leverage its capabilities (related to mechatronics and hydraulics) to also exploit the potential opportunities in offering Tooling and Ground Support Equipment for the Aerospace industry. Low levels of automation, especially MTW JUNE 2015
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TREND SETTER in the MSME segment, coupled with scarcity of skilled labor offers opportunity in Robotics and Automation. In our legacy businesses, we see good market for High Speed High Torque machines. Automated Storage and Handling Systems (ASRS) offers good potential for growth on the back of explosive growth in logistics across sectors.
Q. What are the capabilities you have developed to enter this domain? We have honed our capabilities for manufacture of flying parts, structural components, assemblies, tooling, robotics for automation, materials handling, etc. We will leverage our relationship with our technology partners. Talent induction and development continues to be our focus.
Q. Who are your major customers other than Tata Motors? JCB, John Deere, VECV, Bombardier, CNH, Tata Hitachi, International Tractors, Amul, FIAL, TASL, TLMAL, Jindal, etc. are some of our key customers. We also export our products- 25-30% percent of our turnover comes from exports, primarily to Aerospace OEMs.
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Q. Whatever be the value addition, the customer still would like you to be cost competitive. How do you address this? We address this through lean manufacturing, enhancing operational efficiency, design optimization, standardization and innovation. We take pride in offering innovative solutions to customer problems. A recent example is the design and implementation of electronically managed counterweight mechanism on a multi-variant cabin assembly station we did for Volvo Eicher Commercial Vehicles.
Q. What are your expectations from the new Government at the Centre? Policies and actions to revive the capex cycle, labor reforms and good governance are the immediate expectations from the new Government. Business confidence has already improved on the back of several measures including FDI in Defence and Aerospace that the government has initiated. Lower interest rates will be the trigger for the revival of investments.
Q. What are the challenges ahead for you? Talent management is the greatest
challenge in today’s context. Maintaining our cost-competitiveness and widening the markets add to the challenges. We have to maintain our technological edge all the time. Of course, our people are our biggest strength – TAL’s highly experienced team is ready for the exponential g rowth. We are confident that we will convert these challenges into opportunities.
Mr. Rajesh Khatri, who has been steering TAL Manufacturing Solutions transformation for the past two years, is a veteran production engineer and an alumnus of VJTI, Mumbai. He had long innings at L&T Mumbai in the Heavy Engineering Div. spanning over 24 years followed by a 4 ½ years’ stint at JCB, Talegaon. He has a successful track record of business transformation and profitable growth. Talking of the tenets of corporate excellence, Mr. Khatri quotes Goethe thus: “The greatest thing in the world is not so much where you stand as in what direction you are heading”. Under his stewardship, TAL is indeed heading in the right direction.
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FACE TO FACE
& Machine Tools Industry Eyeing the prospects Q: What are the Machine Tool Industry trend that is driving industry in current scenario?
Mr. Shrinivas Shirgurkar Ace Designers Limited
A: More than half of demand for machine tool industry is from Automotive Industry and the other half is shared by General Engineering and the rest of the manufacturing industry. One of the main demands in the manufacturing sector is for very high accuracy; reliable machines with automatic loading and unloading system in the automobile industry and the rest of industry want sophisticated multi-function machines for completing all the operations for the components with minimum set up change. Above all there is need for affordable machining solutions.
Q: How did budget made imapact on the industry? A: The budget announcement has several new initiatives to promote investment in manufacturing such as
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Infrastructure projects, easing of FDI in Defence and Railway production creating demand in the entire manufacturing value chain. To support easier implementation the Government has announced several reforms in easier land acquisition, quick clearance of the necessary licences. Above all government has announced a strong ‘Make in India’ Initiative covering all facets of setting up and ease of doing business. Additionally the implementation of GST regime from April 2016 has given hope and comfort to the manufacturing Industry. All these will certainly see growth picking up perhaps after three or four quarters, when many of the projects fructify. However in the immediate future there is no specific announcement whether in direct or indirect taxation to spur demand, except that with lowering of inflation, there are hopes of lower interest rates.
FACE TO FACE www.mtwmag.com
Mrs. Kelkar
Make in India
The booster of machine tools industry Q. What trend will drive machine tools industry in near future ? A: You can see a clear cut trend for fully automatic machines and factory automation. The customers are also interested in complete solutions which comprises of the machine, the tools and the process of manufacturing. Customers want the machine tools that are flexible and can be easily tooled up for another type of component. The set up change time should be minimum as the need to quickly change over and produce another variety based on their market demands. Machine tools and automation is expected to be very robust with 0 down time and lower maintenance cost. The concept of “Total cost of ownership” is catching up very fast within India.
Q. What is the impact of Union budget on the industry ? A: The budget hints that Retrospective taxation will not be there & this will give feeling of security to the foreign investor.
They will get the feeling of Stability which will help in getting more foreign investments. Various Exemptions will be removed & corporate tax will be brought down to 25% from 30 %. Such clarity & simplicity in tax laws will help not only foreign investors but also Indians to focus on improving their operational profitability rather than increasing the profits by working around the vague tax laws. The announcement of GST by April 2016, is the absolutely welcome step/ initiative. This will go a long way in enhancing Business environment & will certainly simplify Business Process. They have also announced Business Portal which is expected to give certain approvals on line. Now, how they execute this needs to be seen. Good Execution of all these declarations will make “Doing Business in India” easy & will give a large boost to Domestic as well as foreign investments & Industry..
Director (Sales & Marketing) Grind Master Machines Pvt. Ltd.
Q. What are the remedies do you suggest to improve the positioning of the industry you are into ? A: Prime Minister has taken the “Make in India” initiative which is expected to give a boost to the Capital Goods Industry. It is difficult to do this quickly & one should not expect dramatical results in one year.. The Prime Minister has met most of the CEOs of top 500 companies worldwide to promote MAKE IN INDIA & it shows extreme hard work & commitment towards this campaign. Industry believes that this initiative will give Boost to the Indian Economy. Capital Goods industry should step up the production capacity in order to keep the delivery times within the expected limits of the buyers. This Make in India initiative has also opened up several opportunities of cooperation and Technological Partnerships and machine tool industry should take the benefit of this. MTW JUNE 2015
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FACE TO FACE
& Machine Tools Milieu
Mr. A.P. Jayanthram
Managing Dirtector Heidenhain Optics & Electronics India Pvt. Ltd
Q. We are boasting of our achievements in the machine tool industry. How come 70% of the country’s machine tool requirements are still being met by imports? A: Yes. Over 70% by value gets imported, though our Machine Tool Industry is over 6 decades old. Majority of Indian Machine Tool makers belong to the small and unorganised sector and the big players are busy meeting
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the comparatively low technology low accuracy needs. The business driver is mainly the automotive industry, which has comparatively lower class demands and when it comes to high end needs like for example, skin panel dies, they are predominantly being imported . Equipment for high speed machining, Die and Mould , 5 axes and aerospace jobs, come to India from reputed global players. In the segments that Indian Machine Builders operate, there is too much focus on low priced offerings, that originates from demands on ‘just enough’ technology. With this defensive reaction of price sensitiveness, we have unknowingly compromised on quality and yielded ground to imports from leading countries like Germany, Japan Italy and Switzerland and also from those like Taiwan, South Korea & Czech Republic. Thankfully, this situation is changing due to the lead taken by a handful of top Indian Machine Tool companies who are making significant steps to enhance technology by R & D,global acquisitions and joint ventures .
Q. What should we do to reverse the situation or at least reduce the imports substantially? A: Imports will continue to be there, as long as there is technological
leadership with global companies who put their heart & soul in producing the best for a world market. India can certainly increase the share of the global pie by multiple strategies of Import substitution, local sales maximisation and exports. It is quite clear that “producing cheap” is not the solution, especially in the background of the quality perception that pulls us down in the global market place. We must do everything possible to enhance the quality of our manufacturing education, upgrade our attitudes towards avoidable Jugaad to be replaced by an uncompromising high quality orientation in manufacturing. We must produce machines using the best high end components that the world leaders use.
Q. How will the PM’s ‘Make in India’ campaign help in realizing the above goal? A: It is a welcome initiative. But, to persuade technology leaders to come to India and produce, the first thing we need to do is to restore the confidence of the global manufacturing fraternity that we can provide a healthy infrastructure to produce with simpler regulations, better quality of infrastructure, with good roads, high quality power and a corruption free business environment.
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FACE TO FACE
Effica unleashes robotic automation in India Q. Effica is a name to reckon with in automation. What precisely is your niche? A: We started off in 2005 designing and manufacturing special purpose machines (SPMs) for a plethora of applications. We even developed robotized special plasma cutting systems for marking and precision cutting power transmission poles of 60 ft long. Way back in 2009 we executed a project worth Rs. 2 crores in Houston. This was a complex job involving different disciplines – mechanical, electrical, electronics, robotics, and industrial PCs. It involved handling, rotating, marking and cutting of poles where cost of error was very high. Over the years, we have changed our focus. Since 2011, to be precise, our focus is on material handling automation using robots which includes machine tending, palletizing and conveying.
Q. What are the automation solutions you offer for the manufacturing sector? A: We offer robot based component loading and unloading systems. The solutions are available for multiple
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CNCs, forging presses, sheet metal presses, plastic injection moulding and similair processes. Along with this we offer all the accessories required to complete the solution like conveyors – roller, belt, and slat, the end effectors for gripping various types of components, the safety systems, infeed and outfeed component stacking magazines. We also offer gantry machine tending to replace articulated machine tending projects for payloads from 2 kg to 100 kg. This is an economical solution, and with this the existing plant layout need not be disturbed. We also do bag conveying & palletizing automation. This is a robot-based high speed palletizing system with a speed of 20 tonnes per hour. For the FMCG segments we offer pick and place solutions for the packing requirements. These are very high speed solutions for light weight products with a special emphasis on hygiene. We have made our systems modular and user-friendly so that in the event of a failure, the end-user can fix it themselves. This way we have removed the fear of breakdown and consequent downtime from the mind ofthe end-user.
Mr. Arjun Prakash President, Effica Autiomation Ltd.
FACE TO FACE www.mtwmag.com
Q. Could you throw some light on your infrastructural facilities? A: Well, we have a sprawling manufacturing facility housed in a land of 10,000 sq. mtrs. We have an in-house machine shop, assembly shop, design department, quality control section and so on. Our main strength is in our software and programming capabilities required for our solutions. We have a dedicated trained workforce of 35 people. Marketing has traditionally been done directly. However, we now have channel partners in strategic locations like Coimbatore, Chennai and Bangalore to extend our reach to the customer.
Q. Productivity enhancement is understandable. How do you increase efficiency and flexibility? A: Robots help enhance flexibility. Special purpose machines need retooling but robots need only reprogramming. The changeover is minimal and not timeconsuming. Practically we observe that our customers have seen an increase in machine utilization by upto 35% while using our solutions. This is because people are prone to fatigue and night shift efficiencies are very low. This is not there when robots are at work. Naturally efficiency levels are high.
Q. Could you elaborate on the cost saving aspects? A: To begin with there is form of instant savings from the increased machine utilization. In the case of CNC machines if we are able to tend to 3 machines and increase their machine utilization by a factor of 35% then it is the equivalent of having the fourth machine which may be priced similar to our robotic solutions. This is even more pronounced in the case of forging presses where the cost of a single press can run up to multiple crores and the savings are massive in terms of capital investments when robotic machine tending is used. Added to this the unavailability of skilled labour
and the attrition turnover of trained people is a bugbear. This disrupts production and uptime of machines. When you switchover to robotic automation, the breakeven is achieved in less than 18 months in most cases and in some cases even instantly as mentioned above. The risk factor is less and no recurring costs. All these bring enormous savings to be accrued to the bottomline. Today we see even very small scale machine shops and businesses breaking even with robotic automation . As the prices of robots keep dropping in the future we are only likely to see more and more of this trend.
Q. Who are your major customers and markets? A: Our customers vary from small machine shops to automotive ancillary manufacturers like Pricol, Amara Raja, and Rane. In the engineering sector we have customers like LMW and in the FMCG sector we have customers like ITC. Even large companies like Ford, Nissan and Saint-Gobain have been our customers in the past.
Q. Why do customers come to you again and again? A: We are highly customer-centric in our operations. Since the time we have increased our focus to material handling robots, we have been able to standardize a lot of our internal processes and respond to our customer very fast at a much lower cost. This results in much higher customer satisfaction and quicker ROI. This must be the reason why customers come to us again and again. Recently we supplied one robot to Rane EVL. They were so happy with its performance that they immediately ordered six more systems!
Q. What are the challenges ahead for a company like you in today’s con text? A: The field of Robotics is in a massive growth phase similair to what IT was in the late 90s. When this happens,
we have to be ready to scale up our production to ride the growth wave. Side by side, we must educate the customer on the benefits of automation. They must be induced to adapt the manufacturing processes to make room for robots to take charge. We have to remove the fear from the minds of the customer that there won’t be any issues of breakdown and idle time since they themselves can address the snags if any and keep the machines humming.
Q. What is the shape of things to come in factory automation and how do you envisage making a dent in this exciting field? A: Some 20 years ago a robotic solutions cost Rs.30 lacs. Today it is in the vicinity of Rs.20 lacs. The inflation adjusted prices are dropping down massively and will drop down further in the days to come. This will help manufacturers to go in for more and more robotic automation. There has not been any change in technology in Robotics for the past four decades. However, we are seeing significant changes in technology in the last 2-3 years. The next wave of robotic technology like collaborative robots which work side by side with humans and super easy programming and operation methods which are similar to your mobile devices and apps are already rolling out. The worldwide robotic sales for the year 2013 is said to be 179,000. This is nowhere near the potential demand for robots in the world. In the year 2014 China is the largest consumer of robots. Indian SMEs should think progressively and take path-breaking decisions to reap the benefits of productivity and flexibility offered by robots. We in India are on a growth trajectory. And robots will play a pivotal role in enhancing our quality, productivity and operational efficiency in the days to come.
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TECH UPDATE
Innovative features for monitoring and controlling distributed assets & IP networks
P
cVue 11.1 is the latest release of PcVue SCADA solution created by ARC Informatique. It now features the monitoring of geographically distributed assets and IP network devices. The innovative design improves operator effectiveness with powerful data analysis tools and developer productivity with advanced automation of configuration. GEO Map Control, a built-in component for GIS decision making, provides live interactive maps from popular mapping services such as Google and Microsoft. Maps are interactive and dynamic; supporting both off-line and on-line maps access. PcVue graphical objects (Symbols) may be used as markers including animations and display of real-time asset status and alarms. No scripting or programming is required to configure the Map Control. PcVue’s communication driver pack, CIMWay, has been expanded to support SNMP for monitoring and controlling devices on IP networks. This native capability not only allows PcVue applications to monitor the health of the network, but provides access to an ever increasing number of IED’s and other equipment with IP interfaces. Designed for optimization of large IP networks in mind, the PcVue SNMP solution capability supports the growing Internet of Industrial Things (IoIT). Data Analysis for operator decisionmaking support is an increasing requirement in a modern SCADA application. PcVue 11.1 provides powerful analysis, with a few clicks operators may move from real-time to analysis mode and back. The resulting visualization may be with dashboard KPI displays or the powerful new X-Y charting control for
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correlation and statistical analysis. Enhancements to BACnet® Scheduling and new SMART Generators for BACnet® and TwinCAT® - Beckhoff for automated configuration are some of the many additional new features and improvements to PcVue Solutions with PcVue 11.1. Other additions are worth to be noted: the implement of a new license utility, a unique tool for license management, and improved client drivers for Energy management such as DNP3, our DNV Kema certified IEC 61850, IEC 60870-5-104, etc. To preserve your SCADA investment and ensure its longevity, PcVue has been maintaining backward compatibility for 20 years. This new version is compatible with the latest technologies (Windows 8.1, Microsoft SQL Server 2014, etc.) including virtual environments.
Paris, France, is an independent global leader in HMI / SCADA software. Founded in 1981 and certified ISO 9001 and 14000, the company is establishing an international presence through direct technical and sales offices in the US, Europe and Asia. Thousands of licensed copies of its SCADA PcVue are installed all around the world. PcVue Solutions provides a flexible solution for supervising industrial processes, utilities and infrastructure. It meets industrial standards of reliability, security and performance while maintaining the user-friendliness of an office application. It spans requirements from single-user standalone applications to complex client-server systems with redundancy.
ARC INFORMATIQUE
For more information www.pcvuesolutions.com
ARC Informatique, headquartered in
MACHINE TOOLS WORLD |
37 | June 2015
• ExactDress™ Dressing Control
© 2013 Schmitt Industries, Inc. All rights reserved. SBS DYNAMIC BALANCE SYSTEM is a registered trademarks of Schmitt Industries, Inc.
SBS PRECISION SYSTEMS (INDIA) PVT. LTD. Tel: 033-32920078, Cell: 9331140202, Email: enquiries@sbsindia.in | Web: www.sbsindia.in See us at EMO 2013. Hall 6 Stand C37. Fax: 033 24003097 • Kolkata • New Delhi • Pune • Bangalore
• AEMS Acoustic Emission Monitoring
• ExactControl™ Grind Cycle Management • SBS In-Process Balancing
Grinding Process Innovation
www.schmitteurope.com
TECH UPDATE
More efficient production thanks to tool presetting Attractively priced and professional – the tool presetters of the new UNO series from DMG MORI Microset convince with innovative features Mr. Lothar Sommer; Managing Director, DMG MORI Microset GmbH
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here the UNO series is concerned DMG MORI Microset relies on proven technology in tool presetting plus consistent further development. So the latest models combine optimum ergonomics with extensive technical equipment. “The diverse options ensure the UNO series a level of individualisation that is unmatched in this price category”, explains Lothar Sommer, Managing Director of DMG MORI Microset GmbH. In addition to a touch display, RFID chip system and post processors for all standard controls the range of potential equipment now also includes completely new options such as the autofocus and automatic drive. The UNO autofocus differs from the manual UNO in that it automatically focuses the cutting edge to be measured. This option proves enormously time-saving in particular for tools with several cutting edges around the circumference.
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TECH UPDATE www.mtwmag.com
Measuring range
Max. tool diameter Max. tool diameter snap gauge Max. tool length, Z-axis
Operation
manual Manual with autofocus CNC fully automatic with manual mode Infinite fine adjustment
Accuracy
True running accuracy at spindle nose Repeat accuracy
Spindle
Precision spindle SK50 Vacuum clamping Spindle brake 4 × 90° Indexing for turning tools (e.g.: VDI)
Rotational centre measuring device
Dial gauge Second camera
RFID tool identification
Manual handling (Balluff, Siemens, Euchner, Pepperl+Fuchs, Big Daishowa)
Software
MICROVISION
O
NS
19” screen. There is a 22” or 23” touch display available as an option as well as the comfort system cabinet. Unique here is the possibility of measuring tools with diameters up to 100 mm with the snap gauge principle even with the standard version thanks to a traverse path of +200 mm to -50 mm in the X-axis. And of course all conventional tool interfaces such as HSK, Capto, VDI, KM or BMT can be realised by adapting the spindle in
PT I
both equipment configurations if needed. The UNO autofocus and UNO automatic drive from DMG MORI Microset come with a comfort system cabinet and a 22” touch display in their standard versions. The models of the UNO series are available in two sizes. The UNO 20|40 kicks off with a 400-mm traverse path in the Z-axis while the UNO 20|70 has a travel of 700 mm. Both versions are available as tabletop devices with a
µm 2 µm ± 2
O
In addition the UNO automatic drive positions the cutting edges automatically. No special knowledge is required of the user because the machine carries out fully automatic measurement of complex tools with several cutting edges and steps at the press of a button. In other words the UNO automatic drive constitutes an additional worker in tool presetting. The same manual operation as in the standard version is also possible with
mm 400 mm 100 mm 400 / 700
• 22” or 23“ touch display with 50-time magnification • Pneumatic indexing and brake of the spindle • Second camera for rotation centre setting • Release-by-touch operation • Comfort system cabinet • Adapter/ tool tray • High-quality adapters • Thermal label printer • Tool identification with RFID data carrier • Post processors for all standard controls
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TECH UPDATE
addition to the SK 50 that comes with the standard version. Lothar Sommer goes on to explain the solid basis of the UNO tool presetting devices: “You can only get this class of FEM-optimised and thermally stable grey cast iron construction from DMG MORI.” The inherently rigid bed with 3-point support not only ensures safe footing but highest flexibility in the workshop as well thanks to simple setup. The integrated infinite fine adjustment in both axes and the segment incident light for visual control of the cutting edge are also outstanding features included in the standard version. The UNO “sets new standards in the entry class of tool presetting”, claims Lothar Sommer. “The release-by-touch operation in particular and the large touch display for even better handling of the MICROVISION software make work so much easier.” The high-performance software enables simple and operator-
Highlights • New design, enhanced ergonomics and top precision • FEM-optimised and thermally stable grey cast iron construction • Individual design thanks to modular concept • Tool dimensions: diameter 400 mm, measuring length up to 400 mm (optionally up to 700 mm) • Measurement in snap gauge principle up to diameters of 100 mm (Travel up to x -50 mm) • Infinite fine adjustment • SK 50 precision spindle • Segment incident light for visual control of the cutting edge • 47 cm (19”) screen in 16 : 9 format with 45-time magnification
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independent measuring in all equipment configurations. Lothar Sommer highlights the benefits of the latest generation of this software: “MICROVISION offers intuitive operation for the user and with its helpful functions quickly achieves highly accurate measuring results. Accuracy
is aided by a focusing window, which enables exact positioning even for highly complex tools. A thermal label printer, vacuum clamping, a second camera for setting the centre of rotation and a multitude of other options round off the latest UNO series.
TECH UPDATE
HAAS: Full control Some of the most powerful features of the Haas control take only the push of a single button. For example, the operator can set tool offsets with the push of a single button – without having to manually enter numbers into the control.
H
aas Automation will soon be shipping its 160,000th machine. Every one of these machines is equipped with a Haas control, making the US machine builder one of the four largest control manufacturers in the world. The American firm’s philosophy: operators should be able to achieve their aim as easily as possible. Company founder Gene Haas set himself this development goal right from the start: the intention was for the control to be equipped with functions allowing users to get to grips with the machine and be productive quickly. These requirements stem from practical experience, as Gene Haas had worked with other controls for many years in his workshop before beginning production of his own machine tools. Together
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with chief developer Kurt Zierhut, Haas implemented his ideas for a user-friendly control – made by users for users. This concept becomes clear even as one begins work. The operator switches on the machine and needs only to press a button for the machine to be referenced and ready for work to start. All machine axes are reset at the touch of a button. Most other controls require more inputs before work operations can commence. This operating philosophy is continued elsewhere. Some of the most powerful features of the Haas control take only the push of a single button. For example, the operator can set tool offsets with the push of a single button – without having to manually enter numbers into the control. He simply jogs a tool to the surface of the part, pushes the Tool
Offset Measure button, and the tool’s length is automatically stored in the tool length register. He pushes the Next Tool button to repeat the process for each tool. Setting work offsets is just as easy. The Help function is a builtin, searchable operator’s manual that explains the various functions of the Haas machine. The user simply types in a keyword to find a topic, or hits F1 for G-code help and F2 for M-code help. The Calculator pages have powerful tools for solving triangle equations, circlecircle-tangent equations, and circle-linetangent equations, as well as a speedsand-feeds calculator, and a standard math calculator. The solution to any equation can be pasted directly into a program from the calculator.
The same control for all machines The controls are built in-house by Haas in its factory in Oxnard, California, including the corresponding software. All machine tools from Haas – vertical and horizontal machining centres and lathes – are equipped with the same control. This is intended to allow the same operator to operate a lathe and a milling machine, without having to attend expensive training courses. Even the screen display remains the same, also with new machines and new versions of the software. New functions are always integrated into the existing menus. The operating concept is based
TECH UPDATE www.mtwmag.com
on three modes – Setup, Edit, and Operation – each of which is assigned a screen. On the display, the control always shows the user his current location. The Current Commands page displays the current running status of the machine, including the program running, the position, which tool is in the spindle, the spindle and axis loads, the spindle speed, and the feedrate. Additional screens show the commands and G-codes being used in the current program, and timers show cycle time, cutting time, power-on time, and M30 count (number of parts). Other displays show macro variables, provide tool-life information, and show the minimum and maximum spindle load for each tool.
Intuitive operation The Haas Intuitive Programming System allows the operator to perform basic milling operations without knowing G-code. “Our IPS is a dialogue control,” explains Wim Meeus, Technical Support Coordinator in Brussels, where Haas has its European headquarters. “You find the relevant image and simply select the corresponding function.” The conversational operating system uses an easy-to-understand tabbed format to guide the operator through the steps necessary to machine a part. First, the control leads the operator through basic job setup: setting tool and work offsets, selecting the tool type, and specifying the material being cut. The operator then selects an operation to perform and fills in basic information as prompted. Default values for spindle speed, depth of cut, and feedrate are filled in automatically, based on the information provided. The operator can change these conservative values if desired. Once all necessary information is entered, pushing “Cycle Start” performs the desired operation. Multiple operations can be recorded and saved as a single G-code program that can be played back to duplicate the part. Help menus are available directly on screen, and a
graphic dry-run feature allows operators to check their work before running a part. It is possible to prevent the accidental or unauthorised editing of the program memory with a program lock. Settings, parameters, offsets, and macro variables can also be protected in this way. If necessary, the control can be set in the production, for example, that only one program is running and the operator cannot change anything in the programs or the offsets. He can then only select “Cycle Start,” as well as “Power On” and “Power Off.” The jog handle on the Haas control is particularly ingenious. Most machines use the jog handle only to move the axes around. The multi-function jog handle from Haas can also be used in other modes to cursor through the program for faster editing, override spindle speeds and feedrates, or scan through offsets, parameters, etc. A smart accessory is the remote jog handle. The handy unit has a 7 cm colour display, an 11-button keypad, a triple-knob motion-control system, and a built-in LED inspection light. One can set tool and work offsets, jog up to nine axes, display machine position, show the current program running, and more – all from the jog handle. To enter a new offset or zero point, the operator doesn’t
need to physically go back to the control. An important criterion to increase productivity is to maximise the tool life. The Haas control can monitor the spindle load for each tool, and automatically adjust the feeds when a limit set by the operator is exceeded. Depending on the setting on the control, in these cases the set feed is decreased, the operator is informed, the feed waiting mode is activated, or the corresponding alarm is triggered. When a program is first run, the Haas control automatically records the maximum load measured for each tool. This data is used so that the operator can set limit values per tool using the “Tool-Load Monitoring” function.
Strong features According to Wim Meeus, combining this load monitoring function with the Wireless Intuitive Programming System (WIPS) option on the machine creates a powerful tool. WIPS is the fully integrated wireless tool and work probing system on Haas machines. It permits the seamless setup of machines, the rapid implementation of machining processes, as well as the reliable control of tools and parts during machining work. “The system also checks whether or not the machined part is OK, a change MTW JUNE 2015
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TECH UPDATE
in the offset is required or if a new tool needs to be fitted,” according to Meeus. A strong feature of the Haas control is also the data import. “Many users have a drawing, generally from a CAD program such as Autocad,” confirms technician Meeus. “The CAD program can be used to make a DXF file easily that can be used directly on the control. This means that a program is ready to use in a flash.” If necessary, by taking advantage of the editing functions of the Haas control, the user can modify features, change the order of operations, or even conveniently put them into other programs – all at the control, without going back to a computer. The folks at Haas are fully aware that an operator doesn’t generally welcome getting to grips with a new control. For this reason the control has been kept relatively simple. With Haas there are also things that operators will be familiar with from other controls, such as IPS functions. “Anyone who has already used other controls and who is familiar with CAD/CAM won’t have any problems using the Haas control,” reiterates Wim Meeus from Technical Support. “After a few weeks, operators say that they are quicker using the Haas than with other controls they’ve used before.” After a short period of familiarisation, a lot can be achieved on the Haas much more quickly, not least because very little needs to be programmed directly on the control. Many programs that have been created for Fanuc controls, for example, can be transferred across with minimal changes. A converter in the control input automatically translates the program for the Haas control. “Essentially, we use an ISO control here,” explains Meeus. “Several Haas cycles are included for which a few modifications may be required.” It is not so simple to convert programs from Heidenhain controls to Haas. “Typical tasks for tool & die work and mould making can also be programmed quickly on a Haas control,”
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according to Meeus. Haas intends to demonstrate this in the coming year. Jens Thing, Managing Director at Haas Automation Europe, comments: “At the Moulding Expo 2015 in Stuttgart, we will place our strengths in tool & die work and mould making at the forefront. On our fast machines, we will demonstrate the multipass machining of 3D shapes. We are convinced that we have an attractive offering for the tool & die work and mould making sector in Germany, as well.” For Jens Thing, there is a significant advantage in that all servicing for a machine comes from one source. “We do not have any control specialists or mechanical engineering specialists, and no specialists for Siemens, Fanuc, or Heidenhain. We have trained service technicians who provide servicing both for the machine and for the control,” according to the European boss.
Connected to the machine As a native control, the Haas control is deeply connected to the Haas machine. This becomes clear on the tool changer, for example, and at speeds that can be dynamically adapted for every program run. This also makes possible options such as high-speed machining (HSM), which reduces cycle times and improves accuracy considerably. Using a motion algorithm called “acceleration before interpolation,” combined with full look-ahead, HSM allows higher contouring feedrates without risk of distortion to the programmed path. All programmed motions are accelerated before interpolation to ensure the movement of each axis does not exceed the acceleration capability of the machine. The look-ahead algorithm determines the fastest feedrate at which each stroke can be blended into the next without stopping. This results in higher accuracy, smoother motion, and a higher actual feedrate – even with complex part geometry. Haas builds many options for the machines in-house, also including the programmable coolant nozzles.
Whilst the program is running, the coolant jet follows the tool, taking the coolant precisely to the right location. To do this, the position of the coolant nozzle is stored in the tool table so that every tool has the relevant setting. The through-spindle coolant (TSC) important for mould making is integrated into the control as an option. Despite the closed system, the ISO control underlying the Haas offers the advantage of also being able to connect external enhancements, such as pallet changers or robots. Haas uses the same control for all its machines – regardless of whether it’s a lathe or vertical/horizontal machining centre. Many functions can be executed by pressing a single button. The native control also makes highspeed machining possible. To handle the control produced inhouse by Haas in the USA, the same service technician can be used as for the machine. The fully integrated wireless tool and work probing system (WIPS) makes a significant contribution to the performance of the machine. The access can be restricted to “Power On,” “Power Off,” and “Cycle Start” if necessary. The jog handle from Haas can also be used to cursor through the program for faster editing, override spindle speeds and feedrates, or scan through offsets and parameters. The remote jog handle provides the machinist with many functions directly at the work area. For more information Web: www.HaasCNC.com
TECH UPDATE
3D
Printing helps Swany Reinvent Itself Injection molded prototype of LED headlight reflector that will be applied to metal backing to form finished piece.
“Some people say 3D printing takes jobs away from mold companies. But here at Swany, 3D printing is creating jobs in both fields. It would be great if this kind of new partnership can help the economic revival of manufacturing in Japan.” — Yoshihiro Hashizume, President, Swany Co., Ltd.
A New Way To Do Business Founded in 1970, Swany Company Ltd., located in Nagano, Japan, initially prospered as a small manufacturing company building micro-motors for electrical appliances. But in the 1990s, when major manufacturers began moving their facilities to more costcompetitive locations in Asia, Swany’s business declined steeply. Help arrived in 2010 when Yoshihiro Hashizume became the company’s manager. An engineer experienced in many facets of product development, Hashizume quickly shifted Swany’s business focus from manufacturing to new product design. Today, the company works with nearly 200 different manufacturers in a range of industries, assisting with product planning, conceptual design, and prototyping.
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To compete in this new market, Hashizume knew that the company would need to present its ideas in ways other than drawings and computer models; it needed to create immediate excitement by placing functional and sophisticated prototypes in its customers’ hands. With this strategy in mind, Swany installed an Objet® Connex™ 3D Printer in 2011.
An Idea Machine Injection molding – the process of injecting plastic material into a mold where it cools and hardens to the configuration of the cavity – is the world’s most popular massmanufacturing process. It is used to mass-produce highly accurate, and often complex, three dimensional (3D) parts
TECH UPDATE www.mtwmag.com
and products. The development of injection molds, however, is often expensive and time consuming. Generally made from steel or aluminum, each mold costs tens of thousands of dollars and takes weeks to make. But to test a new injection molded part for design, fit and functionality, manufacturers had few options besides creating a metal mold. To help its customers address these issues, Swany began experimenting with 3D printers. Now as a new product nears production, Swany builds a 3D printed mold, which is placed onto an injection molding machine to create a limited number of prototypes in end-use materials. The prototypes replicate trueto-life results at a fraction of the time and cost associated with using traditional metal molds. Because prototype molds and one-of-akind creations can be made inexpensively within just a few hours and at a modest cost, Hashizume encourages the company’s engineers to use the Connex 3D Printer as a way to explore new ideas, solutions and concepts. He explains, “It is important for our engineers to be able to make mistakes. If they are afraid to fail, they won’t challenge orthodox thinking and create new ideas. Without new ideas, we cannot compete.”
The 3D printed injection molds allowed the engineers to precision craft their designs easily and efficiently, which in turn, allowed their customer to put the final design into full production and move its product to market faster.
Expanding the Work Force
Swany’s engineers instantly became fans of the Connex 3D Printer and its ability to print 14 material properties simultaneously in a single part. It has allowed the company to give shape to its customers’ most creative ideas quickly, easily and cost effectively. One example of this process was a recent assignment to design a new automotive LED headlight reflector. Swany’s engineers 3D printed a series of molds using their prototype designs, and then injected acrylic resin into each mold. In each case, only a small handful of parts were produced, but that was all they needed to make their evaluations.
As versatile as they are, 3D printed molds are not intended to be replacements for metal injection molds. They cannot withstand the constant heat and pressure needed to handle long production runs. As a result, printed molds do not pose a competitive threat to traditional mold-making companies; each has its place in the production cycle. Hashizume concludes, “Some people say 3D printing takes jobs away from mold companies. But here at Swany, 3D printing is creating jobs for them. It would be great if this kind of new partnership can help the economic revival of manufacturing in Japan.” For more information please log on to www.stratasys.com
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PROJECTS
Automobile
AUTOMOBILE ENGINEERING FORGINGS
PROJECT
MANUFACTURING METALS & MINERALS TRANSPORT POWER TEXTILES
UPDATE
RAILWAYS
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Volkswagen India Pvt. Ltd. German automobile firm plans to increase its production to 200,000 units by 2018 and add more new models from the Chakan plant. The company also plans to increase the production capacity at the Aurangabad unit in the next two years. Place: Maharashtra Contacts: Ingrid Dantas, PS to Director, 3, North Avenue, Level 4, Maker Maxity, BKC, Bandra (E), Mumbai- 400051, Maharashtra, T: 022-33137000, F: 33137201, E: ingrid@volkswagen.co.in Hitachi Automotive Systems India Pvt. Ltd. Japan-headquartered Hitachi Group, has set up an auto parts manufacturing facility at Panchanthiruthi village in Tiruporur Taluk in ancheepuram District. This unit will manufacture valve timing control systems and ignition coils. The production will commence from October 2015. Place: New Delhi Contacts: Anuj Kohli, GM (Corporate Communications), 802A and 802B, Tower 2, 8th Floor, Konnectus Building, Bhavbhuti Marg, Near Minto Bridge, Connaught Place, New Delhi – 110001. T: 011- 30605252,
E: anuj@hitachi.co.in
Engineering
Pennar Industries Ltd. Bagged 23 MW order from Sterling and Wilson for supply of solar module mounting systems in Madhya Pradesh. Place: Madhya Pradesh Contacts: Daya Sagar, VP (Operations), IDA, Patancheru, Medak District 502319, Telangana. T: 08455- 242191, M: 9848757755, E: dayasagar@pennarindia. com, corporatecommunications@pennarindia.com Pennar Industries Ltd. Bagged an order from Southern Railway and East Central Railway for supply of components for Wagons. Place: Telanganah Contacts: Daya Sagar, VP (Operations), IDA, Patancheru, Medak District - 502319, Telangana. T: 08455-242191, M: 9848757755, E: dayasagar@pennarindia. com, corporatecommunications@ pennarindia.com Pennar Industries Ltd. Bagged 20 MW order from Sun Technologies for supply of solar module mounting systems in Orissa. Place: Odisha Contacts: Daya Sagar, VP
PROJECTS www.mtwmag.com
(Operations), IDA, Patancheru, Medak District - 502319, Telangana. T: 08455-242191, M: 9848757755, E: dayasagar@pennarindia. com, corporatecommunications@ pennarindia.com Pennar Industries Ltd. Bagged an order from Integral Coach Factory for the supply of components for Coaches. Place: Chennai, Tamil Nadu Contacts: Daya Sagar, VP (Operations), IDA, Patancheru, Medak District - 502319, Telangana. T: 08455-242191, M: 9848757755, E: dayasagar@pennarindia. com, corporatecommunications@ pennarindia.com
Forgings TVS Group The two-wheeler maker plans to set up one of its largest forging units close to Krishnapatnam port. Talks are on with the state government. Place: Andhra Pradesh Contacts: Srivats Ram, MD, Padi, Chennai- 600050, Tamil Nadu, T: 044-26258511, F: 26257121, E: srivatsram@wheelsindia. comcorporatecommunica tions@pennarindia.com
Manufacturing Steelbird Helmet manufacturer plans to set up a new manufacturing facility at Tapukara in Rajasthan. The unit will have production capacity of 10,000 units a day and which could be later expanded to over 50,000 pieces a day. This unit will be ready in the next two years. Place: Tapukara Rajasthan Contacts: Vishal Vich, Group Commercial Manager, B2B-17 Janak Puri Metro Piller - 540, New Delhi -110058, T: 011-45123456, F: 011-40687440, M: 9911483566, E: vishal.vij@steelbirdhelmet. com
F: 42965455, E: kk@pocl.co.in
Transport
Government of Andhra Pradesh Plans to implement Metro project for Vijayawada. DMRC has submitted a Detailed Project Report (DPR) for this project. The Metro would have two corridors from Pandit Nehru Bus Terminal to Penamaluru covering 12.76 km and 13.27km stretch from Pandit Nehru Bus Terminal to Nidamanuru. The phase-I is likely to complete by January 1, 2019. The Metro Rail Depot would require a chunk of 11.34 hectares out of overall requirement of 31 hectare.
constructed as part of Phase-III. Place: Delhi Contacts: Tamojit Bhattacharya, Manager (Public Relations), Metro Bhawan, Fire Brigade Lane, Barakhamba Road, New Delhi-110001, Delhi, T: 011-23417910-12, F: 23417921, W: www.delhimetrorail.com Jharkhand Urban Infrastructure Development Corporation Ltd. Plans to construct inter state bus terminals at Ranchi, Jamshedpur, Dhanbad in Jharkhand. Bids will be finalised for preparation of DPR and to provide Project Management consul-tancy services.
Place: Andhra Pradesh Place: Ranchi Jharkhand
Metals & Minerals Pondy Oxides and Chemicals Ltd. Chennai based company has commenced trial run of the new smelter plant at Gajulamandyam, near Tirupati. This unit will manufacture lead and lead alloys and has an installed capacity of 36,000 mt per annum. Place: Andhra Pradeshn Contacts: K Kumaravel, Company Secretary, 4th Floor, KRM Centre, No: 2, Harrington Road, Chetpet, Chennai– 600 031. Tamil Nadu. T: 044–42965454,
Contacts: T.Ramachandraiah, Chief Planning Officer, Lenin center, Governorpeta, Vijayawada-520002, Andhra Pradesh. T: 0866-2571271, 272, 274, 2577745, F: 2577357, E: vc@vgtmuda.gov.in Delhi Metro Rail Corporation (DMRC) Plans to set up elevated depot facilities at Vinod Nagar and Kalindi Kunj due to space constraints. The construction of a metro train depot involves approximately 2.5 lakh square metres space for the setting up of stabling lines, inspection bays, workshops, washing plants and so on. These depots will be
Contacts: V K Sinha, Chief Engineer, 2nd floor, Vasundhara Mega Mart, Argora, Ranchi-834002. Jharkhand. T: 0651-2400962, M: 09470122768 Kochi Metro Rail Ltd (KMRL) Plans to install platform screen gates (PSG) at 22 metro stations in Phase 1. Approx 70 metre long PSG system is planned for the metro. Place: Kochi Kerala Contacts: Reshmi CR, Senior Communication Manager, 8th Floor, Revenue Tower, Park Avenue, Kochi-682011. MTW JUNE 2015
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T: 0484-2380980, 2350355, F: 2380686, M: 09446418222, E: reshmi@kmrl.co.in Kerala Monorail Corporation Ltd. (KMCL) Light metro is proposed in Thiruvanan-thapuram. The detailed project reporter has been prepared by DMRC. The state finance department has suggested to take up this project using hybrid approach combining direct investment for some components and a PPP financial model for the rest. Place: Thiruvananthapuram Kerala Contacts: S. Madhavan Pillai, CGM (Construction), (KMCL), TC 4/ 1636, Bellayambalam, Kowdar Road, Kowdar PO, Thiruvananthapuram-695003, T: 0471-2720256, M: 9495963789, E: cgm@keralamonorail.org Mumbai Metropolitan Region Development Authority (MMRDA) Metro 4 will be developed as a 32-km Wadala-GhatkoparThane-Kasar-vadavali corridor providing connectivity to commuters from eastern suburbs such as Bhanup, Mulund, Thane and Ghodbunder Road. Once the propos-als are approved by the state government, they will be forwarded to the Centre to arrange funding from agencies such as the World Bank (WB), the Asian
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Development Bank (ADB) and the Japan International Cooperation Agency (JICA). The project is targeted to complete by 2021 Place: Mumbai, Maharashtra Contacts: S K Gupta Director (Projects), Bandra- Kurla Complex, East, Mumbai - 400051. T: 022-26590001-04, 26594129, F: 26591264 Mumbai Metropolitan Region Development Authority (MMRDA) The Metro 2 project is planned as a fully underground 40 km corridor from Dahisar to Mankhurd via Bandra. Once the proposals are approved by the state government, funding will be sought through the Centre from global agencies such as the World Bank (WB), the Asian Development Bank (ADB) and the Japan International Cooperation Agency (JICA). The project is likely to complete by 2021. Place: Mumbai, Maharashtra Contacts: S K Gupta Director (Projects), Bandra- Kurla Complex, East, Mumbai - 400051. T: 022-2659000104, 26594129, F: 26591264 Chennai Metro Rail Ltd. (CMRL) Plans to implement phase 1 extension of Chennai Metro corridor project. Centre is yet to approve this exten-sion.
The extension project comprises a nine-km stretch from Washermenpet to Wimco Nagar. This alignment partly runs underground from Washermen-pet to Korukkupet and then runs as an elevated corridor till Wimco Nagar. CMRL plans to finalise a design consultant who will prepare detailed drawings and designs for the architectural and civil work for the stations along this alignment. Place: Chennai, Tamil Nadu Contacts: B.S.Srinivas, Chief Project Manager (Stations), Admin Building, CMRL Depot, Poonamallee High Road, Koyambedu, Chennai – 600107, TamilNadu. T: 044 - 23792000, F: 23792200, chennaimetrorail@gmail.com
Power Rain Cements Ltd. The company plans to set up waste heat recovery-based power plant with 7 MW capacity at Boincheruvupalli Village, Peapully Mandal, dist. Kurnool. This project will be set up at the existing cement plant. Funding is planned through debt and internal accruals. The contract is awarded to Thermax Ltd. The work is likely to start by March 2016. Place: Kurnool, Andhra Pradesh Contacts: V M Moorthy, CGM (Technical),
Rain Center 34, Srinagar Colony Main Rd, Srinagar Colony, Hyderabad-5000073, T: 040 40401234, E: vm.moorthy@priyacement. com. NTPC Ltd. The company is looking to assign construction works of Head Race Tunnel (Balance Works) Package for Tapovan Vishnugad Hydro Electric Power Project (4x130 MW) on the River Dhauliganga in Chamoli District. Bids are currently invited. Place: Uttarakhand Contacts: Rohit Prakash, AGM (CS-I)/Manager (CS-I), 6th Floor, Engineering Office Complex, Plot A-8A, Sector-24, Noida-201301, Uttar Pradesh. T: 0120-4948664, 4948659, F: 2410335, 2410011, E: rohitprakash@ntpc.co.in Alstom T&D India The company is selected to lead the smart grid pilot project by Himachal Pradesh State Electricity Board Ltd (HPSEBL). This pilot project will be located at the Kala Amb industrial area of Himachal Pradesh in Northern India and will serve over 1,500 consumers. This will be the second out of fourteen projects under the Indian Ministry of Power’s flagship “Smart Grid Pilot” programme. Alstom will design, develop and implement
PROJECTS www.mtwmag.com
an integrated set of smart grid applications targeting power quality issues, managing peak demand, power outages and limiting violations at distribution network nodes. Place: Himachal Pradesh Contacts: Shreyosi Sen, Assistant Manager (Corp Comm) A-7, Sector - 65, Noida-201301, Uttar Pradesh, T: 0120-4790000, F: 4791140, M: 09811908403, E: shreyosi.sen@alstom.com Alstom T&D India The company has got three orders from Bihar State Power Transmission Company Ltd (BSPTCL) to build two 220 kV and four 132 kV air insulated substations (AIS). These substations aim to enhance the capacity of power evacuation systems and improve the power situation. The substations will strengthen the transmission network at 220 kV level with a potential to be further upgraded to 400 kV in future. Alstom T&D India will construct the 220/132/33 kV turnkey substations as well as the two units of associated 132 kV bay extension in Supaul. Alstom will provide control and relay panel based on the SCADA system, for 16 units of 220 kV bays, 39 units of 132 kV bays plus 52 units of 33 kV bays and other auxiliary equipment. All major equipment will be supplied from Alstom T&D India’s manufacturing facilities.
Place: Madhya Pradesh Contacts: Shreyosi Sen, Assistant Manager (Corp Comm) A-7, Sector - 65, Noida-201301, Uttar Pradesh, T: 0120-4790000, F: 4791140, M: 09811908403, E: shreyosi.sen@alstom.com Power Grid Corporation (PGCIL) PGCIL is setting up 150 km 765 kV D/C ChittorgarhAjmer transmission lines project. The contract is awarded to Kalpataru Power Transmission Ltd. The work has started and completion is targeted by March 2016. Place: Rajasthan Contacts: Chetan Verma, GM (Corporate Communication), Saudamini, Plot No. 2, Sector 29, Gurgaon-122001, Haryana. T: 0124- 2571845, 2822393, 2571830, M: 9811661133, E: Chetan@powergridindia. com
Textiles Southern District Textile Processing Cluster Pvt. Ltd. Plans to come up with a textile processing cluster near Kariyapatti in Virudhunagar district spread over 100 acre of land, SPV will be formed. The park has received inprinciple consent of the State and the Centre under the Integrated Processing Development Scheme of
the Union Ministry of Textiles. Place: Virudhunagar Tamil Nadu Contacts: M Elango, Director, Dr. Ambedkar Road (near Madurai Corporation Office), Madurai - 625020, Tamil Nadu. T: 0452 2523966, 98421 40004, M: 8925369514, 9789336547, F: 2523967, E: bharathielango98@gmail. com, maditssia@sify.com, info@maditssia.com, W: www.maditssia.com Southern District Textile Processing Cluster Pvt Ltd The company is promoted by around 400 family-run textile manufacturers of Madurai, Sivaganga and Virudhuna-gar. The company plans to have 36 state-of-the art bleaching and dyeing units, at Pottakulam and Thamaraiku-lam villages. Place: Virudhunagar Tamil Nadu Contacts: M Elango, Director, Dr. Ambedkar Road (near Madurai Corporation Office), Madurai - 625020, Tamil Nadu. T: 0452 2523966, 98421 40004, M: 8925369514, 9789336547, F: 2523967, E: bharathielango98@gmail. com, maditssia@sify.com, info@maditssia.com, W: www.maditssia.com
Railways Ministry of Railways MOU is signed with National Institute of Design (NID) to set up a Railway Design Centre in the campus of NID in Ahmedabad for Indian Railway. The Centre would work on developing new concepts in design & innovations in various fields pertaining to railways like passenger amenities at station areas and in trains, improvement to coach layouts, IT and communication facilities, etc. Place: Gujarat Contacts: V K Gupta, Member Engineering, Rail Bhavan, Raisina Road, New Delhi -110001, T: 011-23381332, F: 23385215, E: dpr@rb.railnet.gov.in Coal India Ltd. The company has planned to lay 52 km long track between Jharsuguda and Barpalli in Orissa. The stage-I clearance is received for this project from the environment ministry and survey work has begun. Stage-II clearance and land acquisition are due. Place: Odisha Contacts: T.K.Sinha, GM (PMD), 10 Netaji Subhas Road, Kolkata - 700001, West Bengal. T: 033-22488099, Extn-4223, E: gmpm@coalindia.in W: www.coalindia.in MTW JUNE 2015
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PRODUCT SHOWCASE Cutting Oils – Hangsterfer’s Cutting Oils for Sliding Head Machines
For Product Enquiry Contact
Sanjay Tools & Adhesives X-20, MIDC, Ambad, Nashik - 422010 Tel.: 0253-6696318 Email: hangsterfers@sanjaytoolsnsk.com
Hangsterfer’s Cutting Oils are recognized by Swiss Style Screw machine manufacturers around the world. Hangsterfer’s Hard Cut oils have improved tool life and surface qualities by as much as 300%! They are the first choice of leading Aerospace, Electronic and Medical component manufacturers. Aluminium, nickel, stainless steel and titanium alloys are machined with much greater ease. All of our oils are engineered to withstand the extreme condition at the tool work-piece interface. In addition to the lubricity provided at the cutting zone, our cutting oils provide excellent lubrication for the machine’s slides, guide bushings, bearings and spindles. Some can even be used in bar feeders. These products are available in a wide range of viscosities and chemical compositions. We have an oil for every application, from tapping and threading of small, pin-like components, to broaching and fine blanking of large gears. Hangsterfer’s Hard Cut Series is formulated with the industry’s safest chlorinated extreme pressure additives. The CC Series has all the quality of the Hard Cuts but are Chlorine Free. Our Missile Lube Series is both Chlorine and Sulphur free. It was developed in the early 1960’s for the aerospace industry. Dr. Hangsterfer created a synthetic fat that met the performance and chemical standards needed for aluminium, magnesium, nickel and titanium alloys. This valuable technology, although highly concentrated in the Missile Lube series, is also contained in many of our other products. This results in unparalleled performance. No matter what the environment, Hangsterfer’s has a cutting solution for your facility.
Scrubber Drier – RootsScrub BT 4545 With Traction Drive ROOTS has introduced the RootsScrub BT 4545 onto the market , a zero-emission,battery powered Scrubber drier with traction drive .The RootsScrub BT 4545 distinguishes itself through its efficient scrubbing performances and robust construction ,making it ideal for commercial use. • • •
For Product Enquiry Contact
Roots Multiclean Ltd RKG Industrial Estate Ganapathy, Coimbtore-641 006 Phone: 0422-4330330 Email: rmclsales@roots.co.in
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• • • • • • • • •
Easy guidance, excellent steering and high degree of maneuverability Traction Drive Optimum vacuuming of dirt water even when negotiating corners with the straight squeegee with spring suspension Brush exchange with the press of a button Excellent view of the control panel Optimum view of the working area and protruding brush head Easy clean of aisles and corners Squeegee lip can be exchanged without tools Robust build for tough environment Service friendly Non-corrosive, robust rotomould tank are resistant to damage Easy access of all components
PRODUCTS www.mtwmag.com
KING CUT PRO – The Large Gantry Type CNC Cutting Machine Ador’s KING CUT PRO is a CNC portal cutting machine which is very precise and reliable. The machine has one head for plasma sheet metal cutting and one head for flame cutting of sheet metal with a dual side longitudinal drive with AC motors. The standard equipment comes with a basic machine package with CNC controller, one torch, central gas diffusion with manometers and a remote flame ignition.
For Product Enquiry Contact
Ador Welding Limited Akurdi Chowk, Chinchwad Pune 411 019 Tel.: 020- 4070 6000 Email: cmo@adorians.com Web: www.adorwelding.com
The following equipment are supplied as required by the customer: Additional Equipment: • Plasma power source KJELBERG with machine torch • Programming software MOST 2D • Support table for sheet metal with segment extraction system • Extraction-filter system • Laser position indicator for determining the cutting point Optional : • Extension of the longitudinal rail • Additional cutting head The CNC Controller – Phantom: The Phantom brings you the performance of a cutting edge CNC that is built on more than 40 years of experience in the motion control and cutting industries. This controller is designed for multiple axis cutting machines and features the latest advances in CNC technology on a proven platform engineered to increase productivity, reduce costs and enhance profitability. The software provides flexibility, ease of operation and technologies that put Ador’s experience and expertise in your operator’s hands, resulting in extremely good cut quality and high productivity. The Phantom can operate any cutting machine and interface with virtually all plasma systems. Following are its standard features: Bright touch screen interface, Touch screen interactive display, Expandable shape library, True multi-tasking environment, Fast Dxt file conversion, Go to(Job interrupt), Quick plate alignment, and Monitor & track consumables. Advanced Plasma Process Control (Plasma Process Wizard) is available as optional extra. Ador offers cost-saving height control unit for simple plasma cutting applications. The KHC1 system provides all the essential functions that are needed for good cuts and optimum utilization of work-piece.
TBD HS - Programmable System for Non-Contact Hi-Speed Tool Checking Marposs S.p.A. has recently widened its range of products introducing the new TBD HS, High Speed, particularly committed when spindle speeds up to 80.000 rpm are needed. The TBD HS is able to recognize in two ways the tool rotating at the actual working speed, thus minimizing cycle times. Selecting “Quick Recognition”, the tool checking is performed at 10.000 rpm spindle speed and its multiples; instead, the “Hybrid Recognition” is suitable when the speed is 1.000 rpm and its multiples or 10.000 rpm and its multiples. In good conditions, an impressive 150 msec checking time is achieved, approximately half the standard time. A fine adjustment for positioning the TBD HS in a very precise way is needed in such applications: an effective system is conceived to make accurate and easy finding the
MTW JUNE 2015
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PRODUCTS
For Product Enquiry Contact
MARPOSS INDIA Pvt Ltd 147 , Sector 7 , IMT Manesar 122050 Tel.: +124 4735762 Email: sales@in.marposs.com Web: www.marposs.in
tool verification position. The reliability of TBD HS is improved by a blower for cleaning the receiver glass (upon request), optimized for protecting the glass from swarf without increasing the air consumption. Moreover, it is possible to substitute the standard protection glass with a sapphire crystal: 9 out of 10 Mohs degrees, this option let the receiver performance always at its best.
TS30 90° Tool Setter - Probe for tool presetting on vertical working centres
For Product Enquiry Contact
MARPOSS INDIA Pvt Ltd 147 , Sector 7 , IMT Manesar - 122050 Tel.: +124 4735762 Email: sales@in.marposs.com Web: www.marposs.in
The new TS30 90° is a compact touch probe for tool presetting at the actual tool rotation speed and it allows to carry out the following checks and measurements: • tool integrity check; • tool diameter and length measurement; • tool wear compensation. The TS30 90° excellent repeatability (2 ≤ 1µm) leads to a significant increase in production quality. TS30 90° maintains its repeatability performance even at high touch speeds, thereby reducing cycle time. The probe has been designed for use in extremely heavy working conditions and its IP67 (IEC 60529) protection rating guarantees high performance even in harsh machine environments. The built-in interface allows the probe to be connected directly to the CNC, and the newly conceived fixing plate has a faster and easier adjusting method, thus reducing the overall installation time to less than 5 minutes. The TS30 90° body can be supplied with three different styli, according to the Customer’s needs, and it has a probe status LED that provides the following information: • Led OFF: Power supply not connected • Led Green: Power supply connected and stylus in rest position • Led Orange: Power supply connected and stylus deflected.
Tungsten Carbide Burrs Workpiece material properties: GRP (glass fibre reinforced plastics) and CRP (carbon reinforced plastics) generally require machining where a high degree of specific strength and rigidity are required. Such particularly light materials should only be machined with special milling cutters which reduce the cutting pressure and prevent damage to the fibres in the material. Market potential: • Aerospace • Automotive • Ship and yacht building • Construction of wind turbines • Model building • Motor sport For Product Enquiry Contact
Supra Industries SP-106,MIDC Bhosari,’S’ Block, Near Century Enka Ltd., Off Telco Road, Pune - 411 026 (India). Tel.: + 91 20 30685648, Fax: +91 20 30685638 Email: info@supraindustries.com Website: www. supraindustries.com
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Examples of application: • Aircraft components • Car components • Pipes • Sport equipment • Components for wind turbines • Applied off-hand or on stationary machines LUKAS-milling cutters: The special milling tool in cut P has been developed solely for the use on CRP & GRP. The special flute geometry allows for precise machining – the choice of different face tooth geometry facilitates drilling (plunge) into the material or simply allows for an optimal facing application.
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SBS PRECISION SYSTEMS (INDIA) PVT. LTD.
37
SOLITAIRE MACHINE TOOLS LTD.
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11
SUPRA INDUSTRIES
41
5&7
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H HAAS AUTOMATION INDIA PVT. LTD.
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MARPOSS INDIA PVT. LTD.
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shekhar@divyamediaonline.com or call: 09820551279
2015 - 2016
MACHINE TOOLS WORLD |
55 | June 2015
Inside Story
Mr.
Terrence
Miranda Managing Director Haas Factory Outlet Mumbai, India
My Life’s Goals Aim & Ambition: In the strong belief that sincerity, integrity and hard work are the cornerstones of success and the realization that nothing in this world is permanent, I would like to make everyminute in my life count for my family, my company, humanity and myself. To aim for perfection, to be self critical and humble with the knowledge that everything I can do there is someone who can do it better and faster and I need to keep improving always. Vision: To inspire through my thoughts, words and actions, a team of people who believe in the same vision I do: to create a company that is extraordinary not just in terms of profitability or operational efficiency but truly stands out in the eyes of our customers and competitors alike for our unwavering commitment and integrity to always do what is right thereby creating the aura of a brand that will live for eternity Social Goal: To work tirelessly to ensure that HAAS tag line “Making Technology Affordable” helps bring HAAS CNC Machining Technology to the smallest of machine shops in India revolutionizing our manufacturing capability, transforming the lives of many in all sections of our society and to truly live the dream of “Make in India”. Business Goal: To create a HFO (Haas Factory Outlet) India team driven by a commitment to excel, innovate and continuously improve at all times in the quest always for perfection thereby dominating the machine tool market in India and clearly establishing HAAS as the market leader
My Leisure Choices
Favourite Tourist Spot: Goa and Udaipur Music I Like: Varied types depending on my mood: Bollywood, blues, Beatles, Country and Western
Sports I Love:Football and Cricket
Ask my Taste Buds
Favourite Food: Indian food of all types especially coastal Konkan Favourite Drink: Jack Daniel on the rocks
In Awe of I Admire: John Roth, Vice President Production at HAAS Automation Inc USA
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BE DYNAMIC! Visit us at IMTOS Hall 18, Stall 1
THE FUTURE OF EFFICIENCY & SPEED IS HERE – MASTERCAM’S DYNAMIC MOTION TECHNOLOGY Since 2008, Mastercam has been building Dynamic Motion into our software. That means it has been shop-tested and proven in real-world environments. Dynamic Motion toolpaths carve out massive amounts of material quickly, reducing cycle times by up to 75% – while doubling and even tripling the tool life – immediately putting more money in your pocket. Sounds unbelievable, right? But as the market leader, we’ve had our Dynamic Motion toolpaths tested in most every conceivable work environment around the world. It works.
For more information, visit www.Mastercam.com 800-228-2877