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
Contents
Vol 1 Issue 2 | July 2015
BUSINESS NEWS
Publisher Shirish Dongre
CEO Shekhar Dongre
06
Editor Shilpa Dongre
JUNKER delivers 500th grinding machine to Volkswagen Group
Marketing Team Ladoji Pendurkar, Amol Powle, Bhavin Shah, Bharat Shah, A.Purohit, Vinod Surve, Kavita Chaudhari
08
Designer & Layout Arun P. Shinde, Pradeep M. Pillalamarri, Nandan Moghe, Dinesh S. Gawade
Ingersoll Rand Expands Line of Precision Fastening Tools with QX Series High Torque Angle Wrench
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
WEST
(Maharashtra & Gujarat) Pune S.Kadam - 09833373371 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 JULY 2015
COVER STORY
22 Mastercam : A heritage of CAM excellence Meghan Summers West President, Mastercam
FACE TO FACE
26
“Way to customers heart is service”
28
“HEIDENHAIN has become a de-facto standard for dependable precision today“
30
“We are focussed on product optimization to improve the design, aesthetics & performance of our machines“
31
“The culture of sticking to the commitments is very strong at Grind Master”
10
Renishaw RLS miniature sensors for space constrained applications
PORTFOLIO
19 INDUSTRY FOCUS
Robotic solutions from Effica
TECH UPDATE
32
38
34
40
Industries riding high on CNC machining
GBQ Microfinishing : The process of perfection
IN FOCUS
46
Tech trends : Competition & CNC
52
MTW Magazine sponsored MTMA-Rajkot AGM on 20th June, 2015 - Hotel Imperial Inn, Rajkot
54
MTW Magazine Inauguration @ INTEC 2015, Coimbatore
New platform for the grinding of large crankshafts
Intoco: Renishaw probing reduces scrap & saves time at precision subcontractor
48
The future begins now
57 PROJECTS 60 PRODUCTS
Our Lean Selection cam reflects our own core values. Precision, reliability, high performance.
Possible cam profiles
JUNKER Lean Selection cam High-performance non-circular grinding.
The Lean Selection cam is an economical and flexible machine concept for grinding camshafts in any lot size. The wheelhead can be equipped with up to two high-capacity grinding spindles. The swiveling B-axis manages rough and finish grinding or the grinding of bearings and cam lobes in a single clamping.
Concave cam profile
Elliptical cam profile
The Lean Selection cam CBN grinding machine combines simplicity in operation, precision and lowest total cost of ownership.
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: 020 255 338 96 E-Mail: info@junker.in
www.junker.in A member of JUNKER Group
Tangential cam profile
Polygonal cam profile
Editorial Board
Editorial Index B
M
Bosch Power Tools
12
Micromatic Machine Tools
26
C P
CNC Software, Inc. (Mastercam)
6, 22
Parker Hannifin
16
Precihole Machine Tools
30
E Mr. A.P. Jayanthram Managing Director Heidenhain Optics & Electronics India Pvt. Ltd
Mr. GK Pillai Managing Director & CEO
Walchandnagar Industries Ltd.
Mrs. Mohini Kelkar Managing Director Grind Master Machines Pvt. Ltd
Effica Automation
19
R
Elesa and Ganter
60
Renishaw Metrology
Erwin Junker
6, 38
Systems Ltd.
10, 46
G
S
Grind Master Machines 31, 40
SBS Precision Systems 61, 62 Stanley black and
H
Decker
Heidenhain
Stitch Overseas
61
61
Supra Industries
60
Hydropack India
I
T
Ingersoll Rand Mr. Arjun Prakash Managing Director Effica Automation Ltd.
Ms.Samina Khalid Marketing Expert
Renishaw Metrology Systems Ltd.
Mr. MIHIR Baxi President – Global Sales Jyoti CNC Automation LTD
18
28, 48
8
K
TaeguTec Tools
12, 15
U
Kennametal
10
L
Unipunch Toolings
62
W
Liebherr Group
9
WIDIA Products Group
51
For editorial contribution contact editor@divyamediaonline.com
Mr. Dinesh Khambhayta President MTMA-RAJKOT
Mr. Ayaz Qazi Director
Precihole Machine Tools Pvt. Ltd.
Mr. Suhas Belapurkar Director - Sales & Marketing ( Industrial Products) Sanjay Tools & Adhesives
MTW Overseas Associates USA Nancy TARTAGLIONE, Mepax USA n.tartaglione@mepax.com / usa@mepax.com FRANCE MEPAX SA, Romain CLASS Tel.: +33 1 39 02 77 78, FRANCE
Mr. P.K. Balasubbramaniian President VBS Corporate Support
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MTW JULY 2015
Mr. B.P. Poddar Vice President - Sales & Marketing FEMCO Fatty Tuna India Pvt. Ltd.
Mr. Jayant Vaidyanathan VP - Sales & Application Tsugami Precision Engineering India Pvt. Ltd.
GERMANY Sebastian OLLIER Mepax Deutschland, Tel: +49 711 222 54 456, deutschland@mepax.com SPAIN Sofiane JEDIDI Mepax España Tel : +34 963 255 886, spain@mepax.com
ITALY Valeria VILLANI Tel.: +39 339 8610117, Via Firenze, Milano, Italia
UK Liz Jones Tel: +44 (0)1227 276016 , l.jones@mepax.com
RUSSIA Garri ZALTS Mepax Russia Tel: +7 495 576-7666 / gizalec@yandex.ru
CHINA/South Korea/Taiwan Mepax - Konaxis Shanghai Julien PENARD Tel : (+86) 21 6252 2731/ china@mepax.com
Detailed 3-D Simulation Graphics
TNC controls from HEIDENHAIN have long featured practical functions for the production of single parts and series. The new 3-D simulation graphics of the TNC 640 are particularly helpful: They precisely display the workpiece and provide a significant preview of the actual machining process when milling or turning. Several new view options expose a precise and freely definable view of details. In this way, the TNC helps with the reliable recognition of faulty information or problematic machining processes prior to workpiece machining. HEIDENHAIN OPTICS & ELECTRONICS INDIA PRIVATE LIMITED
Angle Encoders
= Kreuz 10 pt
Linear Encoders
Chennai 600031, India
Contouring Controls
phone +91 44 3023 4000
Position Displays
Length Gauges
www.heidenhain.in
Rotary Encoders
BUSINESS NEWS
JUNKER delivers 500th grinding machine to Volkswagen Group Grinding machine manufacturer JUNKER celebrates a success story as the Volkswagen Group recently purchased their 500th JUNKER grinding machine. “This statistic”, says JUNKER CEO Rochus Mayer “demonstrates the high regard for our grinding machines in the world of international automotive production.” In recognition of this outstanding business relationship, Mr. Mayer presented Volkswagen with the JUNKER Award. Accepting the award on behalf of Volkswagen was MrGroßeLoheide, who is responsible for general procurement for the Volkswagen Group.Represent-
ing the Volkswagen Group at the JUNKER Award ceremony, MrGroße-Loheidehad the opportunity to visit the JUNKER Technology Center and the adjacent Assembly Building at the company’s headquarters in Nordrach, Germany. This visit allowed MrGroße-Loheide the ability to gain knowledge of the latest machine concepts and also appraise the ordered machine: A JUCAM 1S 11 for grinding individual cams.
For more information, Website: www.junker.in
Dirk Große-Loheide (center), Director of General Procurement for the Volkswagen Group, inspects the JUNKER Technology Center with JUNKER CEO Rochus Mayer (right)
Mastercam and Reseller COLLA Group Receives WSR Official Supplier Status Mastercam, as well as their Authorized Reseller in Russia, COLLA Group, are proud to announce that Mastercam was granted the status of official supplier of CAM software for WorldSkills Russia. Mastercam will be used at the four machining competitions at WorldSkills 2015: CNC Turning, CNC Milling, Plastics Die Engineering, and the Manufacturing Team Challenge. The Manufacturing Challenge requires the teams
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to use Mastercam to produce parts on Lathe and Milling machines that may be assembled together to produce a workable product.
and corporate headquarters) • Status as the worldwide leader in Industry and Education in terms of CAM seats installed and used
Mastercam was chosen for many reasons, including:
WorldSkills
• Versatility and functionality to meet the demands and needs of many industries that use machine tools and CNC machining centers • Ease of use • Availability of the system and special pricing for educational institutions • Partnership with DMG MORI and post processors for its CNC equipment • Large network of technical support and sales (Resellers
WorldSkills has come to symbolize the pinnacle of excellence in vocational training. Every two years, hundreds of young skilled people, accompanied by their teachers and trainers, gather from all corners of the globe to compete before the public in the skills of their various trades, and test themselves against demanding standards. The competitors practice for up to a year honing their skills with Mastercam, either in their
job or their school. CNC Software, Inc. provides Mastercam free of charge to WorldSkills competitors for the year leading up to the competition.
CNC Software is active in this competition at a grassroots level, helping the contestants around the world with software to prepare for the event. This is done in conjunction with the local Mastercam Resellers to get them involved with future engineers and machinists. For more information, Website: www.mastercam.com
BUSINESS NEWS
Ingersoll Rand Expands Line of Precision Fastening Tools with QX Series High Torque Angle Wrench Ingersoll Rand, a global leader in reliable and innovative power tools, has expanded its QX Series™ of cordless power tools for assembly markets by introducing the High Torque Angle Wrench. The new angle wrench reaches a pinnacle of 60 newton metres of torque (44.2 foot-pounds) for the toughest jobs, while providing high accuracy and the comfort for which the QX Series is known. The QX Series delivers the right tool for the right job in industries that require high accuracy for fastening and connecting parts, whether in the heavy equipment, light manufacturing, automotive, or aerospace sectors. “As an industry leader for more than 100 years, Ingersoll Rand has a strong understanding of the functions power tools are called on to perform. The High Torque Angle Wrench is tailor made for our customers who require power tools with enhanced productivity and to reduce defects rates in assembly operations. We have already had successful trials at leading automotive manufacturers in India showcasing favorable results on the tools performance.” said Dipen Shah, Territory Leader – India & Africa, Ingersoll Rand Power Tools. “With the introduction of the high-performance High Torque Angle Wrench we look forward to bringing in a next generation versatile tool that
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MTW JULY 2015
meets the specific demands of a variety of applications, whether simple or complex, while maintaining comfort, accuracy and reliability.” said Brian Welborn, Global Channel Marketing Leader, Ingersoll Rand Power Tools.
High Torque Angle Wrench Reaches New Heights of Torque and Speed The High Torque Angle Wrench is a cordless, rightangle fastening tool that expands the QX Series to cover high-torque applications and complement the existing range of Haz Tools, precision screwdrivers and low-torque angle wrenches already available. It is equipped with a bolstered 40-volt battery that delivers 2.5 amp hours of operation, enough to power the tool through a grueling five to six hour assembly shift without having to recharge the battery. The High Torque Angle Wrench is ergonomically balanced to increase operator comfort, and comes in a sleek but tough black housing. It comes in five different model variations that range from low torque to high torque options, with or without wireless capabilities. The models are available in the following torque to free speed ratios: • 20 Nm (14.75 ft.-lb.) at 1,045 rpm • 30 Nm (22 ft.-lb.) at 775 rpm • 35 Nm (25.8 ft.-lb.) at 640 rpm
• 40 Nm (29.5 ft.-lb.) at 540 rpm • 60 Nm (44.2 ft.-lb.) at 375 rpm
The Technology in the QX Series High Torque Angle Wrench The QX Series High Torque Angle Wrench is built with Ingersoll Rand’s patented closed-loop transducer control at the heart of the tool, delivering precise torque and accurate, traceable results. The multifunction display is the interface for programming multiple torque, speed and angle configurations—saving time and eliminating the need for additional tools. It features a wireless communication option that integrates the tool and the assembly line into a true plantwide network with managed data, process control and the ability to adjust tool configurations in real time. Like all QX Series tools, the communications to and from the tool are exchanged over Ingersoll Rand’s dedicated Process Control Module (PCM). The PCM allows connectivity of up to 10 tools per module to give operators total control of their assembly line, precision fastening tools, and the valuable fastening data it produces. “More and more manufacturers are finding that the highest operational cost in the plant is the cost of quality,” said Mark Hasz, product man-
ager, Precision Fastening Tools, Ingersoll Rand. “Manufacturers need an assembly process and the corresponding tools that get the job done right, the first time. With traceability and connected technology options in every tool, the Ingersoll Rand QX Series enhances the assembly process with diligent tracking mechanisms.”
About Ingersoll Rand in India Ingersoll Rand is committed to India and is implementing strategies for product innovation and design for Industrial Technologies; Food Safety; Energy Efficiency and Sustainability. The company is based out of 18 locations in the country. Ingersoll Rand believes that Innovation for emerging economies is critical for products to succeed in these markets. The company has three world class manufacturing facilities at Naroda, Sahibabad and Chennai; and two Engineering and Technology Centers at Bangalore and Chennai. Ingersoll–Rand (India) Limited is listed on the National Stock Exchange of India and the Bombay Stock Exchange.
For more information, www.ingersollrand.com
BUSINESS NEWS www.mtwmag.com
Liebherr Group’s turnover in the 2014 business year reaches a total of 8,823 million € Against a background of moderate international economic development, Liebherr recorded a slight change in turnover for the 2014 business year, with a total of 8,823 million €, 1.6 % (141 million €) below the previous year’s figure. The international economic situation continued to recover in 2014, though to different extents from one country to another. Global economic growth for the year was 3.4 %. At +1.8 % compared with the previous year, the dynamism of the developed national economies slightly increased. Economic growth dropped slightly in emerging markets, with growth of 4.6 % in the past year compared with 5.0 % in 2013.
Developments in turnover by divisions Liebherr’s construction machinery and mining division achieved a turnover of 5,294 million €, 336 million € or 6.0 % below the previous year’s figure. The result was positive, however, in the area represented by the maritime cranes, aerospace and transportation systems, machine tools and automation systems, domestic appliances, components and hotels divisions, with an increase in turnover of 195 million € or 5.8 % to 3,529 million €.
Germany. The construction and mining machinery sales and service company based in Adelaide, Australia, completed its extension project.
Research & development
Liebherr at the 2015 Intermat in Paris, France previous year’s figure. The pattern of business was also positive in America, with a satisfying increase in the USA in particular. Turnover dropped in the Far East / Australia region. Very weak dynamic growth in Russia, the Group’s largest Eastern European market, had a distinct effect on the region’s overall turnover. Sales revenue also fell on the African continent. In the Near and Middle East the Group achieved turnover slightly above the previous year’s level.
Annual result The profit for the reporting period was 316 million €, equivalent to a drop of 48 million € compared with the previous year.
Employees Developments in turnover according to regions The business year in Western Europe progressed satisfactorily for the Liebherr Group. In Germany, the Group’s largest market, turnover exceeded the
The number of people employed by Liebherr Group companies rose again last year. At the end of 2014 the worldwide total was 40,839, this was 1,415 employees or 3.6 % more than in the previous year.
Investments The Liebherr Group attaches great importance to investment in production and in worldwide sales and service, in order to pave the way for continued successful development. The level of investment has been consistently high: last year the Group invested a total of 816 million € in the expansion and modernisation of its worldwide production network an in strengthening its sales and service organisation. Offset against these investments were depreciation totalling 427 million €. Major investment projects included extension of the diesel and gas engine manufacturing plant in Bulle, Switzerland, and the construction of a branch production facility in Biberach an der Riss, Germany, for driveline and technical control system components. In addition the first construction stage for a new logistics centre to supply spare parts for Liebherr earthmoving machines worldwide was completed early in 2015 in Kirchdorf an der Iller,
The Liebherr Group aims to exert a significant influence on technological progress in the business sectors in which it is active. For a high level of innovative power it is essential to invest considerable funds continually in research and development work. In the past year the Group allocated 446 million € for this purpose, with a high proportion of the total devoted to product development.
Outlook Worldwide economic growth of 3.5 % is expected in the current business year. The Liebherr Group will probably benefit from this rather more dynamic growth. Global economic growth in the current year could be adversely affected by the political and economic conditions in Russia and the Eurozone, and also slower growth of the Chinese economy. The developed national economies are expected to achieve overall growth of 2.4%, and current forecasts suggest that the emerging markets economies will grow by 4.3 %. According to the World Trade Organisation (WTO), the volume of world trade will increase by 3.3 % in the current year. It is also probable that worldwide production will grow more dynamically than in 2014.
MTW JULY 2015
9
BUSINESS NEWS
RLS miniature sensors for space constrained applications Renishaw’s associate company RLS, has announced the launch of high performance miniature encoder sensors for embedded OEM motion control applications. With their small size and lightweight design the new sensors are highly suited to a wide range of applications including medical products, optics positioning, robot control, 3D printers, gimbals and hand held devices. The miniature sensors come in four different shapes and offer linear and rotary performance at resolutions to 0.244 µm for linear applications
and to 753,664 cpr for rotary applications. The new encoders consist of a miniature sensor and a magnetic scale or a ring. The sensors are available either in a potted housing or as PCB board level sensors. The position information is output in incremental quadrature TTL or RS422 and parallel in SSI and BiSS-C formats with the option of a unique or periodic reference mark. The proven RLS non-contact sensing technology brings high reliability and performance in harsh applications.
RoLin – for integration into small motion systems
A miniature packaged, robust magnetic position encoder designed for either linear or rotary position feedback. RoLin is available as a ‘PCB circuit board ready’ readhead for integration into small motion system designs. It is also available as a stand-alone packaged readhead with flex cable connection.
RLB – with FPC flat cable connector for higher volume OEMs Similar to RLC, however with an FPC flat cable connector allowing OEMs the freedom to use
RLC – two designs for direct PCB installation or cable soldering A PCB board level magnetic encoder sensor has been specifically designed for integration into high volume OEMs. High speed, high reliability and high resolution coupled with large installation tolerances all ensure that this sensor can be installed quickly and cost effectively every time. Magnetic scale technology ensures that position feedback is maintained even if the scale is severely contaminated.
a cable and a connector (rather than solder assembly) which is usually the reserve of higher volume deeper integration OEMs. RLS is a world leader in the development of high performance magnetic encoder feedback solutions and as an associate company of Renishaw offers worldwide sales and technical support For more information, Website: www.rls.si
New EXTRUDE HONE™ MF PROGRESS™ Fuel system manufacturers seeking the best fuel performance require flexible high-flow grinding and high-flow test capabilities to achieve finely tuned orifices in numerous design variations. To this end, Kennametal
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Precision Surface Solutions® is announcing EXTRUDE HONE™ MF PROGRESS™, the next generation of flow tuning and flow measurement featuring a flow targeting accuracy to +/1% aimed at orifices 100-350 ?m in parts less than 30 mm in diameter and flow rates up to 5 L/min. “Additionally, MF PROGRESS delivers another exclusive added value that we call Flexibility Through Modularity,” says Sharath Shankaregowda, Kennametal Precision Surface
Solutions MICROFLOW product manager. “Customers benefit from a self-contained modular construction for each process (grinding, flush, flow testing, etc.) and configurable hardware (manifolds, frequency drives, etc.)”. Customers are saying adding such advanced process options can help ensure components meet ever more stringent government regulations. From CAFÉ in North America, EURO6 and expected EURO7 in Europe,
and PRC standards in Asia, all focused on reducing CO2 emissions, EXTRUDE HONE™ MF PROGRESS provides the perfect next step in upgraded manufacturing and finishing. In addition, this all takes place in a 25% reduced machine footprint, 50% less tool wear compared to previous-generation equipment, and depending on the application the output can be increased by up to 100%. For more information, Web: www.kennametal.com
MACHINE TOOLS WORLD |
11 | July 2015
BUSINESS NEWS
Bosch launches the Small Angle Grinder GWS 750 Bosch, a leading global supplier of technology and services, has leveraged India’s power tool segment by launching the GWS 750 Professional in Delhi on June 12, 2015. Targeting dealers, contractors, tradesmen and those engaged in industrial, institutional & construction pursuits, the launch enabled customers to understand differentiating features of GWS 750 apart from giving them a working understanding of the tool. Bosch GWS 750 is a super grinder that is best suited for metal processing, steel working, machine building, and vessel construction, roofing, cutting hard or soft concrete and stone material, deburring moldings,
metal tubes, pipes, beams and sheet metal, beveling and preparing of welding seams.
Functional features for quick, easy ans precise leveling GWS 750 has functional features for quick, easy and precise results. For example, the newly designed motor platform enables higher rate of removal, greater efficiency, lower temperature and improved cooling performance. Additionally, the tool comes with an easy to grip handle for smooth working and a robust metal flange for tougher working conditions. Moreover, vibration and noise is reduced significantly thanks to a machining/spiral bevel gear set. This compact gear housing that features a flat gear head allows the user convenience even in tight spaces. Bosch original carbon brushes
Speaking at the launch, Mr. Vijay Pandey, vicepresident, Bosch Power Tools said, “The range of Bosch Small Angle Grinders ensure users are equipped for every challenge at work. The Vibration Control auxiliary handle offers convenience and protection while the powerful motors guarantee high performance for metal cutting and roughing. This revolutionary product is a solution to affordability, safety and superior quality. As a player that has been manufacturing in India for over two decades, we are delighted to support the Government’s ‘Make in India’ initiative and continue to ensure our range of product offerings exemplify innovation and high performance.” are engineered specifically for each tool application to deliver safe, reliable operation. The wrong brush, of inferior composition or design, can cause severe sparking that may damage other components and lead to premature failure. The compatible carbon brush used in this tool enables easy, routine maintenance and minimal downtime.
The spindle lock design permits quick and easy installation and removal of accessories. GWS 750 is highly effective, delivering great power & torque. The ergonomic design enhances the comfort during extended grinding applications and makes for easy handling, control and an extended lifetime, even under heavy duty.
TopDrill Chip Breakers Pulverize Aluminum, Cast Iron Chip breakers are an intrinsic part in most cutting tools because they improve chip control and reduce cutting resistance which, when properly coupled together, increases the machining performance. TaeguTec has launched two new chip breakers that achieve longer tool life and improve the machinability of the TopDrill line: the “DK” type for cast iron drilling and the “DA” type for aluminum drilling. TaeguTec’ s current “DP” chip breaker was developed for general drilling applications whereas the new geometry “DK” type, which utilizes the
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MTW JULY 2015
TT6080 grade, improves wear resistance when machining cast iron. Both help customers reduce their operating cost and delay the development of tool wear as well as improve stability during the machining process of cast iron materials. The “DA” chip breaker is designed with a polished top face surface as well as a sharp edge to minimize cutting resistance and built-up-edges while drilling into aluminum workpieces which helps to avoid chipping and fracturing of the cutting edge normally caused by vibration. Both the “DK” and “DA”
chip breakers are available in the same size range as the current “DP” geometry inserts. During several case studies
on aluminum workpieces, the “DA” transformed chips into pellet sized shards which were quickly and efficiently evacuated from the insert through the TopDill’s advanced body and flute design in order to avoid any damage to the drill or workpiece. In case studies on the “DK” chip breaker, TaeguTec’s newest offering to the highly popular TopDrill line increase tool life by as much as 88 percent while machining ductile cast iron workpieces. For more information Website: www.taegutec.com
BUSINESS NEWS
Local CNC experts help Chinese company to develop radically improved gear cutting machine NUM China has helped Betek to accelerate the development of a groundbreaking six-axis precision gear hobbing machine. By utilising a direct-drive spindle and NUM’s ultraprecise electronic gearbox and renowned CNC gear hobbing technology, together with a unique HMI developed by a local specialist machine designer, the new Betek YK3132Z gear hobber provides unprecedented cutting speed and processing efficiency. It is up to 10 times faster than conventional mechanical gear hobbers – and more than twice as fast as competitive six-axis CNC gear hobbing machines – and looks set to establish a new performance standard for gear production automation. Based in Tianjin, China, Tianjin Betek Machinery Manufacturing Co., Ltd (Betek) specialises in the production and processing of mechanical parts for industrial applications. The company’s experience of using machine tools in its manufacturing operations, combined with market research, highlighted major opportunities in the domestic gear production market. China has a growing need for CNC gear cutting machines that combine precision, high processing efficiency and ease of use, to replace inefficient mechanical designs. In 2013, the company took the strategic decision to diversify into the production of gear cutting machines, investing 80 million yuan (approximately 13 million USD) in a 25,000 square metre purpose-built manufac-
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Offering unprecedented cutting speed and processing efficiency, the new Betek YK3132Z six-axis gear hobber is based entirely on precision CNC technology from NUM. turing plant and offices. Betek’s latest CNC machine tool, the six-axis YK3132Z gear hobber, is now available – less than two years after the start of development. At the beginning of the project, the company looked at CNC systems from a number of manufacturers, and quickly decided to base the machine on NUM’s Flexium+ CNC platform. According to Betek’s President and General Manager, Mr Jin Guolin, “Our main reason for choosing NUM’s CNC systems for our new gear hobber is that, unlike many competitive control products on the market, they have an open architecture. This provides an unrestricted foundation for development and customisation work, helping us to reduce costs and shorten time-to-market significantly. We intend standardising on NUM CNC for future machines whenever possible
– for example, we are currently developing a new gear grinder that will also be based on NUM’s CNC technology.” For the gear hobbing machine project, another factor behind Betek’s choice of CNC supplier was NUM’s extensive experience in gear production applications, which spans several decades. Its CNC gear hobbing solutions, based on NUMgear software, are used by many leading manufacturers of gear production machines. The proximity of NUM’s facility in nearby Beijing was also a consideration – it means that Betek benefits from responsive locally-placed applications support and technical service. Betek’s new YK3132Z six axis gear hobbing machine is based entirely on NUM CNC equipment. It uses the latest Flexium+ CNC kernel and highend NUMDrive X servo drives in conjunction with compact
BHX and SHX servomotors; high resolution encoders and closed-loop control maximise accuracy of speed and position. Both the hob spindle motor – a built-in model – and the table (C axis) torque motor are powerful direct drive units that are also controlled by a NUMDrive X servo drive. These motors completely eliminate the need for mechanical power transmission components such as worm and helical bevel gears, resulting in precision, backlash-free movement. The hob spindle can handle speeds up to 1,200 RPM, while the table can rotate at up to 280 RPM; this allows use of the latest high-speed cutting tools. Accuracy and reliability are further enhanced by the machine’s use of high rigidity servomotordriven precision ball screws for its linear axes. The NUMgear suite of gear production software that is being supplied includes dedicated hobbing functions and a precision electronic gearbox that allows all master axes and the turret spindle to be fully synchronised. The electronic gearbox minimises synchronisation time by predicting the acceleration rate as well as the speed of the axes. All human interaction with the gear hobbing machine is via a NUM FS152i operator panel with a custom HMI. The operator panel features a 15inch high resolution backlit LCD screen with 22 large function keys and contains a powerful industrial PC. The HMI makes extensive use of graphics and
BUSINESS NEWS www.mtwmag.com
is inherently intuitive; users can operate the machine after just a few hours of simple training. Gear manufacturing data can either be input using a simple ‘fill in the blanks’ method or derived from previously processed parts – the software includes database management functions. The custom HMI software was developed specifically for the machine by Changzhou Mactool Precision Machine Tools Co., Ltd. This company specialises in the design of gear cutting machines and user interface software, and has invested heavily in building up the development and technical support infrastructure necessary to serve China’s nascent precision gear machine tool industry. Mactool’s owner, Mr Wang Haiyu, has more than 15 years’ experience of gear processing applications, with a particular expertise in gear hobbing and grinding machines. Florian Schmidt, NUM’s Product Manager, points out that Mactool and NUM China have collaborated on several high value CNC machine projects in recent years, adding that: “To provide our customers with their ideal solution we combine the best of all worlds.”
Mr. Haiyu agrees on the benefits of collaboration, “I believe that partnerships provide customers with an enormous competitive advantage. By working closely together, NUM, Mactool and Betek have jointly created a highly advanced precision gear hobbing machine that looks set to enjoy significant market success. Based on a fully proven and stable CNC system, the machine is way ahead of the competition in terms of its usability, efficiency and performance. The excellent production management and quality control systems that Betek has put in place will help to ensure that its customers benefit from a world-class precision machine – but at significantly lower cost than comparable products.” The Betek six-axis YK3132Z gear hobber accommodates gear blanks up to 320 mm (12.6 inches) in diameter. Its advanced CNC system can handle five-axis interpolation, enabling complex gear tooth profiles to be created smoothly and efficiently. The entire gear is cut as part of a single process, without interim removal/ reinsertion of the gear blank or manual tool changeover. Virtually any type of gear can be cut, including unusual types such as parallel shaft, herringbone, taper and non-circular gears. For maximum machining accuracy the machine uses dry cutting techniques, capable of achieving Level 6 precision on interim cut gears and Level 3 precision on finished products. Dry cutting also obviates the need for cutting fluid, which is a common form of pollutant in machining industries that requires special treatment and disposal.
Mill2Rush TNMX 18 Triangular Insert First of its Kind
TaeguTec has broadened its Mill2Rush line by expanding the popular TNMX 18 series to be the first in the business to introduce a double-sided triangular insert used in extended flute cutters. To accompany the breakthrough in the metalworking industry, TaeguTec has also added Mill2Rush TNMX 18 splitter inserts, a move that elaborates upon the existing line’s popularity and greatly increases the amount of applications, industries and materials that the family of inserts and cutters cover. The first-of-its-kind TNMX 18 addition is characterized by a double-sided triangular insert with an 8 millimeter thickness and 13 mm depth of cut – all factors that enable for powerful machining and adds to the Mill2Rush family of cutting tools an even greater choice in heavy duty 90 degree machining. Some of the other features include a high helical and positive cutting edge geometry that also makes the machining process stable, which in turn increases productivity while cutting on cost and an angled screw clamp-
ing design that promotes rigid clamping. The latest design improvements have introduced other advantages to the TNMX 18 line. For example, the splitter insert’s grooves located along the cutting edges reduce the cutting load, vibration and noise under unstable machining conditions such as long overhang or weak fixtures. As such, the splitter inserts promote very stable machining and higher productivity as the grooves also generate reduced cutting load which, in turn, allow for higher table feed during machining. With the introduction of the new TNMX 18 chip splitter inserts, the extended flute end mills and shell mills now enable a wider variety of applications. During the product testing phase, the Asian metalworking giant recorded impressive improvements in tool life and productivity compared to leading competitor’s similar offering.
For more information, Web: www.taegutec.com
MTW JULY 2015
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BUSINESS NEWS
Parker launches innovative CNG fuel regulation module for mediumto heavy-duty vehicles with 5-to-12 litre engines An advanced fuel regulation module, the industry’s first fully integrated CNG (compressed natural gas) flow control and regulation system for mediumand heavy-duty vehicles with 5- to 12-litre engines has been launched by the Instrumentation Products Division of Parker Hannifin - the global leader in motion and control technologies. Parker’s advanced FM80 withstands extreme variations in temperature, flow, vibration, supply pressure, and gas composition, setting a new standard in CNG fuel handling. Most current gas handling systems are typically comprised of a rubber-like diaphragm regulator, filter, sensors and solenoid plumbed together with a multitude of fittings. Unlike current systems, Parker’s FM80 features an advanced FM80 metal piston-style regulator, coalescent filters, pressure sensors, a lock-off solenoid valve, heat exchanger and low-pressure relief valve, integrated in one compact body. Other Parker components to complete the fully customisable, integrated system include hoses, fittings, seals, manual shut-off valve, check valves, receptacles, and nozzles. The system offers customisable levels of integration and more configuration options than comparable products. The complete CNG fuel system exceeds industry standards for leakage and safety. It has been tested on a variety of engines
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and meets the flow and regulation specifications of all leading OEMs with CNG options. The FM80 was designed by the Veriflo Division of Parker, well known in the industry for its wide range of robust and reliable regulators. According to Madhukar Puniani, Business Development Manager (Natural Gas Systems), “Aside from being the only complete system solution on the market, the Parker FM80 fuel regulation module offers several breakthrough features to improve performance and vehicle uptime. A larger oil sump means longer times between filter drains, helping increase driver productivity and asset utilisation. Innovative technology prevents freezing problems in the winter and eliminates leakage of gas into coolant from wear of soft diaphragms and seals over time.” FM80 was engineered for medium- to heavy-duty vehicles like delivery and day cab trucks, cement trucks, school and mass transit buses, and waste refuse/ recycling vehicles. Optimised for advanced fuel handling performance in 5- to 12-litre engines, Veriflo’s piston-style regulator design offers stable pressure delivery and control of CNG throughout the full range of extreme engine and environmental operating conditions. Integrated internal regulator components, with fewer connections, work together to eliminate fuel line failures due to freezing, dampen
flow-induced vibration, reduce drop at high flow, and extend cycle life. The manifold design of the regulator system reduces the chance of fuel line pressure increase due to reduced volume of fuel between the solenoid valve and regulator seals. In addition to the FM80, Parker offers multiple fuel module options for system integrators and OEMs. The FM80 is designed to achieve the highest nominal flow rate (80 kg/hour) in the industry and the lowest lowpressure operating parameter (250 PSIG), which increases the usable range of CNG vehicles by a critical 3-to-5 percent. Other key features and advantages include: an integrated heating circuit that uses heated radiator fluid to condition the gas before it enters the engine, offering improved reliability at low temperatures and eliminating fuel line failures due to freezing; good response to power demand for better drive-ability; a well-dampened piston that reduces flow-induced vibration; reduced pressure drop; constrained motion poppet design that eliminates lateral loads and seat wear; thermal shielding of internal components with PTFE seals to isolate gas flow, allowing continuous operation even in extreme -40 to +120 degrees C ambient temperatures; optional boost pressure augmentation for optimised outlet pressure and performance of turbocharged engines, and com-
The first fully integrated CNG flow control and regulation system for medium/ heavy-duty vehicles with 5to 12-litre engines has been launched by Parker. pact size – offering maximum efficiency in a small space. Tamara Horne of Parker Veriflo Division adds: “Parker is committed to providing cuttingedge technologies to reduce the world’s dependence on diesel fuel, which is widely used in medium- and heavy-duty fleet and industrial vehicles. Natural gas is cleaner, more economical, and less toxic to the air and environment than diesel. Parker is proud to be the first manufacturer to offer a fully integrated, high-performance CNG fuel management system. The FM80 is the ideal system when performance and productivity of a transport fleet is critical to a business.” Parker leads the way in the design and manufacture of multi-technology systems, subsystems, and components that filter, regulate, control, and convey CNG. Parker also offers the industry’s best fleet dispensing solutions for high-flow, highcycle CNG applications.
BUSINESS NEWS
Stanley Black & Decker launches a range of POWER TOOLS for the tradesmen & SMEs in India Stanley Black& Decker, the world’s largest tools and storage Company now introduce a range of Power Tools under the Stanley brand, specifically engineered for the tradesmen & SMEs in the Emerging Markets. Stanley is the longest established and largest hand tool brand in the world. Its history of innovation spanning 170 years has made Stanley a trusted name and an industry pioneering brand. All Stanley Power Tools have been developed keeping in mind the specific requirements of SME (Small & Medium Enterprises) and Tradesmen (like Electrician, Fitters, Plumbers, Assembler, Carpenters etc.) in Emerging Markets & have been intensively tested in more than 15 markets to ensure performance and durability. By offering a choice of power options, tool-bit configurations and speed variations Stanley Power Tools deliver the versatility, superior power and longer life required by Tradesmen &
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SMEs in Emerging Markets. The Stanley Power Tools offer bestin-class performance, durability and are ergonomically designed to provide comfort and ease during long usage. All, at an unbeatable value to our customers. They are designed for a variety of applications – from Concrete Working to Metal Working & Wood Working to Specialty Applications. Stanley Power Tools range in India has 22 products in its repertoire across various application segments. The range includes 7 products in Concrete Working, 9 in Metal Working, 2 each in Drilling & Fastening and Speciality and one each in Cordless and Wood Working. The power tool product offering consists of Cordless Drill Drivers, Rotary & Percussion Drills, Hammers, Small and Large Angle Grinders, Chopsaw, Planer and Speciality tools consisting of Blowers and Heat Guns. While introducing 22 different Power Tools under the
Stanley Brand, the brand is particularly proud to announce the Stanley 5Kg & 10Kg Demolition Hammers to Construction Tradesmen & Demolition Contracting companies in India. The 5 kg /10kg Demolition Hammers offer excellent performance, durability at best-in-class value for chipping & medium-to-heavy Demolition applications in concrete working. The range of 2 and 3 Mode Rotary Hammers provide exceptional power to weight ratio at superior value for various applications of drilling, chipping & light demolition. The Metal Working Range has a range of Small and Large Angle Grinders offering target customers a choice of wattages from 600W to 2200W and disc diameters ranging from 4” to 9”. These products are designed for heavy duty usage and longer durability resulting in faster material removal/ cutting with greater accuracies and comfort. All with the Stanley guarantee of best
performance and durability at great value to customers.
About Stanley black & Decker Stanley Black & Decker is a world-leading provider of tools and storage, commercial electronic security and engineered fastening systems, with unique growth platforms and a track record of sustained profitable growth. Since 1843, our goal has been simple: provide tools and solutions that improve productivity and make life easier. Whether it’s a hammer that punches above its weight while going easy on your elbows, a door that unlocks for you at a glance or a toolbox smart enough to find a missing socket anywhere in an airplane hanger, our products have a way of making a big impact on your daily life. No matter where you live, what car you drive, what stores you shop at, or what building you work in, you can bet that we had a hand in making it work.
COMPANY PROFILE www.mtwmag.com
Robotic solutions from Effica
C
oimbatore-based Effica Automation, incorporated in 2005, is today in the focal business of materials handling automation encompassing machine tending, palletizing and conveying, making the most of robots. Under the stewardship of Mr. Arjun Prakash, President, who is the grandson of late Dr. G.R. Damodaran – a statesman, educationist, humanitarian and founder of the legendary PSG Tech, Effica is eminently poised to take industrial automation in India to subliminal heights. A mechanical engineer from PSG, Mr. Arjun pursued an internship and intensive training and experience in the field of mechatronics. The education and insights he received in mechanical engineering, electronics, robotics, computers and software applications helped him build a strong foundation for Effica Automation which is today in the forefront of integrating robotic systems to enhance operational efficiency, productivity & profitability in Indian industry which is poised to join the big league using robots for automation and manufacturing excellence. Effica started off in 2005 designing and manufacturing special purpose machines (SPMs) for a plethora of applications. It
even developed robotized special plasma cutting systems for marking and precision cutting power transmission poles of 60 ft long. Way back in 2009 it executed a project worth Rs. 2 crores in Houston. This was a complex job involving different disciplines – mechanical, electrical, electronics, robotics, machine vision and so on. It involved handling, rotating, holding and cutting of poles where cost of error was very high and forbidden. Present focus
Over the years, the company has changed its focus. Since 2011, to be precise, its focus is on materials handling automation which includes machine tending, palletizing and conveying. The company offers robot based CNC and machine tending systems. These include multiple CNC, forging presses, sheet metal pressing machines and other process machine loading and unloading using robots. It offers conveyors – roller, belt, overhead, slat and special food grade; we provide servobased 2, 3, 4-axis pick & place systems with flexible gripping solutions for CNC & machine loading and unloading, secondary packing and palletizing systems; and machine vision based picking and intelligent gripping solutions for packing
and inspection. It also offers gantry machine tending to replace articulated machine tending projects for payloads from 40 grams to 100 kg. This is an economical solution, and with this the existing plant layout need not be disturbed. It also does bag conveying & palletizing automation. This is a robot-based high speed palletizing system with a speed of 20 T per hour. Effica’s automation systems are used by machine tool, forging, plastic injection molding, sheet metal fabrication and FMCG segments. “We have made our systems modular and user-friendly so that in the event of a failure, the user can also fix it. This way we have removed the fear of breakdown and consequent downtime from the mind of the end-user,” reveals Mr. Arun Prakash. Modern facilities
Effica has a sprawling manufacturing facility housed in a land of 10,000 sq. mtrs. It has an in-house Machine shop, Assembly shop, Design & Dev. Dept., Quality Control section and so on. The Controls Dept. has multiple robots and PLCs. The company has a dedicated workforce of 35 people. Marketing is done directly. However, it has channel partners in strategic locations like Coimbatore, Chennai and Bangalore to extend its reach to the customer. Automobile industry and automobile ancillaries are its major customers. Its growing client list includes some big names like Ford, Nissan, L&T, LGB, LMW, Saint-Gobain, Amara Raja, Pricol, Roots, etc. Effica is highly customer-centric in its operations. “When we offer tailor-made solutions, we go beyond the call of duty to satisfy the customer and entail him the benefits of flexibility, efficiency, safety, savings and quicker ROI,” states Mr. Arun Prakash.
MTW JULY 2015
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COVER STORY
Meghan Summers West President Mastercam Q. Mastercam has gained substantial market share in machine tool industry , please brief its journey from the inception & share some its milestones? Mastercam was launched more than 30 years ago. It was driven by two brothers’ specific set of skills in mathematics, programming, and shop-floor machining experience. Since then, we’ve maintained a tight focus on what made us successful from the beginning. We talk directly with machine shops around the world to see what’s needed and what’s coming. This means we not only provide practical programming tools to get jobs done quickly, but groundbreaking new techniques to inspire CNC programmers.
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Q. Please brief us about company’s global reach & what are the global alliances that has been made in order to out-front the competition? Our reach extends across the globe, with many of our representatives having decades of experience with both their local market and with Mastercam directly. We choose our partners carefully to ensure that they can build long-term support relationships with Mastercam users. As the world’s most widely-used CAM system, we need to be able to work smoothly with virtually any machine tool. To this end, we’ve forged many mutually beneficial relationships with machine tool manufacturers that let us prepare for “the next big thing” as well as helping them demonstrate what their
COVER STORY www.mtwmag.com
Mastercam : A heritage of CAM excellence machines can do. Similarly, we have excellent relationships with CAD developers because our users require us to work with virtually any type of CAD file. And we do have excellent relationships with CAD developers. SOLIDWORKS® is a great example. We have a tightly integrated Gold Partner version of the software that runs within SOLIDWORKS®, and we have a good relationship with the company to help keep us on top of what’s going on in the industry.
Q. What are the market prospects for the Mastercam products in India and How do you plan to position these products? For us, India represents an unsurpassed collection of talent, experience, skill, and opportunity. The economic growth outlook for the next few years is great by all reports. Large and rapidly growing sectors such as Aerospace, Automotive, Telecom, Medical, and even infrastructure expansion require the backbone of manufacturing that we can help support. Our strategy in India is similar at its root as our strategy across the globe. Understand the needs of the industries engaged in manufacturing and, more importantly, the practical needs of the people responsible for programming parts for those industries.
Q. Can you brief us about the marketing strategies that were applied in order to stand out in the competition of the industry? I can sum up our strategy in three simple words: Practicality, Support, and Advancement. By practicality, I mean that we strive to make sure every tool in the software solves a problem or improves a process that we’ve seen in day-to-day machine shops. We want to ensure that the toolset in Mastercam gives a programmer a way to complete any project they take. In the end, our goal is not our software itself, but the results it achieves for our users. Support is the second pillar of our strategy. We feel we have the best and most experienced global support network today. We have local representatives with decades of experience, ready to share their knowledge with their customers and with the entire Mastercam community. This is vital, because in many ways, machining is the most unforgiving part of the entire manufacturing process. CAD designs can be edited, but once metal is removed, it can’t be put back. Finally, advancement is crucial to make sure that our users are as competitive and productive as possible. Our proprietary Dynamic Motion technology is a great example of this. It’s a
cutting motion engine that drives many of our toolpaths. It can save up to 70% of machining time; at the same time it dramatically extends tool life.
Q. Brief us about the R&D and Quality policy for your business? Our development is built on a repeating cycle of constant creation and testing so that as many issues as possible can be worked out as quickly as possible. At the same time, we have a large R&D machine shop in our facility that constantly tests the software in a wide variety of real-world machining situations. Finally, we run a wide and extremely valuable public Beta program so existing users can try out new features and report back with comments and suggestions.
Q. What are the key technological trends that are driving your industry? The key trends in CAM software are simple but powerful: constantly increase the speed and efficiency of the software, automate where possible, deliver programming methods that make the best possible use of machine tools, tooling and material, and make the software capable of handling the increasing variety of jobs a shop encounters. I mentioned our Dynamic Motion
MTW JULY 2015
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COVER STORY
The Mastercam corporate headquarters in Tolland, CT, USA.
technology earlier. It’s a good example of a software advancement designed to address many of these points. It can dramatically reduce machining time, it’s governed by “smart” algorithms that automate much of the complex work, and it generates cutter motion that is easier on the machine, extends the life of the tool, and is smoother in the material.
Q. Could you brief us on Indian & Global perspective of machine tool manufacturing industry? What are the distinguishing factors? The machine tool market has seen dramatic ups and downs since 2009. During that year, the machine tool market as a whole took a sharp drop with some manufacturers losing as much as 80% of their orders. But as the global economy began to rebound, the pent up demand for those machine tools rose quickly and has stayed very healthy since. In the United States, the machine tool market is exceptionally strong, and there are many other countries that show strong machine tool consumption including China, Germany, South Korea, and Mexico.
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Q. Please comment on the current machine tool scenario in India ? India remains one of the top machine tool consumers, as well as a very large producer. However, the demand is surpassing the supply, potentially creating a gap and a demand for more machine tools than are currently available. The industry is rapidly moving toward ever more advanced CNC equipment as segments such as medical, automotive, and consumer products demand it.
Q. In your opinion how can the Indian machine tool industry become globally competitive? From working with our Indian representatives, we feel the Indian machine tool industry is on an excellent path now. Although there may be a gap between the supply and demand of machine tools, it appears more companies are looking to fill that gap. And the equipment they appear to be filling the gap with (increasingly sophisticated CNC machines)should yield not only a stronger machine tool market, but even more competitive machine shops. Another powerful tool for increasing global competitiveness is heavy emphasis on manufacturing education.
Whether it’s a machinist sharpening their Mastercam skills through training, or a classroom of students getting prepared for and excited about the industry, manufacturing education is vital. This is especially true in any market where growth is expected – that growth will require new, intelligent, skilled people to sustain it. We’ve been dedicated to manufacturing education since we started, and it will always be an important part of our company.
Q. How do your perceive the future of the Indian machine tool industry ? We’re excited by it. There are so many positives and so many manufacturing and machine tool opportunities that India represents for itself and for the world, and we’re eager to see how we can help.
Q. What is your vision for Mastercam ? Our vision is to remain focused on the fundamentals that help make Mastercam shops successful every day – deliver software that makes day-today machining easy, that constantly offers creative new techniques, and that inspires machinists.
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FACE TO FACE
& “Way to customers heart is service� Q. What do the Indian customers look for in a CNC machine? A. The CNC revolution in India kind of
Mr. T K Ramesh,
CEO, Micromatic Machine Tools believes that their impeccable service that has helped them become one of the largest CNC manufacturers in India
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sparked off in the early 90s, fundamentally from the automotive industry. Maruti coming in to India not only brought volume but also the concept of quality. There was a need for a machine that could control quality and that is how the need for CNC machines increased. Earlier, the technology was new, people were scared and worried, also the cost was very high. Another problem the customers faced was that not everyone could operate a CNC machine. Today, it is very different. Over the years the CNC has evolved, firstly the accuracy is better and time taken to make a part is shorter. Also, the machines are tropcalised and more rugged to suit Indian conditions. We at Ace Micromatic also follow the same, but in addition we make them affordable and support these machines with whole lot of education. We train our customers, hand-hold them
and educate them on how to maintain the machine and get the best output from the machine among others. To sum it up, customers today look for productivity, cost effectiveness and reliability.
Q. Difference in demand in India and in other developing/ developed countries? A. The basic operations are the same but the level of automation is different in the developed countries. The most important factor is the maturity of the environment. By environment, I mean the infrastructure, awareness and input quality among others. As the input quality is better, the output quality is also better in those countries.
Q. R&D among the Indian CNC manufacturers. Please share something about your R&D activities? A. I believe Research &Development (R&D) should be done keeping in mind
FACE TO FACE www.mtwmag.com
the market and its needs. More companies should come forward to invest in R&D activities. At Ace Micromatic, we continuously work to make our machines more cost effective and affordable. We spend somewhere around 2-3% on our R&D activities and we will continue to invest in our R&D activities further.
Q. Technology breakthroughs that we can expect in the next few years? A. Currently, the machines have feedbacks and tell you about measurement, perhaps now they will give you the state of health and safe guard themselves against misuse. But the larger area of development is going to be in the area of automation.
Q. How does Ace Micromatic tackle competition? What are your focus areas? A. We always have and will continue to focus on what we can do to differentiate ourselves. The customers want reliable and accurate machines and most of all a buy-able or affordable machine. I believe to stand out it always has to be something different from the technical specifications. As a company, we believe in education and training, we handhold our customers and make them successful. This I feel is our biggest strength. We are the only company in India that has 32 offices with 400 people on the field. Pro-
viding extremely good service, we are the also the only service company that works in shifts. A customer works in various shifts and can have a problem in any shift or any any time during the production process. To serve them best, we have our offices in every area that has more than 60 of our machines. We made a decision to help our customers throughout their journey. After all, a way to customer’s heart is the service.
Q. Many believe countries like China, Taiwan and Korea are a threat for Indian companies? Your views... A. Yes, they are a threat to Indian product making companies. We should aim to be better as competition will be always there. One can’t ignore competition, but find out ways to get past it. Customers look for solutions not mere products but a package. Do you think the industry-academia partnership can be helpful for India? Absolutely. It is very important. By the industry-academia partnership, we can get the right kind of skill from day 1 and not day 5 or day 35. The education system for engineering and technical education is still very theoretical and bookish. I believe they can understand a job better on a shop-floor than a classroom. In India, Engineers are thinkers and the technical workmen are the doers. This is entirely different in advanced countries like Japan and China, where Engineers
are the doers. It is extremely important for such partnership and a lot more has to be done to get this practice in place.
Q. There are reports that say Ace Micromatic is looking at increasing its global footprint. Your comments... A. Last year around 89 to 90% of our business came from domestic market and 11% from exports. In the next 5 years our target is to make that 75-25% (75% domestic and 25% exports). We have an office in China with 20 people and in the last few years we have had around 650 machines installed in China. Turkey, South-East Asia are market we are looking at for growth and expansion. We are working on creating good partners in these countries, training them and having joint working ventures. Among the Indian machine tool companies we are the best performers when it comes to export but we still have a long way to go.
Future plans... New offices are part of our growth plan. We are also looking at acquisition of distributors across the globe. In the short term, we plan to take our export from the present 11% to at least 15% in the next two years. Year ended 31st March 2015, as a group we grew by 21% and we intend to grow further.
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FACE TO FACE
“HEIDENHAIN has become a de-facto standard for dependable precision today“ and ACCURATE machining with high surface definition, and encompasses concepts like DYNAMIC PRECISION covering Cross Talk compensation, Active Vibration Damping, Position Adaptive control, Load Adaptive Control and Motion Adaptive control. The concept of DYNAMIC EFFICIENCY, is built around a set of comprehensive technological features like Trochoidal Milling, Adaptive feed control and Active Chatter Control.
Q. What drives new product developments and launches at your end? A. HEIDENHAIN’s R&D team is always
Mr. A.P. Jayanthram Managing Dirtector Heidenhain Optics & Electronics India Pvt. Ltd
Q. What are the latest trends in technology related to your field? A. In the CNC Control area, component manufacturers are more and more looking for robust solutions that will handle both milling and turning in the same set up, which not only saves money, but increases the accuracy and productivity by avoiding multiple chucking. They are looking for solutions that enable the most accurate and efficient machining possible with high process reliability from the very first piece. Discerning Machine tool users now want not just accuracy and high surface quality in machining, but achieve them within the shortest machining times and with excellent motion control. In the field of dimensional feedback system, better optical scales with highest level of contamination protection are demanded.
Q. Being a trendsetter, what are the innovations you have spearheaded? A. Our controls today feature FAST 28
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working on the future, addressing the high end concerns of discerning demanding customer segments of 5 axes machining and high speed / high accuracy milling / turning. Our R&D is at the back of many day-to-day manufacturing efforts though not visible. For example, over 3000 mobile phones are produced every minute and they all need housings and plastic parts that need moulds which are produced in CNC Machine Tools. Again industries like aerospace and medical equipment need many three dimensional parts with high accuracies and surface quality and HEIDENHAIN manufactures both measuring devices (encoders) and controls for such high end machine tools. Another example is elevators. China installs about 600,000 elevators every year and India, roughly 10% of that. More than half the elevators will use HEIDENHAIN rotary encoders and there is an interactive Research and Development philosophy that makes these products better and better.
Q. What’s your niche and competitive edge? A. In the CNC control area, HEIDENHAIN has the largest share in 5-axis simultaneous machining applications
worldwide and in Machine Tool encoders too we have the biggest share. In modern metal cutting, it is more important than ever to manage the balancing act between speed, process reliability and accuracy and new technologies demand very high precision during production. This is where HEIDENHAIN speaks a competent language.
Q. Could you throw some light on your quality obsession & value systems? A. The high quality standard of HEIDENHAIN is documented through certification in the ISO 9001 quality systems model and by authorization as a DAkkS inspection station for units of length and angle. Long product service life and recyclable designs on the one hand and careful use of resources and optimized energy consumption on the other, are preconditions for the Environmental Declaration in compliance with ISO 14001. The high quality of HEIDENHAIN products depends on special production facilities and measuring equipment. Masters and sub masters for scale manufacturing are produced in a clean-room building, with special measures for temperature stabilization and vibration insulation, built especially for this purpose. The copying machines and the machines required for the manufacture and measurement of linear and circular graduations are also developed and built by HEIDENHAIN. HEIDENHAIN has become a de-facto standard for dependable precision today and the large family of over 15 million Rotary and Angle Encoders, over 6 million Linear Encoders, 500,000 position displays and 2,60,000 TNC controls working with our customers stand testimony to the confidence in our quality philosophy.
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3 Easy-to-operate FANUC CNC and Windows® based software.
3 For all gear types and cutting tools up to 175 mm in diameter.
3 Optimized for high-speed wet or dry hobbing; featuring new G90 Hobs to reduce tool cost per workpiece. 3 With quick-change workholding.
3 Surface roughness, fine pitch and CMM measurement options.
...All serviced and supported by Gleason from Bangalore, Mumbai, Delhi, Chennai and Pune. For worldwide sales locations and additional information, visit: www.gleason.com • bangalore.sales@gleason.in
FACE TO FACE
& “We are focussed on product optimization to improve the design, aesthetics & performance of our machines“ Q. What trend will drive machine tools industry in near future ? A. Some factors that propel spending
Mr. Parag Kulkarni
Director, Sales & Business Development Precihole Machine Tools
on capital equipment in general are current state of the economy, confidence in economy in near future and orders in hand. In the past year, we have seen signs that there is sufficient movement in the market for many industries to spend on capital equipment. We see some decent movement in private sectors like auto parts, hydraulic cylinders, medical implants, die and mould as well as government sectors like defense. We really hope that the economy picks up even further and drives corporates as well as SMEs to invest in machine tools.
Q. What is the impact of Union budget on the industry ? A. Since the union budget was released, we haven’t really noticed any big changes to the industry happen yet. The pace of the industry seems to be the same as
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what it was a quarter before the budget was released. We hope the impact of economic policies declared in the budget shows up during the third and fourth quarters of 2015.
Q. What are the remedies do you suggest to improve the positioning of the industry you are into ? A. Precihole Machine Tools is a leader in deep hole drilling and hole finishing. We are into a niche area of the engineering industry. We are focussed right now on product optimization to improve the design, aesthetics and performance of our machines, while reducing costs. India is a very cost conscious market and customers push for getting German quality in machine tools while wanting to pay Chinese prices. We are trying to achieve just that. We have achieved that quite successfully and the new line of machines we are introducing this year should really “wow” the industry in a big way.
FACE TO FACE www.mtwmag.com
“The culture of sticking to the commitments is very strong at Grind Master�
Q. What are the latest trends in technology related to your field? A. The modern machines demand quick setup change time and minimum maintenance features. Also automatic job load / unload is the requirement from the buyers. Apart from this, the robustness of the process of manufacturing is important to ensure consistency of the results in terms of CPK values.
Q. Being a trendsetter, what are the innovations you have spearheaded? A. Grind Master has been innovating right from its inception in 1984. We have developed indigenously a very wide range of automatic and semi automatic machines for deburring, polishing & super finishing which are used in automotive, steel industries, cookware & hardware manufacturing. Our machine designs have been continuously upgraded to incorporate the innovations. For example, our Nano Finish Control System, which is extremely user- friendly and its operation can be learnt quickly by a layman. For hydraulic industry, we have super finishing machines to achieve specific finishes on the piston rods, gear pump shaft, spools, etc. Our indigenously devel-
oped Precision Deburring systems for fuel pump parts and compressor plates are also exported to Europe. The unique design features on our Crankshaft Microfinishing machines enable faster set up change and the smaller footprint. In our Robotic Division we developed Robotic Deburring Grinding and Polishing of Non-ferrous castings. Our latest innovation has been Robotic Fettling of iron castings. We continuously innovate the various processes of deburring, polishing, super finishing and micro finishing.
Q. What drives new product developments and launches at your end? A. We are committed to provide complete solutions to our customers in our field of expertise i.e. deburring .grinding, polishing & microfinishing. Therefore we experiment with various consumables from worldwide sources. Our systematic R&D of these processes helps us to develop new machines that offer optimized running cost and consistent results for our customers.
Q. What’s your niche and competitive edge? A. Our ability to offer customiszd solu-
Mrs. Mohini Kelkar
Managing Director, Grind Master Machines Pvt. Ltd.
tions at affordable price provides us competitive edge. Every customer requirement is unique and different from other customers and therefore tailor- making and adding of some features and toolings is necessary to completely satisfy his requirement. Our organization is geared up for this and this is what differentiates us from our competitors.
Q. Could you throw some light on your quality obsession & value systems? A. We are totally committed to all our stakeholders. The culture of sticking to the commitments is very strong at Grind Master. Secondly we believe in transparency in all the dealings. The resultant quality and consistent quality entirely depend on the organizational culture apart from research & development of innovative products which we are engaged in.
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INDUSTRY FOCUS
Tech trends :
Competition & CNC As awareness about new technology is increasing, more and more people are opting for more advanced CNC machines. The industry is ready to shed the traditional methods and embrace the latest technology and challenge the competition. Taking a look at the trends in this fast growing segment: Article compiled by Ms. Nishi Rath Smart CNC Aftter smart phone, smart car and smart TV, now it’s time for smart CNC. There has been various talks and developments in making the machine tools ‘smart’. Smart here means incorporating intelligence in a product to enhance the productivity and efficiency of the product. Among the hot trend today is integrating intelligence in mechanical products. To prove it further, the theme that attracted attention was at EMO Hannover 2013 was ‘Intelligence in Production’. Various intelligent solutions were on display at EMO Hannover. Today when every business is looking at cutting down on costs while keeping in mind the efficiency and environmental impact. Production experts believe that ‘Intelligence in Production’ is the key.
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There are machine that are built with technologies that can provide huge data related to the operation and machine among others. Imagine a machine that can inform you that the coolant needs to be changed, grease has to be replaced or the tool condition even before the breakage. This will not only save money but also increase efficiency. This can be done by adding intelligence in the machine. Many global CNC manufacturers are putting in huge efforts to increase the predictability of the machine operation to make it more simpler and enhance productivity. Intelligence in Production helps machine operators to reliably fulfill every task. The tools used include multi-media elements in the control system, web-based diagnostic systems, remote servicing, innovative hotline concepts, and more.
Tailored training also supports the necessary skills for customers over the long term. Intelligence in production ensures that intelligent machines communicate autonomously with their supervisory management and control systems, known as Industry 4.0.
Increase in automation According to TechNavio, the Automation market in India will grow at a CAGR of 7.94% over the period 2012-2016. 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. As the Indian industry grows, the demand for high productivity will increase to meet the global standard and
INDUSTRY FOCUS www.mtwmag.com
demand. This has also led many of the domestic as well as foreign CNC builders to come up with automated CNC machine. In these machines, robots and measuring devices are mounted which not only cuts down human intervention, but also provides more accuracy and efficiency in less time.
Indian gearing up for tough competition Indian machine tool industry has been dominated by the global giants. With their excellent technology, vast experience and Indian Governments 100% FDI rule in machine tool, various MNCs have made India their key market place as there was no competition in the domestic market, but this is changing with time. India is no longer a place for cost effective compromised technology manufacturers. After replacing imported 3-axis machines, Indian CNC manufacturers are now aiming for 5-axis and competing with the global players. If you take the list of top 20 global machine tool builder there are no Indian company, but experts are confident that this will change soon. “The Indian industry has high hopes from all three Indian CNC giants ACE Micromatic, BFW and Jyoti CNC. They are investing in technology, skill, acquiring global companies, exporing and are aggressive,” said an industry expert and a distributor on CNC machines on condition of anonymity.
CNC + Additive Manufacturing Additive manufacturing is said to be the future of manufacturing and machine tool has always been referred to as the ‘back bone industry’ and CNC machine the game changer. What if everything is put together? One of the largest CNC machine tool manufacturers DMG MORI has developed a technology that combines both process, in one machine. The machine LASERTEC 65 3D (Laser Deposition Welding & Milling -additive Manufacturing in Milling quality) The company brought together for the first time the additive manufacturing into
a high-tech 5-axis milling machine. This innovative hybrid-solution combines the flexibility of the laser metal deposition process with the precision of the cutting process and therewith allows additive manufacturing in milling quality. The process uses the metal deposition by powder nozzle, which is up to 10-times faster than the generation in the powder bed. Up to now additive technologies have been used to generate prototypes and small parts. By combining both, additive manufacturing via powder nozzle and the traditional cutting method in one machine, totally new applications and geometries are possible. Especially large workpieces with high stock removal volumes are now possible to be machined in an economical way. We hope to see many more such machines in the near future.
Make in India sets off more trends With the ‘Make in India’ initiative providing a boost to the Indian manufacturing sector many new technologies such as multi-spindle and multi-turret turning centres have gained popularity. The use of quick setting tools and work fixtures have also picked up. Indian manufacturers showcased some of the trending products and solution at IMTEX 2015. Machining centres with higher precision, higher speeds, high stability and static rigidity were also displayed. This is not all green initiatives like coolant purification and shop air cleaning solutions have also attracted eyeballs in the recent times. “Vision based inspection has also gained popularity. Vision based re-engineering systems are also trending. Hydraulic servo exciters and spindle testing, gear testing, air leak detector and testing machines are also gaining popularity,” Ashutosh Pratap Singh, CEO, Syphase Engineering Pvt Ltd. As per industry speculation, demand for CNC machines will continue to grow and as we all know that machine tool is a consumer driven industry, we can expect many more developments and trends coming up in the near future.
“Vision based inspection has also gained popularity. Vision based re-engineering systems are also trending. Hydraulic servo exciters and spindle testing, gear testing, air leak detector and testing machines are also gaining popularity,” Ashutosh Pratap Singh, CEO, Syphase Engineering Pvt. Ltd.
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Industries riding high on CNC machining Compiled by Ms. Nishi Rath
F
rom SMEs to the leading players, today CNC machines can be found in almost all industries. There is hardly any facet of manufacturing that is not touched by the automated CNC machining center. There are various advantages cited for using CNC Machining, not only the process is more precise than manual machining, it can be repeated in exactly the same manner over and over again. Looking at the precision, CNC Machining can produce complex shapes that would be almost impossible to achieve with manual machining. These qualities make CNC Machining preferable to various industries, especially that require a high level of precision or include repetitive tasks. CNC technology is being used in industries such as aerospace, automobile, energy, medical and mould-making, yet each industry has specific applications and needs that determine how a given manufacturer gets the job done. Multiaxis machines are gaining prominence with each passing day, as it saves time
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by machining complex shapes in a single setup. Taking a look at those industries:-
Automotive Automotive industry, globally, is the biggest consumer of machine tool industry. More than 50% of machine tool is consumed by the automotive industry. Automotive industry directly affects the demand and quality of the machine tool. Now, as several global giants have setup their manufacturing base in India, it will have a positive affect on the Indian machine tool industry. When it comes to machine tool tech-
nology used in automotive industry, recent trends indicate that for machining of auto components like cylinder blocks, cylinder heads, crank arms, crank rods, etc, production is usually carried out using appropriate size of machining centres, turning centres with adequate auto tool changers and auto pallet changers. Sometimes, a dedicated machining line equipped with a tool presetter in the process measurement probe with required fixtures and toolings forms the criteria for selection of equipment for the required volume of production. Some of the commonly used tech-
INDUSTRY FOCUS www.mtwmag.com
niques in automotive machining is electric discharge machining (EDM) and five-axis machining. Wire Electric Discharge Machining (EDM) uses a wire electrode that travels through the conductive workpiece. In this process, the electrically charged wire is monitored by a CNC system. With careful consideration of specific applications and various alternative means of achieving five-axis capabilities, there are numerous benefits that five-axis machining can bring to the automotive industry. Multi-axis machines reduce the machine setup time and increase production rates. Elimination of multiple setups helps reduce time and errors. Other advantages of five-axis machining are that simultaneous movement is allowed along the X- and Y-axis, shorter and more rigid tools may be used. Also, higher spindle/cutting tool speed may be achieved while reducing the load on the cutting tool.
Aerospace The aerospace industry has been continuously evolving and is a hotbed of manufacturing activity and advanced machine tool technology. The design and development of new aircraft engines are working towards becoming lighter and environment-friendly. As aerospace parts require high geometrical accuracy and small tolerances, the technologies used such as tools, fixtures and cutting fluids providing high efficiency is chosen in order to guarantee precision. Industry experts see a strong trend of increased interest in machine tools with 5-axis capabilities for aerospace part machining. Aerospace manufacturers prefer machines that have high rigidity and high-torque spindle capabilities to process the tough, high-alloy materials and titaniums. Titanium alloys is one such material which is widely used in aerospace industry. Because of its characteristic it is very difficult to cut titanium alloys,
it demands a high precision machine tool like a CNC. The machinability of high-temperature and titanium alloys is 10 times lower in comparison to conventional steel alloys. As the aerospace industry is fast growing in India, one can predict more and more use of CNC machines catering to this sector.
orthopedic implants, which are made of stainless steel and titanium. Other manufacturing technologies that are used for micro-sized components used in the medical device industry also include CNC milling, which uses computer- controlled cutting tools to sculpt materials to tolerances of Âą 0.0002 in.
Medical
Infrastructure
Medical parts manufacturing is another fast growing segment for CNC builders. The rising demand for joint replacements, heart catheterisations and abdominal surgery among others have generated an increased need for precision instrumentation. These demands have given rise to opportunities for machine tool manufacturers and CNC manufacturers. Machining of medical parts or devices is different and more complicated as it requires precision at a micro level. As reliability and quality are critical in the medical instruments industry, manufactures of these precision instruments are focused on finding quality products that will streamline costs and efficiency without affecting the quality. Manufacturing processes for various devices in medical industry are now being automated through the use of CAD/ CAM systems that communicate with CNC milling and grinding machines as well as 5-axis Electronic Discharge Machines (EDM). These are used for production of medical devices such as
The Indian machine tool industry has an important role to play in the infrastructure sector. They can develop solutions to achieve better quality with better safety standards. After attracting global attention in automobile and aerospace segments, the power & energy sector is said to be the next hot spots for the machine tool industry. With business pouring in from all quarters, Indian companies are taking keen interest in diversifying their machining capabilities. When it comes to energy -- wind turbine, solar panel, hydro turbine are growing significantly in India. The government has also announced several projects and tax benefits for the sector, the renewable is said to be the most lucrative target for many MNCs. This sharp growth for renewable energy in the country is an excellent opportunity for CNC builders. Another vital part of infrastructure is construction equipment. The demand for machine tool in construction equipment is almost similar to automotive industry.
Committed to accuracy Catering majorly to automotive, aerospace, general engineering, medical, energy, etc, CNC machine finds application in almost all the industries. Looking at the growing demand for perfection, accuracy and timeliness we can say that the CNC manufacturers should be ready to meet a surge in demand for these machines in the coming years.
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TECH UPDATE
Used CNC machines : A reasonable alternative No doubt new machines offer various advantages like latest technology with low maintenance cost and energy efficiency, but the cost of new machines is still high and not every business can meet the expenses. India is a price sensitive country and the Indian machine tool industry has been witnessing a strong demand for used CNC machines. The industry expects the demand to grow further. A report...
O
ver the years, used machinery market in India has matured, but is still fragmented and very limited data is available for the same. Used machinery market has grown substantially since 2005. With economy slowing down and cost of capital remaining high, the volume of India’s second hand and recycled market including consumer products, automobile and industrial raw material & machinery, is likely to grow up to Rs 1,15,000 crore in 2015 from the current estimates of Rs 80,000 crore, according to an ASSOCHAM paper. “Whether consumer goods like electronics, durables or automobiles – used cars, or the industrial machinery in the capital goods sector, the options of retrofitting and re-usage are being considered more actively than ever before,” said D S Rawat, Secretary General, ASSOCHAM. He also added that high interest rates, risk aversion and subdued investment appetite have led to this state of this culture. Growing demand & imports
India’s total consumption of machine tools amounted to Rs 103 billion. About 65% of total consumption was met by imports of new and used machine tools. As per the industry estimates the share of used machinery in the machine tools industry sector is 40% – 45%. Used machines are also being imported and some of the key importing nations are Germany, Japan, Italy, Spain, Switzerland, China, South Korea, Taiwan and USA among others. The key machines consumed in India in the recent times are CNC lathes, machining centers, presses,
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boring milling machines and special purpose machines. Imports comprising of new and used machinery cater to more than 80 % of the domestic consumption. Domestic production accounted for about 60 % of total consumption of machines such as lathes, EDMs, and VMCs. SMEs & Used CNC
The SMEs are said to be the engine of economic growth and promote equitable development. In India too, the SMEs play a pivotal role in the overall industrial economy of the country. With the changing times, SMEs have realised the importance of adapting to the technological advances. “We have understood that investing in the right industrial equipment is essential for every business, but at time there are financial constraints, especially when is comes to CNC machines. Today, used machine tools form a major part of the machine tools market of India and used CNC machines are very much in demand,” said A Acharya, Owner, Shree Shakti Pvt Ltd. As India is a cost sensitive country, the demand for used machinery especially CNC machines is very high. “Looking at the demand and growth potential, giants like DMG have also started giving guarantees on their used machines. Used machines of various other global companies are also being imported into India,” added Acharya. Factors leading to used CNC demand
Among the most important factors are internationalisation of the markets, internet penetration and Industry 4.0. High import duties along with long delivery time are
also adding to the demand for used machines in India. “The market for used machines has increased in the last few years and the economic slowdown has further fueled the demand. Used machinery plays a crucial role in developing countries and countries with industrial regions. In such countries demand is high for used CNC machines and metal-processing machines,” said M P Sharma, Owner, Sai Engineering Pvt Ltd. Used CNCs will continue to thrive
As companies continue to upgrade their manufacturing operations, used machinery from each industry will continue to be placed in the used market. Further, the used market dealers and exporters market it to interested consumers. Used machinery, including CNCs can prove to be a great alternative for SMEs who are looking to expand their capacity in the near future. BOX
Key market facts which highlights the used machines market potential:• India is the third largest consumer of used machinery in the world. • India being an emerging economy and the requirement for used machinery to run small, mid and large businesses has been the key demand driver. • India has made considerable progress, in the last 10 years, in attracting private investment into the manufacturing & infrastructure sectors. The sector is estimated to grow at the rate of 10% over the next few years. The sector offers tremendous opportunity for consumption of a wide range of used machinery.
TECH UPDATE
New platform for the grinding of large crankshafts
J
UNKER builds a new platform for cylindrical and non-cylindrical grinding of workpieces with a swing diameter of 470 mm and a part length capacity of up to 4,800 mm, initially applied for grinding of large crankshafts “Your CBN technology is so economical. Do you also have a machine for grinding large crankshafts?� was a question repeatedly posed to JUNKER. The grinding machine specialist researched the request and discovered: To one point, primarily antiquated machines are installed worldwide for large crankshaft grinding. To another point, downsizing can be observed in generator and marine engine design; several smaller
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engines are of course easier to handle than one large one. As a result, the need for modern production methods and new machines is on the rise. To satisfy this need, JUNKER decided to develop a larger platform with many technical refinements. The platform will first be used in the JUCRANK series for grinding large crankshafts. As these weigh up to 1,000 kg, it is a challenge just to set the parts up for the process. To adjust the table assemblies, JUNKER has developed a slide with an integrated length measuring system. As a result, the setup technician first brings the work heads into position, then the steadies.
TECH UPDATE www.mtwmag.com
Newly developed steady with CNC control
First, to enable the processing of such unstable workpieces JUNKER had to develop its own steady. Currently available systems are simply too bulky and not rigid enough for high speed grinding. The new patent-pending steadies are CNC-controlled and have only one axis each. This considerably increases their stability and stiffness. Each of up to a maximum of 11 steadies can be controlled individually and applied to a section at any time – even during the process. This key feature allows for higher sequence flexibility of the grinding process. To make this possible, JUNKER applied its proven control concept to a larger, high-performance control system. After all, in its simplest execution the JUCRANK 8 already offers 24 CNC axes. Integrated measuring
Large crankshafts are mainly produced in small batches, and in some cases as single pieces. Furthermore, the forging
and hardening costs are so high that scrapping a part is disastrous. JUNKER has added an integrated measuring system to overcome these challenges. First the two grinding wheels, each mounted on a wheelhead with its own X and Z-axis, pre-grind the main and pin bearings. The diameters are measured during the process. Then it becomes apparent that the grinding machine is also a measuring machine, as it measures the entire workpiece after pre-grinding: The taper of each element, the bearing widths, lift heights - simply everything is measured. Based on the measuring data, the JUCRANK 8 finishes the grinding process while using the WK axis developed further by JUNKER: During grinding it swivels the grinding spindle, compensating for tapers in the process. With this technology the grinding machine can provide each main and pin bearing with its own profile shape, i.e. if necessary with specific crowning. With this functionality, the machine then also grinds the two shaft ends if required. These
often feature a taper and not a flange or post end. As a result, the forged crankshaft is completely ground and ready for installation after only one set-up. Another possibility of applying the new JUCRANK technology is for the re-grinding of used crankshafts. The crankshafts are ground based on the measurements taken by the machine in record time. Prospective applications outside of crankshafts
The first two machines were ordered for grinding of large crankshafts, however there is also plenty of potential for other applications – for example: printing rollers, electric motor shafts, and many more. JUNKER therefore built the first JUCRANK 8 for its technology center to develop the grinding of new applications together with its customers.
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TECH UPDATE
GBQ Microfinishing : The process of perfection The Author: Milind D. Kelkar, graduate in Production Engineering from VJTI is Chief Executive Officer of Grind Master Machines Pvt. Ltd., pioneers and leaders in the field of Metal Finishing Machines. An energetic leader and innovator, who won CMTI-PMT Trust Award for Microfinishing in the year 2001 & is proud to be the World Class Supplier of Microfinishing Solutions. Preamble: As the world is progressing forward, Designers of Auto parts are resorting to varied and stringent surface finish parameters. In a bid to meet noise and pollution norms as well as decreased warranty claims, a mundane finish like 0.4 Microns Ra which can be achieved by grinding, is suffixed by the word “Microfinished’ to ensure 200,000 KM Warranty from the same part !!!
Mr. Milind D. Kelkar, Chief Executive Officer, Grind Master Machines Pvt. Ltd.
GBQ Microfinishing - The Process of Perfection for Auto Industry.
Machining has come a long way in the last one hundred years. Machine tools have become increasingly accurate, routinely achieving workpiece tolerances not even imagined fifty years ago. Finishes of critical bearing surfaces achieved by grinding, honing and polishing, while excellent processes, have been surpassed. Even lapping is no longer adequate in the manufacturing of today’s more fuel-efficient automobile and truck engines. While the perfect bearing surface will never be achieved, it is possible to come very close with Microfinishing. Process of Microfinishing with film backed abrasive was developed to achieve consistently uniform finishes faster and
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Microfinishing with contact wheel
Microfinishing with non-resilient shoes
more efficiently than other traditional roll grinding and cylindrical finishers For years, grinding wheels and bonded abrasive stones, abrasive sheets – even slurries have constituted the usual means for resurfacing, dimensioning and polishing rolls and cylindrical parts. These traditional methods of roll finishing are typically slow and leave room for operator error. Fortunately, film-backed and flexible diamond abrasive offer fast, easy-to-use predictable alternatives. Film-backed abrasives provide predictable, consistent and repeatable performances every time for finishing operations. These film-backed abrasives enable you to quickly remove traverse marks and feed lines, eliminate chatter, follow existing geometry (including crowns) and
consistently obtain sub-1 micro inch Ra (.025 microns) or finer finishes on chrome, compressed paper, nylon, chilled iron, rotogravure, epoxy and polyurethane rolls and other non-roll surfaces. IMPCO patented GBQ Microfinishing is the process that employs rigid shoes instead of a contact roller or platen to support the abrasive film. The workpiece, such as a crankshaft or camshaft, is turned and oscillated between centers as shoes introduce the abrasive to the work interface. Fresh abrasive is incrementally indexed after each part is processed, resulting in uniform stock removal and finish, part after part. Microfinishing removes the damaged or amorphous layers to improve the surface finish and roundness of the part and, in many cases, can eliminate the need for an entire grinding operation.
TECH UPDATE surface, leaving base metal for greater bearing loads. Brinnelled Surface
Compared to conventional cloth and paper backings, film is a far more consistent substrate for the precise application of resins and micron-graded mineral. Film backings hold abrasive particles on top of the substrate, do not compress or lose particles in the backing. Compared to conventional cloth and paper backings, film backings provide a superior, uniform surface to coat with micron graded minerals. The uniform application of abrasive mineral with a unique resin bond creates the ability to provide a more consistent, repeatable finish.
When was micro-finishing developed?
In the mid 1930’s, it was discovered that automobiles transported to the west coast from Detroit, had a much higher rate of wheel bearing noise, such as chatter, clicking, etc. than did the cars sold closer to Detroit. It was discovered that the bearing races (which were only ground) brinnelled during shipping due to the constant vibration of the railroad carrier. What is micro-finishing?
Micro-Finishing is a method or process to remove the surface material of a dimensionally finished part to provide a precise fit to the mating part. An examination of the texture left on a metal surface as a result of machining operation will reveal tool marks, fragmented metal, chatter, etc. It is the micro-finishing operation that must be used to generate the final surface texture required for service life, perfor-
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mance and reliability of a product. A non-microfinished surface relates to a snow covered lake. A person’s weight will produce foot prints in the snow whereas, the ice will even provide support for the concentrated pressure of a person on ice skates. When a metal or steel part is machined, the surface becomes fragmented and also annealed if a heat generating grinding process is used. This type of surface will not support high bearing loads. Microfinishing is the process that removes the fragmented and annealed
The weight of the vehicle and vibrations of the shipping carrier caused the stationary needle bearing to compress the non micro-finish surface, as shown in the enlarged view. The needle bearing thus rolling over the brinnelled low spots, caused an undesirable clicking noise. The following diagrams show the effect of roughness & waviness on the performance of bearing in an engine. The view in the centre shows the shaft supported in the bearing by a thin oil film. Loads are equally distributed if the shaft bearing journal have correct geometry and surface texture. Roughness on a bearing journal breakes up the supporting oil film and allows the surface to contact each other and cause pre-mature wear. Waviness in roundness geometry is referred to as Chatter or lobing and it is another factor which increases the bearing loads. Combination of roughness and waviness geometry are most detrimental to bearing life. Automotive companies are now demanding crankshafts and camshafts with bearing surface Ra’s that are within a 0.05um (2mu) to 0.2um (8 mu ) range. The leading company that has spent more than a half-century developing the metal removal process needed to produce more
TECH UPDATE www.mtwmag.com
reliable and more fuel-efficient engines is IMPCO Machine Tools in Lansing, Michigan (USA). It is not easy to achieve such surface finishes. However, before working with microfinishing, it is important to understand the surfaces and geometries of bearing journals. Surface measurement, Ra
Roughness average (Ra) surface measurement are nearly always shown on engineering drawings where surface finish is specified, but it is not the only surface measurement that indicates a good bearing surface. Ra can be misleading. Both the surfaces shown in sketch below have same Ra value, but surface with flat areas separated by deep grades makes a better bearing surface with good oil retention.
finish specifications help engines maintain maximum hydrodynamic oil film on journals, but oil seal surfaces generally do not require cross hatch finishing. A cross hatch finish on an oil seal may cause a vane-type pumping action to pump oil past the seal. An oil seal with a straightline finish is much more effective.
Roughness, waviness and form are a factor in all surfaces. Most surfaces will show the combination of these 3 forms. They are never isolated. Each of these characteristics are measured by different methods as shown below.
Geometry profile
Grinding operations of crankshaft main bearings and connecting rod journals, camshaft lobes and bearing and transmission shafts will produce bearing journals with many different types of errors, including errors in roundness, waviness, chatter, taper, barrel, hourglass, etc. Even though a bearing journal has optimum surface finish, the hydrodynamic oil film cannot be maintained if any of these conditions exist.
Bearing ratio, Tp
Bearing ratio Tp is extremely important since it illustrates the amount of bearing area one can expect from a surface. When normal beak-in occurs on bearing surfaces, highest peaks will be worn away in a short period of time leaving a longer supporting surface slice level at depth which should be specifieded for Tp measurement. Controlling bearing surface finish and geometry
Surface Comparisons
Now, newer more fuel-efficient smaller engines produce higher bearing loads than engines produced a decade ago. Engine test studies have shown that some bearing surfaces with slight cross hatch
Microfinishing, as developed by IMPCO removes what is best described as unstable surface material from a dimensionally finished part. This amorphous (non-crystalline) material layer exists on every ground or turned part. That is not a problem with previous machining operations, but simply an undeniable physical fact. Left on bearing journals, this layer can, at best, cause poor performance and, at worst, bearing failure.
Microfinishing – Closing in on Perfection
GBQ Microfinishing is the process that enables manufacturers to accurately remove the amorphous material layer
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TECH UPDATE nodular iron parts. • Optional: generate oil hole radius. To accommodate varying production requirements, process parameters--including shoe pressure, oscillation frequency, stroke, part rotational speed, cycle duration, and amount of abrasive tape index--are fully adjustable for optimum performance and productivity. Now, many automobile engines use nodular iron crankshafts, which include ferrite caps protruding above the material
and thus to control surface finish, bearing ratio, geometry, and even size of bearing journals. It is used by manufacturers of auto parts to assure efficient, troublefree, long-term performance.
GBQ Microfinishing process uses a noncompressive, coated abrasive film backed by patented, precision-shaped non-resilient tooling for full, consistent part-to-abrasive contact through the finishing cycle. The film is automatically indexed after each cycle to present fresh abrasive to each workpiece and thereby help to achieve consistent finish specifications. The benefits of GBQ include:
• • • •
Reduced warranty costs More uniform oil clearances No component break-in required Lower friction, allowing high performance • Higher component efficiencies • Removal of ferrite nodules (caps) in
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ing film management system saves the valuable operator time & also ensures complete safety. surface. Other finishing processes do not adequately remove the ferrite caps, presenting a serious component durability problem. GBQ microfinishing effectively removes the very hard ferrite nodules protruding above the bearing surface on iron bearing journals. It is a capability that engine manufacturers worldwide require. Although the ferrite caps or nodules may be no more than 0.0005-in. (0.020 mm) above the bearing surface, they can cause bearing failure, resulting in expensive warranty claims. New Modular microfinishing system Nanofinish GBQ_600Cr CNC Series designed by Grind Master, has more flexibility and quick change tooling to tool up different varieties of crankshaft , camshafts & transmission components. It is designed for easy manual loading as well as automated gantry style part loading system. These models have a unique Nano Finish Control System which is designed by Grind Master to make the machines most user friendly. This system also generates MIS data which can be accessed and used. These models have easy access for tooling from front of the machine, simple film loading & trouble free film disposal. The unique space sav-
The Nano finish series by Grind Master is a benchmark for production machine tool reliability & automakers worldwide find this essential in the production of long life, high performance engines, both gas & diesel with minimal warranty costs. Grind Master Machines Pvt.Ltd B.11/B.14 MIDC, Near Railway Station, Aurangabad 431 005 , Tel: 0240-2374104 / 2374114 Fax : 0240 – 2376205, E-mail: sales@grindmaster.co.in
Power Quality
need not be a problem anymore When you use Unity Controls’ DigiVolt Stabilizers, Ultra Isolation Transformers and Power Conditioners, specially designed for CNC machines, power quality disturbances will no more be a problem hampering your production and quality. These silent sentinels protect your sophisticated, high precision production equipment from the ill-effects of voltage, spikes, surges, transients, sags, noise and harmonics affecting AC power lines. Thus ensuring continuous uptime and enhanced productivity.
DigiVolt Voltage Stabilizer l
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l
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l
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Tranquil Ultra Isolation Transformer l
High noise attenuation better than 100 / 120 dB
l
Very low leakage current
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Low running cost and long life
Powercon Power Conditioner l
Two-in-one voltage and spike correction
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Low energy loss, high efficiency
l
Ground and neutral fault protection
UNITY CONTROLS PVT. LTD 405, Sapphire Arcade, 42 M.G. Road, Ghatkopar (E), Mumbai 400 077, India. Phone: +91-22-2501 3832 / 33 | Email: sales@unitycontrols.in | www.unitycontrols.in The power quality & energy experts
Ahmedabad l Bangalore l Chennai l Delhi l Gurgaon l Hardwar l Indore l Jalandhar l Jamshedpur l Kolkata l Kanpur l Pune l Rajkot
MACHINE TOOLS WORLD |
45 | July 2015
www.vijayamcreations.com
Contact us for Power Quality Audits to Conserve Energy & Save Costs.
TECH UPDATE
Intoco: Renishaw probing reduces scrap and saves time at precision subcontractor
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he advanced manufacturing division of Intoco (Independent Tool Consultants Ltd) a Gloucestershire, UK, based company, is a showcase for precision subcontract engineering. Five-axis simultaneous machining centres and 3D solid modelling capabilities are supplemented by an unerring commitment to quality control, with three of the company’s high-specification CNC machine tools being fitted with touch probe technology from Renishaw. Whilst efficient and economical productivity is a major factor behind the success
Intoco uses Renishaw’s machine tool probing systems on its Mazak INTEGREX machine tools
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of most sub-contract machine shops, quality is of paramount importance in a market place where “right-first-time”, with zero scrap allowance is critical. After all, rejected components mean unpaid invoices. The target then, was to build measured accuracy into and during the manufacturing process. Machine shops that fit CNC machines with measurement probes quickly realise the benefits derived from automated tool setting, broken tool detection, component setting, in cycle gauging and first-off inspection. Intoco, based in Staverton near Cheltenham, UK, is a prime example of a subcontract manufacturer taking advantage of the touch probe technologies available from Renishaw. Managing Director Tony Preece founded Intoco in1972. Originally serving the aluminium extrusion industry, the company has evolved to serve a variety of markets that demand high quality products, fast delivery times and price competitiveness. Intoco is particularly responsive to very short lead-times, partly because the company also has a special steels and alloys division, which means it has stocks of raw material on site ready for component machining. Tony states that the fastest return on any investment
Wayne Parkins, Production Development Engineer at Intoco, with the Renishaw RMP600 probe
that Intoco has made has been the Renishaw probing. Rapid turnaround
As with all manufacturing companies, time spent setting work piece positions and inspecting finished products manually could be better invested in machining. A probing system can eliminate costly machine downtime and the scrapping of components associated with manual setting and inspection. This was first appreciated at Intoco around seven years ago when the company invested in a Mazak
Wayne Parkins, Production Development Engineer at Intoco, with the Renishaw RMP600 probe
TECH UPDATE www.mtwmag.com
Integrex e-1850V - a machine so large it arrived in kit form in about 30 crates and at the time the only one in the UK. It came fitted with a Renishaw RMP600 touch probe, a factor which opened the company’s eyes to the competitive gains on offer. “Currently the metals extrusion industry commands 50% of our production capacity, but we also manufacture components for the oil and gas, green energy and pharmaceutical industries”, says Wayne Parkins, Intoco’s CNC Production Development Engineer. “We purchased the Mazak Integrex e-1850V to machine very large critical components up to 2300 mm in diameter and 1500 mm in height, manufactured in Alloy C22, super duplex and high alloy pre-hardened tool steels. With our clients not allowing any possibility of ’weld repair’ in the event of a mistake ’right first time’ on 1 off components is critical with no margin for error. This was the reason for the integration of the Renishaw inspection probing on our Mazak Integrex e-1850V.”
ing options, tool offset compensation by percentage of measured error, and data output. “Inspection Plus is great because you can do in-process measuring and adjust tool sizes automatically with the controller, so from a measurement perspective it takes a lot of problems away from the operators”, explains Mr Parkins. “We’ve got a CMM which will accommodate 800 mm on the X-axis, but when we get components over that size, we can’t measure them as accurately as we need to. The Renishaw probing system and software are essential.” Intoco also machines 1500 mm diameter turbo fans on the same machine, where once again Inspection Plus is highly valuable: “We measure the fans using Inspection Plus and export the data to a suitable file, such as a Word document or an Excel spreadsheet,” says Mr. Parkins. “We can then present a document to the customer showing nominal size, check size and tolerance band.” More investment
Inspection Plus
The Mazak INTEGREX e-1850V at Intoco also has Renishaw’s Inspection Plus software for machining centres installed. This is an integrated package of macro software which includes vector and angle measuring options, print options and an extended range of cycles, as well as an SPC cycle, one-touch or two-touch prob-
Recently Intoco has added further Mazak multitasking machines to its production facility, including a Mazak Integrex e-650H, which machines components for extrusion presses, pharmaceutical and defence processes. A typical batch size at Intoco is one to four, with ten being the maximum. Mr. Parkins explains: “originally the
Intoco use Renishaw probing systems to measure large components during the manufacturing process
Mazak Integrex e-650H was delivered without a Renishaw touch probe. However, we required it to machine components up to 1000 mm diameter, which were difficult to measure with conventional inspection equipment. We then contracted Renishaw to fit a touch probe with a radio signal transmission to enable Intoco to inspect and record tight tolerance dimensions”. Intoco now also has a smaller capacity Mazak Integrex e-420H, fitted with Renishaw touch probe technology and it also uses a Renishaw MH20i manually adjustable probe with a TP20 touch trigger probe on its co-ordinate measuring machine. “The biggest challenge for us is the demand for very fast and critically urgent delivery of components to our clients”, says Mr. Parkins. “The elimination of the ’off machine’ inspection process and manual measuring, with the potential for inaccuracy and misreading that can occur, coupled with the length of time that this entails and the machine delays involved, gives us an improved ’floor-to-floor’ time together with printed accurate measurement data to pass to our clients.”
Intoco uses a Mazak INTEGREX e-1850V to machine components with large diameters
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TECH UPDATE
The future begins now The TNC is ideally equipped for tomorrow’s production Successful new products unite technological progress with the dependable strengths of their predecessors, and are also future-safe. This principle also applies to the new TNC 640, adding innovative functions and the necessary potential for the future to the typical strengths of TNC controls. As a consequence, the system will not only support coming developments in control technology but decisively shape these, as many HEIDENHAIN controls have also done in the past.
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orkshop-oriented programming, a uniform operating concept and program compatibility were and continue to be the strengths of HEIDENHAIN TNC controls, in addition to over 35 years of consistent development of highly practical functions. From generation to generation, TNC controls have significantly contributed to improving machining quality and have achieved increased process safety and productivity. The TNC 640 is also guided by this tradition, supporting the functions of its predecessors while at the same time providing many new options for machining. The TNC 640 is suited for HSC and 5-axis machining on machines with up to 18 axes. It will be the first milling-machine control by HEIDENHAIN offered with optional turning functions. With this
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control, HEIDENHAIN expands its selection of high performance controls into the complete-machining market, which had not been covered until now. It is now possible to perform turning operations on a milling machine fitted with a TNC 640. The turning operations can be programmed in plaintext, just like the familiar milling operations. Comprehensive turning cycles are available for frequently repeated operations, such as roughing, finishing, recessing and thread cutting. The synergy effects of the new NCK become apparent on the TNC 640. The field-proven lathe controls from HEIDENHAIN provided the software basis for the turning functions. The TNC 640 is based on HSCI, the new and completely digital hardware platform. The new and ergonomic design of the 19� screen and the operating panel (see figure below) with stainless steel
TECH UPDATE fronts provide the TNC 640 with a suitable appearance. The user interface of the TNC 640 is more modern, making it even easier for the operator to find the various functions and status displays. The new smarts elect function makes it easier, for example, to select cycles, and syntax color highlighting improves clarity for the editing of machining programs. Improved: 3-D graphic simulation
With the new, finely detailed 3-D graphic simulation of the TNC 640, operators can precisely evaluate the result of milling, drilling or turning processes before actual machining. This means they can detect critical tool motions in good time and quickly carry out necessary modifications to minimize scrap and avoid damages to machines and tools. More capabilities: Milling and turning in one setup
The TNC 640 enables combined milling and turning operations on the same machine, meaning that the system not only saves space and money for another machine, but manufacturing also benefits from increased precision and productivity because workpiece rechucking is no longer necessary. Users can switch as desired between turning and milling within an NC program. The TNC 640 implements this switching and all requisite modifications, while standard path functions, free contour programming, conversational programming and comprehensive cycles mean that the programming and performing of turning operations for newcomers coming from milling is highly simple.
components with clean surfaces and perfect contours in shorter time periods. ADP dynamically calculates the contour in advance, and can therefore use acceleration-limited motion control with smoothed jerk to adapt the axis velocity in good time at contour transitions. In this way the function permits optimized motion control of the feed axes with 3- and 5-axis milling. Dynamic Precision brings together the competing demands of precision, high surface quality and short machining times with specially designed functions counteracting the effects of misalignments and oscillations of the machine and machining process with intelligent control technologies. Simpler: Concise operation
• HEIDENHAIN has fine-tuned both the user interface and the handling of the TNC 640 to make the control more simple and user-friendly. The results: • The concise display of NC programs with user-friendly screens and modern color design • A higher-performance editor • The simplified handling of DXF files • The direct display of PDF files on the control • A context-sensitive cutting-data calculator, enabling simple and quick calculation of technology data for immediate transfer to the feed rate and speed dialogs Highly practical probing functions and various calibration cycles on the TNC 640 mean that setting up the machine is simple and convenient, and they also ensure high process safety without the disruption of ongoing processes.
Greater precision: Clean surfaces, perfect
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contours
Conclusion:
With Advanced Dynamic Prediction (ADP) and Dynamic Precision functions, the TNC 640 enables the machining of
HEIDENHAIN controls are renowned for exploiting the accuracy potential of highperformance machine tool with a variety of perfectly matched functions. The high machine utilization level and resulting increase in efficiency demonstrate that the combination of shop floor management and automation can lead to real competitive advantages.
TECH UPDATE www.mtwmag.com
New high-performance WIDIA VSM490™ family achieves true o 90 shoulder milling Excellent cutting and extended tool life mean more parts at higher quality
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he new VSM490 double-sided shoulder milling platform from WIDIA is a powerful advantage for achieving true 90-degree shoulders and floors with superior surface finish.Numerous precision parts in transportation, moldmaking, general engineering, and more require true 90-degree shoulders and floors with superior surface finish. Economic and competitive pressures require manufacturers of all parts to maximize metal removal and tool life. The new VSM490 double-sided shoulder milling platform from WIDIA is a powerful advantage for achieving all this and more. “Go ahead and get aggressive with feed rates,” says Global Product Manager Juan Seculi. “Not only will you see the depth of cut is much bigger (up to 15mm or 0.590 inches), scallop or stepdown marks are
barely noticeable. Poor surface quality means additional operations and higher cycle times. Take the VSM490 performance upgrade and add that doublesided inserts deliver a sizeable cost benefit over single-sided tools and the VSM490 advantages become compelling.” Designed for low horsepower draw and free machining, VSM490 delivers an effective one-two punch of reduced horsepower at the machine and higher speed and feed rates that get jobs done faster and/or with an improved surface quality. State-of-the-Art Design
With four cutting edges and multiple corner nose radii available, the robust VSM490-15 inserts provide added stability and reliability in addition to delivering true 90-degree shoulders and floors. Two insert geometries are available: MM (universal), making it the first choice for a range of work materials; and ML (light) with sharper cutting edges resulting in lower cutting forces for mild steels and stainless. VSM490 cutter bodies made with tight tolerances to ensure minimum run-out have an integral chip gash design for excellent chip evacuation along with hardened-steel construction and hardened pocket seats for improved resistance to deformation. They are available in shell, screw on, cylindrical shank, and Weldon shank models with internal air and coolant capability. “The VSM490 portfolio is engineered for multiple applications in multiple materials, making it a go-to milling tool,”
Seculi says. “Users should expect true 90-degree shoulders and floors, superior surface finish on both, and higher metalremoval rates at lower horsepower for savings all around.” Featured in NOVO
Moreover, VSM490 is available through NOVO™, WIDIA’s digital process knowledge application. With powerful process knowledge available on iPad™ and other digital devices, NOVO helps users define machining features, such as shoulder milling in specific work materials, and then immediately reduces the product set to those like VSM490 that can do the job, taking into account constraint requirements such as material, tolerance, and machining sequence for both single tools and multi-tools. NOVO then ranks the results—based on knowledge-based rules—to best meet the challenges of the application as defined by the customer’s operating environment and user preferences. This provides far more useful process knowledge than any online catalog alone, all obtained in a fraction of the time. VSM490 Starter Kits in both metric and inch, including cutter bodies, end mills, and WIDIA Victory™ grade inserts covering a variety of applications are available by contacting your WIDIA distributor. For more information, Website: www.widia.com
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IN FOCUS
MTW Magazine sponsored MTMA-Rajkot AGM on 20th June, 2015 Hotel Imperial Inn, Rajkot
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IN FOCUS www.mtwmag.com
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IN FOCUS
MTW Magazine -Inauguration @ INTEC 2015, Coimbatore
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IN FOCUS www.mtwmag.com
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IN FOCUS
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PROJECTS www.mtwmag.com
Automobile Terra Motors India Pvt. Ltd.
AUTOMOBILE EQUIPMENT FOOD PROCESSING
PROJECT
IRON & STEEL RAILWAYS TRANSPORT POWER
UPDATE
TYRES
A Japanese manufacturer of electric- powered twowheelers and three- wheelers company setting up its own manufacturing facility in Gurgaon. The capacity of the unit will be 30000 units per annum in the frst year of operations.
Place: Gurgaon Haryana Contacts: Teppei Seki (Director), E.: info.in@terra-motors.com, W: www.terra-motors.com/in
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
Mercedes- Benz India Pvt. Ltd. German luxury car-maker Mercedes- Benz is executing expansion project at its Chakan plan located near Pune. After expansion the, capacity will be doubled to 20,000 units a year.
Place: Pune Maharashtra Contacts: Shekhar Daschowdhury, Sr Manager, E-3, MIDC, Chakan. PhaseIII, Chakan Industrial Area, Kuruli & Nighoje, Khed, Pune-410501, Maharashtra, T: 02135-673001, F: 673953, M: 9850836477, daschowdhury@daimler.com itachi Automotive Systems India Pvt. Ltd. Japan-headquartered Hitachi Group, has set up an auto parts manufacturing facility at
Equipment GRT India Pvt. Ltd. The company purchased largest cold recycling equipment from Wirtgen India. This equipment will be used to deliver on its multi-million dollar program of new-generation road works in the states of Maharashtra and Madhya Pradesh.
Place: Maharashtra Contacts: 21 Madhuli Co-operative Hsg Society, Worli, Mumbai-400 018, E: headoffce@grt-india.com
Food Processing Cargill India Pvt. Ltd. Setting up corn milling plant at Davangere with a capacity of 800 tonne per day and an-
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PROJECTS
nual capacity of 3 lakh tonne. The plant will produce modifed starch for the processed food and phama industries. The unit will be operational in October.
25 on well foundation between Kaurahi-Kusheswar Asthan in connection with construction of new line project between Sankari-Hasan- pur Road. The completion will take 18 months.
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: Patna Bihar
Place: Odisha
Contacts: D B Patra, GM (Projects), JC - 25, Sector - III, Salt Lake, Kolka- ta-700098, West Bengal. T: 033-40507000, 40507621, F: 40507999, E: info@gptgroup.co.in
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
Place: Davangere Karnataka Contacts: 14th Floor, Building 9 A, DLF Cyber City, Phase III, Gurgaon-122002, Haryana. T: 124-2358939, 4090489, F: 2358977
Iron and Steel Tata Steel The company is likely to start commercial production at its greenfeld steel unit at Kalinganagar in Odisha by the end of the current year.
Place: Odisha Contacts: Sumitra Patnayak, Head (Corp Comm), 2-B Fortune Towers, Chandrasekharpur, Bhubaneswar - 751023 Odisha, T: 06746651019, M: 09937012643
Railways GPT Infraprojects Ltd. Bagged contract in joint venture with Hari Construction and Associates Pvt Ltd from East Central Railway, Patna. The contract includes foundation substructure and super- structure of major bridge no. 21 and bridge no.
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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
Transport Mumbai Metro Rail Corporation (MMRC) Plans to take up construction of Colaba-Bandra-SEEPZ Metro corridor - 3 covering 33.5 km. The project has received 31 bids from 9 consortiums have been received for 7 packages.
Place: Maharashtra Contacts: S. K. Gupta, Director (Projects), MMRCL Building, E Block, BKC, Bandra (E), Mumbai-400051, Maharashtra, T:022-26381604, 26384602, 26384604, E: subhod.gupta@mmrcl.com
and elevated. Approval is received from the local administration for two Metro corridors, one starting from Sikandra crossing to Trident Hotel and Agra Cantonment Station to District Court. The detailed project report is being prepared by RITES. The elevated routes is likely to cost Rs 200 crore per km and the under- ground route costs Rs 450 crore per km.
Place: Uttar Pradesh Contacts: Shiv Raj Singh, Civil Engineer, Near Sales Tax Offce, Ratan Muni Rd, Jaipur House Colony, Agra, Uttar Pradesh-282010, T: 0562 2811009, M: 9639004477 Hyderabad Metro Rail (HMR) The work on Hyderabad metro project is progressing well. As per the HMR estimates, the metro rail stage-1 from Nagole to Secunderabad railway station covering 9 km under Corridor- III and stage-2 from Miyapur to SR Nagar covering 11.9 km under Corridor-I would be made operational for passenger services by early 2016..
Place: Hyderabad Telangana
Agra Development
Contacts: Metro Rail Bhavan,
Authority (ADA)
Saifabad, Hyderabad- 500004. T: 040-23388591, 23388589, F: 23388582, M: 08978877113,
Two metro corridors are planned for the city of Agra covering 25-km. The corridors can be both under- ground
E: nvsreddyiras@gmail.com
PROJECTS www.mtwmag.com
Railway Vikas Nigam Ltd. (RVNL) RVNL is implementing 32-km New Garia-Kolkata Airport Metro project. Housing and Infrastructure Develop- ment Corporation (HIDCO) had cleared the proposed Metro alignment on the important stretch from Salt Lake to airport via Rajarhat. The state government waived the cost of 1,861 kottah land required for the project.
Power Alstom T&D India Bagged an order from Power Grid Corporation Ltd to supply two gas-insulated substations (GIS). The scope of contract includes design, engineering, manufacturing, installa- tion and commissioning of the GIS at Betul, including supply and erection of two 400/220/33 kV, 315 MVA auto transformers.
Place: Kolkata West Bengal
Place: Betul Madhya Pradesh
Contacts: Vijay Anand
Contacts: Shreyosi Sen,
Director (Projects), Plot No. 25, First Floor, August Kranti Bhawan, Bhikaji Cama Place, R. K. Puram, New Delhi-110066, Delhi. T: 011-26738299, 26169637, M: 9560697005, E: vanand369@gmail.com
Manager (Media Relation), 6th Floor, IHDP Bldng, Plot No 7, Sector - 127, Noida - 201301. T: 0120-4731676, M: 9811908403, E: shreyosi.sen@alstom.com
Kerala State Electricity Board
Kochi Metro Rail Ltd 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.
The electricity board has started works to install 110 KV GIS substation at Kollam in Kerala. As of now, the piling work is going on and completion is targeted by the end of 2016.
Place: Kochi Kerala
Place: Kollam Kerala
Contacts: Reshmi CR,
Contacts: Murlidharan P, Chief Engineer (Transmission South), Vydyuthi Bhavanam, Pattom, Thiruvananthapuram - 695004, Kerala. T: 0471-2446471, F: 2514460, M: 9446008010, E: cets@ksebnet.com
(KMRL)
Senior Communication Manager, 8th Floor, Revenue Tower, Park Avenue, Kochi-682011. T: 04842380980, 2350355, F: 2380686, M: 09446418222, E: reshmi@kmrl.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 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
Tyres TVS Tyres Plans to invest for capacity addition in its two plants in Tamil Nadu and Uttarakhand, aiming to add 30 lakh units per month to its production line by December 2015. Funding will be done through internal and borrowing for the capex.
Contacts: M.Thilaka, Branding & Communica- tion, Vellaripatti, Melur Taluk, Madurai-625122 Tamil Nadu, T: 0452- 2420461, E: thilaka@tvstyres.com.
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PRODUCTS
PRODUCT SHOWCASE Lamellar Flap Discs LUKAS offers a flap disc for almost every application. These abrasive tools are produced with a wide selection of backing materials (e.g. glass fibre, resin, metal and even with a bio-degradable raw material) to suit every application. The large choice of grit sizes cover high stock removal applications (from grit size 36) to the finish machining application (grit size 240) The flap discs are available in 100 mm diameter (with 16 mm bore) and in diameters 115 mm, 125 mm, 150 mm and 178 mm (22.23 mm bore); They fit all commonly used angle grinders. You can choose between the flat or angled versions depending on application.
Examples of application: For Product Enquiry Contact Supra Industries SP-106,MIDC Bhosari,’S’ Block, Near Century Enka Ltd., Off Telco Road, Pune - 411 026 (India). Cell: +91 8888893791, Tel.: + 91 20 30685648, Email: info@supraindustries.com Website: www.supraindustries.com
• • • •
deburring fettling derusting finishing
Hinge with brake
For Product Enquiry Contact Elesa and Ganter India Pvt. Ltd. A-54, Sector -83, Noida 201 305, U.P. Tel. +91 120 472 6666 Fax +91 120 472 6600 Website: www.elesa-ganter.com Email: info@elesaganter-india.com
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The free and easy movement of doors, flaps and other covers is not always desirable – to open or close these elements, using greater force is sometimes the better option. Elesa+Ganter has therefore fitted its GN 437 hinges with adjustable friction for precisely this purpose. The zinc die cast GN 437 hinges come with two slim friction cones made of polyacetal (POM) which are pressed into the conical swi- vel range of the hinge by means of an axial set screw. The friction of the hinge can so be changed by tightening or slackening the set screw counter-locked with a long nut. The braking torque remains constant across the whole 180 de- grees swivel range, preventing the inadvertent closing or opening of doors, hatches or flaps. The large friction surfaces and the low-wear polyacetal used for the friction cones interact to ensure a long service life of the element. Particular mention may be the standard connection dimensions. The new friction hinges can easily be attached, for example, with the holes of GN 237 and replace of course the standard sizes 40, 50 and 60mm. Naturally, the attractively designed hinges also comply with RoHS. Incidentally, the GN 437 hinges are also suitable for applications calling for a high degree of precision: the friction cone principle ensures that the radial motion and the movement in the axis of the hinge are free of play.
PRODUCTS www.mtwmag.com
Hydraulic core or shell making press
For Product Enquiry Contact Hydropack India Pvt. Ltd. Plot No-19, Sy No-323, Majgaon Industrial Area, GIT Collage Road, Udyambag, Belgaum- 590008. Tel:- 0831-2442559, 09449595046 Email: vpk@hydropackindia.com
Hydropack india Pvt Ltd an ISO 9001-2000 company offers Hydraulic Core or Shell making Press. This is a new generation horizontal parting line type machine with unique features of Movable overhead sand shooting assembly for easy & fast removal, fitment of heavy dies using over head crane, Ejector mechanism to eject the core/ shell out of die, retractable tie rod for easy removal of components & PLC controlled power pack with option of SCADA makes machine fully automatic. Technical specifications: Machine capacity-Max core box size- 1500 mmX600 mm, Max core box thickness- 400 mm, Max blow area- 1400 mmX500 mm, Hydraulic Power pack- 10 Hp capacity, Pneumatic pressure required- 6 Kg/ cm.sq, Max weight of product:- 50Kg. Hydropack manufactures fully automatic & customized machines as per requirement of the customer to ensures accuracy of product & reduces the production time of core making process reducing cost of production.
Schmitt hofmann HK5000 hydrokompenser balancer upgrade
For Product Enquiry Contact SBS Precision Systems (India) Pvt. Ltd. 24, Ram Swarup Khettry Road First Floor, New Alipore, Kolkata 700 053 Tel: 033-32920078. Mobile: 09331140202. Fax: 91-33-24003097 E-mail: enquiries@sbsindia.in
Due to popular demand, SBS India is pleased to present a complete electronic upgrade kit for the Hofmann Hydrokompenser HK-4410 and HK-5000 grinding wheel balancer controllers. The Hydrokompenser is one of the original grinding wheel balancers, and has been around for almost 30 years with hundreds still in operation worldwide. The Hydrokompenser uses the grinding machine coolant as a balancing mass to compensate forimbalance in the grinding wheel and spindle assembly. A filtered supply of coolant is injected into an annular ring container mounted either inside the grinding wheel arbour or on the flange of the wheel arbour. The mass of the coolant held in the container counter acts the imbalance in the wheel assembly. This is done as the wheel is rotating at normal grinding speed ensuring optimum balance of the whole assembly is quickly achieved. The original electronic controller used to drive the balancer was the HK4410, which was superseded by the HK5000. The Hydrokompenser is still a popular system with many grinding machine OEMs and end users. The upgrade is ‘Plug-and-Play’, installing in minutes, and features SBS’s latest SB5500 series modular electronic controller.
Power Hydro Chuck PHC.A from NT TOOL CORPORATION has improved clamping pressure for higher precision. This system is additionally equipped with “Dual Clamping Points System” for stable and high precision clamping as well as with stopper pin for higher precision chucking between PHC.A Chuck and Collet.
Features: • 20% more clamping force than a collet holder. • Numerous ID sizes in 1mm increments (4mm-32mm).
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PRODUCTS For Product Enquiry Contact Stitch Overseas Private Limited Plot Nos. 179 & 180, Industrial Estate, Udyog Vihar Phase-VI, Sector-37, Gurgaon - 122 004. Tel.: + 91-124-4755400; Fax: + 91-124-4755430; E-mail: stitch@vsnl.com; Website: www.stitchtools.com
• Simple one hand clamping operation with a hex wrench. • Using PHS collet, variety of shank sizes can be clamped and protect inner shank from damage/scratch. • This system has remarkably minimized set up time. • Cutting tool height can be adjusted on the side with a hex wrench. • Anti-vibration effect provides better surface.
High Speed Pipe Cutting
For Product Enquiry Contact Unipunch Toolings Pvt. Ltd. Chennai. India E – Mail: unipunch@gmail.com Mobile : 9941905061
Cutting pipes and tubes is a well established requirement with fabricators in that field. Pipes are generally cut by band sawing, circular sawing, lathe cutting or compression flow cutting. New technology is now available to cut the pipes by shearing and without loss of materials in cutting. Apart from saving of material very high production rates ranging from 3000 to 5000 pieces per hour can be achieved. This method is highly suitable for cold rolled pipes and is good for stainless steel also. Pipes from 9 Dia to 100 Dia can be cut on different models that are available. This machines can be conveniently coupled with automatic bar loader, end finisher, wire brush deburring, washing of components, inspection of components, etc…. All operations can be controlled by one person. The American machine made by Haven Manufacturing Company is represented by Unipunch Toolings in India.
ExactControlTM Process Monitoring from SBS
For Product Enquiry Contact SBS Precision Systems (India) Pvt. Ltd. 24, Ram Swarup Khettry Road First Floor, New Alipore, Kolkata 700 053 Tel: 033-32920078. Mobile: 09331140202. Fax: 91-33-24003097 E-mail: enquiries@sbsindia.in
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Optimization of process control on machine tools (Grinding, turning, milling, drilling, honing) using an additional card and software front end .Process control card utilises an accumulation of 30 years experience in grinding industry ExactDisplay: Process Display Program: The measured signal of a particluar process is stored and can be displayed without the process being active. The grinding or dressing process can be tracked and measured according to the stored signal, making optimising the process that much easier. ExactTouch: Touch Detection Program. Detection of the first contact between grinding wheel and work-piece for time saving .First touch between wheel and dresser .Detects the right infeed rate for dressing .Shorten cycle time through higher feed rates in unproductive parts of the process. This requires reliable detecion of the initial touch so as not to cause damage ExactTime: Threshold-Time Program: Measuring the time the process curve is above a pre-set threshold .Flexible use. Used for monitoring a process where minimum time is a parameter. A minimum length of the grinding wheel can be detected during dressing e.g. Wheel the grinding wheel has a cylindrical and cone shape ExactAdaptive: Adaptive Grinding Program. Upon touch detection, in-feed can be adjusted as high/ low as required, for example as rapidly as possible on rough grind, but before grinder burn occurs. ExactIntegral: Area Integral Program. Calculates the area under the process curve after learning has taken place ExactContact: Contact Dressing Program. Dressing using limits .Minimise material removal on expensive CBN and diamond wheels. Thermal displacements on the machine no longer have any effect on material removal during dressing ExactSegment: Segmented Integral Program. The measuring signal of a good process is represented as a number of grey vertical bars. Each bar represents 100% mean value of this section of the reference curve.
ADVERTISERS INDEX COMPANY NAME
PG. NO.
C CNC SOFTWARE, INC.
COMPANY NAME GRIND MASTER MACHINES PVT. LTD.
PG. NO. 7
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COMPANY NAME
PG. NO.
M MARPOSS INDIA PVT. LTD.
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H D
R
DMG MORI INDIA
20-21
DOWEL ENGINEERING WORKS
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HAAS AUTOMATION INDIA PVT. LTD.
1
HEIDENHAIN OPTICS & ELECTRONICS INDIA PRAIVATE LIMITED
5
E
RENISHAW INDIA (PUNE)
INSIDE FRONT COVER
S SANJAY TOOLS & ADHESIVES
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SBS PRECISION SYSTEMS (INDIA) PVT. LTD.
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SUPRA INDUSTRIES
49
J
EFFICA AUTOMATION LIMITED
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ERWIN JUNKER MASCHINENFABRIK GMBH
3
JYOTI CNC AUTOMATION LTD.
INSIDE BACK COVER
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G GLEASON
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LAKSHMI MACHINE WORKS LIMITED
11
UNITY CONTROLS PVT. LTD.
2015 - 2016
MACHINE TOOLS WORLD |
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Inside Story
Ms.
Meghan Summers West President, Mastercam
My Life’s Goals Aim & Ambition: My aim and ambition starts with my family and extends to yours. My children and my husband motivate me to make the most out of every day so that our partners and our customers may make the most out of theirs. I strive to provide a strong, female role model for my daughter and for other young women around the world. I strive to show others how to lead with compassion, kindness and positive reinforcement. Vision: To help create a working environment that embraces passion, creativity, and happiness. Most people spend a third of their lives at work. It is important to me to provide a place for our employees to feel safe and valued. It is also important to me that our customers enjoy working with our software. If we provide a high quality user experience, our customers will have a higher quality of life altogether. Social Goal: To provide a tool to the world that allows dreams to become a reality. Mastercam started as a two man shop and turned in to a worldwide business. Mastercam is a tool that can make that a possibility for someone else. All they need to do is dream it. Business Goal: To continue to produce the most widely used CAM software in the world.
My Leisure Choices Favourite Tourist Spot: Hawaii Music I Like: All types of music. In particular Ray Lamontagne, Citizen Cope, and The Black Keys.
Sports I Love: I love to watch baseball but I love to participate in running, biking, skiing and paddleboarding.
Ask my Taste Buds Favourite Food: Anything fresh from the company garden.
Favourite Drink: Red Wine
In Awe of I Admire: Mark Summers, Chairman, CNC Software
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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