ue in l a v k the c ring o u l t n c a U anuf m r you ess proc
TM
• Gain more throughput
TM
• Reduce rework and scrap • Increase your capabilities and profit
Energy
Aerospace
Automotive
Electronics
Medical
Are you getting the most out of your manufacturing process? An efficient, competitive and profitable manufacturing process can only be achieved once sources of variation are understood and dealt with. With Renishaw’s world leading industrial metrology solutions, you have the power to identify and control variation at all stages of your manufacturing process.
Call
080-6623 6000or visit www.renishaw.com
Renishaw Metrology Systems Ltd, G.K. Arcade, 3rd Floor #125/1-18, Mariappa Road, Jayanagar 1st Block, Bangalore 560 011, India T +91 80 6623 6000 F +91 80 6623 6060 E india@renishaw.com www.renishaw.co.in
www.mtwmag.com
Volume 1 Issue 3
Contents
Vol 1 Issue 3 | August 2015
Publisher
INTERFACE
Shirish Dongre
CEO
34
Shekhar Dongre
“I foresee India as an emerging manufacturing economy”: S. Ravishankar
Editor Shilpa Dongre
Marketing Team Ladoji Pendurkar, Amol Powle, Bhavin Shah, Bharat Shah, A.Purohit, Vinod Surve, Kavita Chaudhari
TECH UPDATE
Designer & Layout Arun P. Shinde, Pradeep M. Pillalamarri, Nandan S. Moghe, Dinesh S. Gawade
36
Circulation Executive
All New Vertical Machining Centre for Speed, Accuracy & Economy
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
COVER STORY
38
22
Renishaw : Global Leadership With Technology Expertise Mr. Colin R Price, Director - Sales & Marketing (India), Renishaw Metrology Systems Ltd.
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 AUGUST 2015
BUSINESS NEWS
06
Renishaw wins a Queen’s Award for Enterprise: Innovation 2015 for revolutionary absolute position encoder
08
Meghan Summers West to Focus on Manufacturing Education in HTEC 2015 Keynote Address
14
INDUSTRY FOCUS
26
“Indian market is very attractive to foreign capital”
30
“India is a major market but has not succeeded to realise its potential”
COMPANY PROFILE
Coaxial inspection with QMmeltpool 3D
42
Complete System Competence for Maximum Productivity
44
Ceramic Coatings in Machine Tool Industry
46
Steering pinions – efficient production of the basis for electromechanical steering systems
48
First metal 3D printed bicycle frame manufactured by Renishaw for Empire Cycles
Gleason unveils new Gear Production, Workholding & inspection solutions at Gear Expo 2015
32
54
20
72 PROJECTS 75 PRODUCTS
62
JUNKER receives Bosch Global Supplier Award
Brighter Solutions from Bright Burnishing
Improve your competitive Edge by Multitasking Machining Application of Linear Encoders on Machine Tools
Your specifications are our benchmark Premium grinding machines – as individual as your needs
Experience JUNKER grinding technology at our technology centers.
As a technology leader with over 50 years of experience and over 80 patents, JUNKER has what it takes to provide every customer with custom solutions in every field of application.
Powerful solutions The JUNKER Group offers customers from the automotive industry precisely the right grinding technique for their needs. For instance for complete grinding of crankshafts, camshafts, cam units, steering systems, gear shafts and steering rods with nut.
www.junker.in JUNKER premium-service - Guaranteed servicing - Fast and competent - 24 hours a day, 7 days a week - Worldwide service network
Erwin Junker Maschinenfabrik GmbH India Branch Office Office No. 104, City Square 29-2, K.M. Gandhi Path, Bhamburda Shivaji Nagar, Pune 411 005
A member of JUNKER Group
Editorial Board
Editorial Index 3 3m Solutions
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
K Kennametal
57
A American Gear Manufacturers Association 26
L Lakshmi Machine Works Lantek
36 10
B Bright Burnishing
32
M Mayr
52
C Mastercam Concept Laser
8 38
P Precihole Machine Tools
76
78
D Daimler India DesignTech Systems DMG MORI E EMAG Group Erwin Junker
Mr. Arjun Prakash Managing Director Effica Automation Ltd.
Ms.Samina Khalid Marketing Manager
Renishaw Metrology Systems Ltd.
Mr. MIHIR Baxi President – Global Sales Jyoti CNC Automation LTD
18 12 42
30, 46 20
F FARO Fatty Tuna India G Gleason Corporation
8 54
14, 15
H Heidenhain
62
R Renishaw Metrology Systems Ltd. 6, 22, 48 S Sanjay Tools & Adhesives 75 Spraymet Surface Technologies 44 Stitch Overseas 76, 77 Supra Industries 79 T TaeguTec Tools
16, 68
W Walter Tools India
34
Z ZF Friedrichshafen AG
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 AUGUST 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
9
BUSINESS NEWS
Renishaw wins a Queen’s Award for Enterprise: Innovation 2015 for revolutionary absolute position encoder A Queen’s Award for Enterprise 2015 in the Innovation categoryhas been granted to Renishaw for the development and manufacture of its RESOLUTE™ family of non-contact, optical position feedback devices. RESOLUTE enables a step change in the performance of motion control systems used in manufacturing and other environments. The global engineering technologies companyis delighted to have won its eighteenth Queen’s Award in the 50th anniversary year of this prestigious awards scheme. Suitable for the most demanding applications, RESOLUTE is the world’s first single track fine-pitch optical absolute encoder. It can determine position to a resolution ofone nanometre(one billionth of a metre) with motion speeds of up to 100 metres per
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MTW AUGUST 2015
secondfor linear position applications, and is capable of 32-bit resolution at up to 36,000 RPM for rotary (angle) applications. It determines position immediately at switch-on and is compatible with a range of ‘open’ and ‘proprietary’ serial protocols including Siemens DRIVE-CLIQ, BiSS®, FANUC, Mitsubishi and Panasonic. Sir David McMurtry, Renishaw’s Chairman and Chief Executive, said: “RESOLUTE is a phenomenal product that marries our years of experience and expertise in areas such as optics, high speed image processing, system engineering and precision manufacturing. I am proud of the achievements of the many people across the Renishaw Group who have worked tirelessly to produce a globally successful encoder product that is a world-first in its field.” He continued: “We won our first Queen’s Award in 1979 for Export Achievement, and whilst we have been fortunate to have been recognised a further seventeen times over the years, to receive a Queen’s Award is still very special as they continue to be regarded as the UK’s most prestigious
and depends on the quality of the applications received.
About Renishaw
awards for recognising commercial and technological success.” RESOLUTE is employed in a diverse variety of applications including safety-critical position feedback for medical robots, the control of precision metalworking machines, the manufacture of flat panel displays and the production of semiconductors. The Queen’s Awards for Enterprise are made each year by Her MajestyThe Queen, on the advice of the British Prime Minister, who is assisted by an Advisory Committee that includes representatives of Government, industry and commerce, and the trade unions. The Awards are given solely on merit and competition is fierce. The number of Awards presented each year is not pre-set
Renishaw is one of the world’s leading engineering and scientific technology companies, with expertise in precision measurement and healthcare. The company supplies products for use in applications as diverse as jet engine and wind turbine manufacture, through to dentistry and brain surgery. It is also a world leader in the field of additive manufacturing (also referred to as 3D printing), where it is the only UK business that designs and makes industrial machines which ‘print’ parts from metal powder. The Renishaw Group currently has more than 70 offices in 32 countries,with over 3,800 employees, of which 2,500 people are employed within the UK, primarily in South Wales (near Cardiff) and Gloucestershire (five sites). The majority of thecompany’s R&D and manufacturing is carried out in the UK and for the year ended June 2014 Renishaw recorded sales of £355.5 million of which 93% was due to exports. The company’s largest markets are the USA, China, Germany and Japan.
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UNITY CONTROLS PVT. LTD
BUSINESS NEWS
Meghan Summers West to Focus on Manufacturing Education in HTEC 2015 Keynote Address
Meghan Summers West President, Mastercam CNC Software’s newly appointed president, Meghan Summers West, will be heading
to California Polytechnic State University July 27-30, to deliver a keynote address focused on manufacturing. During her presentation at the 2015 National HTEC Conference, West will focus on the need to “Acquaint, Convince and Excite (ACE) the Next Generation of Manufacturing.” “The need for manufacturing jobs over the next few years will be high,” West said, “but formal programs that combine on-the-job learning with classroom education is dropping. This creates an obvious skills gap that needs to
be addressed.”
CNC Educators Training Conference The CNC Educators Training Conference is about sharing and profiling best CNC education practices, program building and innovation, ways to attract students, and developing employment opportunities for students with industry and association partnerships. CNC Software’s dedicated educational division will be on hand to provide training and educational presentations during this year’s event. The educational
division was created to address the current and future needs of the manufacturing industry through a concerted focus on engaging and training tomorrow’s manufacturing leaders. By learning Mastercam, students are better prepared to enter the workforce and secure employment in a wide range of industries and roles.
For more information, Website: www.mastercam.com
New 3D Metrology Software from FARO Delivers Increased Productivity with Simultaneous Measurement Capabilities FARO Technologies, Inc. (NASDAQ: FARO), the world’s most trusted source for 3D measurement, imaging & realization technology, announces the release of FARO® CAM2® Measure 10.5, its latest software for the FaroArm®, FARO® Laser ScanArm® & FARO® Laser Tracker. CAM2 Measure 10.5 leads the market with its capability to connect multiple 3D measurement devices, within the same coordinate system, and simultaneously scan into a single seat of software on one computer. This capability allows users to seamlessly scan large objects with higher speed and precise accuracy in order to complete 3D scanning jobs faster.
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MTW AUGUST 2015
“The new CAM2 Measure 10.5 provides significant advancements that support our customers’ needs to measure faster and more efficiently with improved ease-of-use,” stated Kathleen J. Hall, Senior Vice President and Managing Director - Americas. Significant advancements to Geometric Dimensioning and Tolerancing (GD&T) functionality provide users with streamlined analysis and visual reporting. A part inspection can now be displayed just like a print to easily visualize and determine part quality. This enhanced functionality eliminates the need to look at each feature in sequence to make the same determination.
Workflow efficiencies are maximized with the ability to automate repeat inspections by programing data analysis to automatically occur after the measurements are taken. This new capability reduces required training time, significantly reduces the risk of operator error, & accelerates job completion times. Additional enhancements include expanded point cloud capacity and the ability to easily scan trimmed edges. Users are now able to collect over 20 times more data than our previous versions while maintaining accelerated processing speed. New capabilities also allow trimmed edges on materials
such as sheet metal to be easily scanned, essentially eliminating the need to collect hard-probed measurements on part edges. “The capability to connect multiple devices for simultaneous 3D scanning, automating repeat inspections, and enhanced GD&T functionality represent major advancements in our metrology software. We are excited to launch this new release, and further enable our customers to use our world-class products to drive productivity gains,” Ms. Hall concluded.
For more information, Website: www.faro.com/india
BUSINESS NEWS www.mtwmag.com
ZF Completes Acquisition of TRW Automotive Friedrichshafen. ZF Friedrichshafen AG, a global leader in driveline and chassis technology, and TRW Automotive Holdings Corp. (NYSE: TRW) announced that the companies have completed the transaction under which ZF has successfully acquired TRW. TRW will be incorporated into ZF as a new division called Active & Passive Safety Technology. The combined company operates under the name ZF Friedrichshafen AG. “Today marks the day we combine the strengths of ZF and TRW into a worldwide leading systems supplier in the automotive sector,” said Stefan Sommer, ZF’s Chief Executive Officer. “We are all very excited about our plans for the future, with the combination allowing us to capitalize on strategic opportunities and create near- and long-term sustainable value for our customers and employees.” “The combined company is a powerhouse of automotive technologies, ranging from driver assistance and occupant safety systems, to drivelines and transmissions, and braking and steering systems,” said John C. Plant, President and CEO of TRW. “This unique combination of advanced technologies comprehensively addresses the growing, industry-wide trends
of safety, fuel efficiency and autonomous driving.”
Transaction completed as planned in first half of 2015 On September 15, 2014, ZF and TRW signed a Merger Agreement for the acquisition of TRW by ZF. This agreement was subject to a number of closing conditions, all of which have now been met, including the approval by TRW stockholders and antitrust clearances in various countries and regions such as the U.S., China, and the EU.
Closing serves as starting signal for integration
global automotive supplier,” continued Sommer. “Together with TRW, ZF will be even better positioned to benefit from major trends in the industry by building on the strengths of both companies, remaining focused on current and future business needs, and managing the transition with an emphasis on creating value.” Plant added: “This transaction provides significant benefits for our shareholders, employees, customers and communities, all of which will reap the benefits of being part of a larger, more diversified global organization focused on developing the next
generation of motion, mobility and safety solutions.”
TRW shares to be delisted Pursuant to the terms of the Merger Agreement, upon completion of the acquisition, TRW became a wholly-owned subsidiary of ZF, and each outstanding share of TRW common stock was converted into the right to receive $105.60 in cash. As a result of the completion of the acquisition, TRW shares ceased trading on the New York Stock Exchange prior to market open today, and will be delisted. For more information, Website: www.zf.com
The closing marks the start of the integration process of TRW that is projected to last three to five years. The process will start in those areas where customers will benefit from combined activities first; this includes the development of new products, materials management, sales, and the aftermarket. “Our aim is to combine the best of both worlds,” said Sommer.
Top three global automotive supplier “With pro forma sales exceeding €30 billion and more than 130,000 employees, the combined company is a top three
John. C Plant, President and CEO of TRW (left), & ZF’s CEO Stefan Sommer want to combine “the best of both worlds” of ZF and TRW.
MTW AUGUST 2015
9
BUSINESS NEWS
Lantek surpasses the 16,000 customer mark with the backing of industrial clients world wide The leading multinational in CAD/CAM/MES/ERP solutions reinforces its top international positioning with its marketing strategy and the innovation and improvement of its tools oriented towards productivity and reduced manufacturing times Once again, Lantek, a global leader in the development and marketing of CAD/CAM/MES/ ERP solutions has increased its
Lantek Headquarters
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MTW AUGUST 2015
customer portfolio, consolidating its dominant position at an international level. Today, 16,000 companies rely on the technology developed at Lantek’sheadquarters in Miñano and implemented in cutting-edge companies in over 100 countries. The main sectorswhere Lantek has consolidated its global presence include industrial machinery, shipyards,
automotive industry, tool welding, metal construction, iron and steel, elevators, air conditioning, metallic furniture and distribution. The key to its success is its commitment to internationalization and to continuous improvement and innovation. This year its business is expected to grow by 15%, in line with the trend that the multinational has seen in recent years, despite the global economic crisis. The international market represents 88% of Lantek’s results.It has a strong presence in Europe’s most advanced countries, in the United States, Asia, and Latin America, as well as many other countries around the world. “For Lantek, our global presence and the experience that we have accumulated in very different markets in large corporations operating around the world is strategic. Our aim now is to consolidate our loyalty policies with a powerful marketing strategy and the reinforcement of maintenance contracts through new tools and campaigns in different countries. This strategywill support our marketing teams and have a positive impact on customers’ satisfaction levels”, points out Alberto Martínez, general director of Lantek. Meanwhile, Lantek continues to perfect and introduce important innovations in the technology it deploys
around the world, with a clear goal: to improve the productivity of its customers and to reduce cost and manufacturing time.
About Lantek Lantek provides software solutions CAD/CAM/MES/ERP for companies fabricating sheet metal, tubes, and beams with any cutting (laser, plasma, oxy-cut, water jet, shear) and punching technology. Lantek integrates the most advanced nesting software in the industry with the highest standards in manufacturing management solutions. Its capacity for innovation and its firm commitment to internationalization and emerging markets have led Lantek, founded in 1986 in the Basque Country and with central offices in Vitoria-Gasteiz (Alava), to devise a global-local strategy, which has meant it has become a global reference within the industry with its CAD/CAM/MES/ERP solutions. Today, the company has over 16,000 customers in over 100 countries and its own offices in 15 countries, in addition to an extensive network of distributors that are present throughout the world. In 2014 its international operations provided 88% of its turnover.
For more information, Website: www.lanteksms.com
MACHINE TOOLS WORLD | 11 | August 2015
BUSINESS NEWS
DesignTech Systems inks JV pact with Integrity Tool and Mold INC. DesignTech Systems Ltd. a leading CAD/CAM/CAE, Additive Manufacturing Technologies and Engineering Services provider in India inks a Joint Venture with Integrity Tool and Mold Inc. Integrity Tool and Mold is the largest Automotive Mold, tool and Die manufacturing Companies in North America. Integrity is headquartered in Canada with large operations presence even in United States of America & Mexico. In this Joint Venture DesignTech will hold 45% stake, where as 55% will be owned by Integrity Tool and Mold INC. On this occasion, Scott Allen, General Manager, Integrity Tool and Mold Inc., stated, “We are very happy to sign up a Joint Venture with DesignTech Systems. DesignTech has been our extended arm in Mold design and engineering for last few years and with increasing demand from our customer to offer global support, the JV will be an important step towards expanding our reach
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MTW AUGUST 2015
beyond American subcontinent. The JV has started operations with a small team, trained in Integrity Canada to meet ITM global mold design standards and we anticipate a multifold growth in the team size in the coming years. This engagement will help us expedite our product development process with more hands working on our projects and will also reduce our cost of operations and development. Geographically distributed work force will help us address our customers’ requirements faster and we will be able to hit the Market early. Engineers at our JV are well experienced and committed to work, which will ensure we meet our product delivery and quality timelines and standards. With this we will be able to spread our operations further to start catering to a larger Market with a confidence of a bigger engine powering this growth at the backend.” Integrity is into development of specialized and high end
Molds, tools and dies making them a leader in their segment in the North American Market. Atul Marwaha, Sr. Vice President – International Business at DesignTech Systems Ltd. expressed his happiness exclaiming, “We are very proud to be associated with such an eminent company of their stature. We had been doing business with Integrity since late 2011 and we started with catering to their requirements on case to case basis. Soon we had setup a team of specialists exclusively working for ITM and the model was extremely successful. This prompted both DesignTech and ITM to take this association to the next level. We are extremely happy to get into a Joint Venture with them and establish this new identity of Integrity DesignTech Tool and Mold Inc. Under this JV, we will not only be working for ITM global engineering requirements, but we also plan to use this as a launch pad for expanding mold design and manufacturing services in Asia. Integrity is renowned to provide highest quality, scale, and value to it’s customers and has capacity to develop highly specialized tooling that can range from 200 to 3000 ton presses. With plants and facilities in various locations in Canada, USA and Mexico, together they have a reputation of being the best in their field. Thus this JV is a big milestone for us and we hope this association will keep growing in the near future.” DesignTech Integrity Tool and
Mold Inc. plan to expand their operations in INDIA by initially setting up a large engineering team to cater to various mold design & mold engineering aspects for ITM global clients. The JV will be later expanded to add manufacturing facility to offer local mold manufacturing & mold maintenance services.
About DesignTech Systems DesignTech Systems Ltd. is a leading CAD / CAM / CAE / PLM Solutions, Additive Manufacturing technologies, and Engineering Services provider from India. With more than 16 years of experience we have been working with companies from cross vertical domains from India and overseas to support them in their most complex and challenging engineering initiatives while helping them derive best returns on their investments. DesignTech Systems is strategic business partners in India for Stratasys, Siemens Industry Software, Altair Engineering, and MathWorks. DesignTech Systems is Recipient of some of the prestigious awards like Maharashtra Government IT award in 2010, being adjudged among the top 50 emerging companies of India by NASCCOM in 2010 etc, also operates training centres, “DesignTech CAD Academy” is an authorized training partner of Altair for their CAE and Siemens PLM for their CAD and PLM suite of solutions.
For more information, Web: www.designtechsys.com
india’s source for new gear manufacturing technologies 210H
175GMS
®
Quick-change workholding and G90 Hobs
Faster production of gears and shafts
Versatile inspection of smaller gears
3 Now built in India: GENESIS, the world’s most productive gear hobbing machines.
3 With advanced GAMATM 3 software for fast, easy operation.
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
BUSINESS NEWS
Gleason unveils new Gear Production, Workholding & inspection solutions at Gear Expo 2015 As the industry’s Total Gear Solutions Provider, Gleason will introduce advanced machines, tooling, and global customer support services covering a wide array of processes for the complete production and inspection of all types of bevel and cylindrical gears at GEAR EXPO 2015, October 20-22 at the Cobo Center in Detroit, Michigan. On display at booth #1017 will be: • The Genesis® 200GX Threaded Wheel Grinding Machine - an innovative plat-
form for automotive gearbox parts and more. The 200GX is our latest addition to the highly popular Genesis® series and offers many features. The two spindle concept combines maximum productivity with minimized idle and set up times. Fast, easy software-guided setup of the machine allows you to set up your machine from one workpiece to another in just 20 minutes using only one tool. “First Part Cycle” - fully automatic workflow after setup until grinding the first workpieces and the ability to interface with Gleason GMS® machines via QR codes increase productivity. Easily accessible machine components make maintenance
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MTW AUGUST 2015
simple and efficient while standard dimension grinding wheels and dressing tools allow you to use your existing tools. All of this in an energy efficient small footprint machine designed to meet the needs of customers in high-productivity high-quality environments. • The Gleason 300GMS®P Analytical Gear Inspection System - designed to operate in production environments while yielding reliable measurement results. A unique patent-pending base design includes an active leveling system to attenuate a broad spectrum of normal production environment vibrations, yielding measurement values in parallel with those achieved in controlled calibration laboratories, but without the delay of having to move to the lab location. Thermal fluctuations normally associated with shop floor environments are proactively compensated for as well, allowing for the best possible and most reliable inspection results. The system identifies and applies a compensation for factory floor influences in real time. The 300GMS®P Analytical Gear Inspection System is designed and tested to perform as a turn-key gear inspection system in the manufacturing environment, and is the solution to reliable, accurate, gear inspection for today’s demanding applications in aerospace, automotive, and smaller power transmission industries. Visitors to Gleason Booth #1017 will also be introduced
to a number of other significant products, technologies and services, including: • The industry’s most complete line of gear cutting tool solutions. Gleason is the industry’s leading supplier of virtually every cutting tool type for the production of cylindrical and bevel gears of all types and sizes. For cylindrical gear production, visitors will find a full array of hobs, form relieved milling cutters, solid carbide hobs, shaper cutters, chamfering and deburring tools, shaving cutters, honing tools, coated diamond and CBN grinding wheels, diamond dressing wheels and diamond dressing rolls. Visitors will have the opportunity to learn more about our recent advancements in gear hobbing technology including G90, our tooling material which closes the performance gap between HSS materials and tungsten carbide. Visitors will also find an assortment of Power Skiving tools and learn how Gleason is the total source for supporting this process. Our bevel cutting tool display will feature advanced new bevel gear cutting tools for cutting and grinding straight, spiral and hypoid bevel gears. Of particular note is the Pentac®Plus -RT which can be built faster and more precisely than stick blade cutter systems of the past. With blade seating stiffness equal to the high stiffness of our Pentac®Plus, this new system offers superior surface finish, tool life and cycle time.
• Advanced workholding solutions. Gleason designs and produces a complete range of quick-change, tool-less workholding equipment for bevel gear, cylindrical gear and nonGleason production machines. These systems significantly reduce set-up and change-over times for gearing applications up to 600 mm in diameter. Quik-Flex® Plus, Gleason’s next generation of modular, quickchange workholding systems which requires a single tool, less time and minimal operator experience will be on display for the first time at Gear Expo. We invite you to stop by and see for yourself how easy it is to change these components. Also on display will be our line of hydraulic workholding solutions. The holding force, extreme accuracy and contamination free design are well suited for dry gear processing applications. In addition, our stir-able modular workholding designs allow off spindle assembly and truing to reduce changeover time as well as the amount of total runout in the fixture. • Gleason Global Services. Gleason customers can rely
BUSINESS NEWS www.mtwmag.com
on our factory trained service professionals located throughout the Americas, Europe, and Asia, working around the clock to deliver the full range of aftermarket service and support capabilities including service programs for preventive maintenance, machine inspection, troubleshooting and repair and machine relocations. Learn about our complete range of machine rebuilding and re-controls now offered for all types of Gleason machines. In many instances this work can be completed right in the customer’s factory in less than two weeks. Gleason is also the leading source of education for gear technology. We will be promoting our customer training
classes which offer a full range of courses and education forums ranging from the beginner to the most advanced user covering all aspects of gear design, production and inspection. • Gleason Plastic Gears. Offering plastic gear design and injection molded plastic gears including helical gears, spur gears, planetary gears, internal gears Gleason Plastic Gears provides customers with the benefit of a plastic gear with no weld-line for a stronger, more accurate, and economical drive train, eliminating the additional expense of secondary machining. We will display some of our most recent innovations and have experts available to answer any plastic
gear related question. • Distech Systems - specializing in the design and manufacture of factory automation systems serving a variety of customers in the automotive and other industries. Combining customized automation technology with Gleason products for gear (and non-gear) production allows us to provide a more complete product for our customers. Come visit us at Gear Expo and help us continue our 150th anniversary celebration. Help us recognize our employees and importantly our customers for their loyalty and support of our company over so many years. Gleason Corporation’s mission is to be The Total Gear Solutions Provider™ to its global customer
Gleason to host gear solutions forum in Rochester, New York Gleason Corporation will host the GEAR SOLUTIONS FORUM (GSF) at its worldwide headquarters in Rochester, New York on September 23 and 24, 2015. This year also marks the Company’s 150th anniversary which will be recognized as part of certain events during the two day forum. GSF will include more than 40 demonstrations of products and technologies, covering all major gear production processes addressing a wide variety of industry needs. The event will be accompanied by presentations from international industry experts who will present their research in a wide range of gearrelated subjects relevant to gear design and manufacturing. The Gear Solutions Forum is a unique educational opportunity, giving visitors an unusually in-depth look at many of the
advanced new technologies that will shape the future of gear manufacturing. Demonstrations and presentations will cover bevel gear technologies for spiral and straight bevel gears, including grind from solid and SmartLap corrective lapping. For cylindrical gears, live exhibits will include high speed hobbing, power skiving, grinding and optimum processing of large gears both on dedicated gear machines and five axis machining centers. There will also be a series of inspection and measurement technologies for all types of gears and sizes including single flank roll testing, analytical gear inspection and surface roughness measurement. In addition, there will be a focus on the heat treatment of gears, quick change workholding solutions and a look at the future digital factory for gear
production. The event will also feature a variety of partners and technology providers to the gear industry covering areas such as software, coatings, heat treatment, machining solutions & more. The last GSF which took place in April 2014 at the GleasonPfauter facility in Ludwigsburg, Germany attracted approximately 600 visitors from 30 countries over a three day period. John J. Perrotti, President and Chief Executive Officer of Gleason Corporation, commented that “The Gear Solutions Forum has truly evolved into the global gear industry’s most comprehensive educational event of the year. We anticipate response to our first ever GSF in the United States in September, in conjunction with our 150th anniversary, to be a fantastic experience for all gear enthusiasts and look
base. Gleason is a leader in the development, manufacture and sale of gear production machinery and related equipment. The Company’s products are used by customers in automotive, truck, aircraft, agriculture, mining, energy, construction, power tool and marine industries and by a diverse set of customers serving various industrial equipment markets. Gleason has manufacturing operations in the United States, Germany, Switzerland, India, China and Japan, and has sales and service offices throughout North and South America, Europe and in the Asia-Pacific region. For more information, Website: www.gleason.com forward to welcoming guests from across the globe.” Gleason Corporation’s mission is to be The Total Gear Solutions Provider™ to its global customer base. Gleason is a leader in the development, manufacture and sale of gear production machinery and related equipment and automation solutions. The Company’s products are used by customers in automotive, truck, aircraft, agriculture, mining, energy, construction, power tool and marine industries and by a diverse set of customers serving various industrial equipment markets. Gleason has manufacturing operations in the United States, Germany, Switzerland, India, China and Japan, and has sales and service offices throughout North and South America, Europe and in the Asia-Pacific region. Website: www.gleason.com
MTW AUGUST 2015
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BUSINESS NEWS
Smart technology for smart solutions at the Machine-tool Biennial
Solid Carbide Guide Pads Economically Direct T-Deep Path
“YOU MAKE IT BIG”: EXHIBITORS TAKE CENTRE STAGE AT 29TH BIEMH The participation of the world’s leading machine-tool companies has made BIEMH one of Europe’s biggest trade shows in its field, so the event is dedicating its slogan this year – You Make it Big – to the real stars of the show: the exhibitors. The message is a direct reference to the strength of these firms, which offer specialised, technically innovative products with high added value. It also echoes the 2014 slogan “Think Big, Think BIEMH”. With a new image focused on smart manufacturing and Industry 4.0, the commercial campaign for the event is already under way. It is set to culminate with the 29th BIEMH at Bilbao Exhibition Centre on May 30 - June 4 2016. The “4th industrial revolution” entails new challenges and a new working paradigm, to which the exhibitors at BIEMH must seek to respond by offering advanced solutions in the fields of machinery, tools, components and accessories, automation of processes and manufacturing, metrology and quality control, materials and services and additive manufacturing. The interconnection of machines and systems at production plans and intensive exchanges of information with external equipment are the distinguishing features of the new smart factories. These factories stand out for software
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development, mass analysis and data storage systems, the incorporation of sensors and electronics and a new form of coexistence between men and machines. At BIEMH, moreover, technological advances are translated into new business opportunities thanks to the presence of buyers from all over the world. Delegations of purchasers from priority markets set by the exhibitors themselves take part in each successive edition of the event. In all, 35,500 people from 57 countries visited the 2014 edition, which featured 1314 exhibiting firms and marked the beginning of the recovery of the machine-tool industry. BIEMH 2016 is to be officially presented in Milan in October, during the EMO trade-show. Representatives of firms, organisations and the international media will be invited to attend, and will be informed about key points concerned with the current economic, commercial and technological status of the domestic industry, and about some of its leading firms. The AFM (Spanish Association of Machine-tool Manufacturers) expects to obtain a year-on-year increase in orders of between 5% and 10% by the end of 2015, so the prospects for 2016 are good. For more information, www.bilbaoexhibitioncentre.com
Creating deep holes in some of the most difficult materials created takes not only nerves of steel but also the right cutting tool that alleviates the stress of standing over the machine hoping that the work is performed efficiently and effectively. In order to make sure that deep hole drills are following the correct path, TaeguTec is introducing solid carbide guide pads for the T-Deep line of deep drilling heads and gun drills. The numerous advantages of solid carbide guide pads make their use more economical both in price and performance over brazed guide pads. Lower power consumption, longer tool life, fewer required items covering the same diameter range relative to the competition as well as the introduction of advanced carbide grades all contribute to this new line being the optimal productivity solution. TaeguTec’s guide pads are ideal for any industry that needs to drill deep through various materials. For example, TaeguTec’s solid carbide guide pads used to achieve economical and productive deep hole drilling are utilized in the automotive industry’s fabrication of diesel engines and truck bodies, the energy industry’s production of heat exchangers, the creation of oil holes used in hydraulic parts and heavy industry’s manufac-
ture of ship propeller shafts. Also, guide pads are equally important in the aerospace industry where landing gears and gas turbines have to follow strict safety requirements, the defense sector where the barrels of any number of canons need to follow precise manufacture requirements in order that ordinances reach their intended target, die and mold’s very important coolant holes, the steel industry’s billets, machine builders’ spindles and the construction machinery sector’s production of the incredibly resilient track shoes. The new line of guide pads are available from PAD-06 to PAD-18 sizes and two grades. For general deep hole drilling where both oil and emulsion coolant are needed, the SB grade is suitably adapted to
these cutting conditions. Where higher tool life is needed, a supplementary SA grade using only oil coolant aimed at preventing insert failure in stable cutting conditions is the perfect choice. Solid carbide guide pads are wholly precision ground providing superior tool life and productivity relative to their brazed equivalent. For more information, Website: www.taegutec.com
BUSINESS NEWS
Cambodia - DICV’s next destination for FUSO trucks from India Daimler India Commercial Vehicles Pvt. Ltd. (DICV), a 100% wholly owned subsidiary of Daimler AG, Stuttgart, Germany along with Mitsubishi Fuso Truck and Bus Corporation, Japan (MFTBC), a Daimler Company, started the export of its robust DICV-made FUSO trucks to Cambodia, making it the 13th market for DICV. This market is growing rapidly in many sectors like garments, logistics, mining and constructions. The first vehicles have been retailed and delivered to customers. For these sectors, out of the 5 newly developed FUSO truck models manufactured at DICV’s Oragadam plant, the ‘FA’, ‘FI’
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and ‘FJ’ models have been chosen to reinforce FUSO’s leading presence in Asia. These robust and fuel-efficient trucks are already being exported to Kenya, Sri Lanka, Zambia, Tanzania, Zimbabwe, Bangladesh, Brunei and Indonesia, and are now on their way to Cambodia. While most of the current export markets demand right-hand drive vehicles, the Cambodian market requires left-hand drive vehicles. With that, DICV once again shows its flexibility to cater to specific customer’s needs. DICV’s distributor RMA Cambodia also promises full support on technical services and spare part availability in stock as well as financial ser-
vice. Convinced customers have already made the first orders at the local dealership.
Export out of India Under the umbrella of Daimler Trucks Asia, DICV and MFTBC (Mitsubishi Truck and Bus Corporation) have combined their strength to tap into further sales potential. While DICV
focuses on the Indian market and countries such as Nepal, that are related to the Indian market conditions, MFTBC will service the rising demand in the Asian and African regions with its existing portfolio of Mitsubishi-Fuso trucks from its plant in Kawasaki and the robust Fuso trucks produced in Oragadam. With a clear view on the growth potential in Southeast Asia, DICV is in preparations to establish its presence in this region and will continuously add further markets to expand its reach. For more information, Web: www.daimler-indiacv. com
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MACHINE TOOLS WORLD | 19 | August 2015
BUSINESS NEWS
JUNKER receives Bosch Global Supplier Award
From left to right: Dr. Karl Nowak, Bosch, President Corporate Sector Purchasing and Logistics. Rochus Mayer, JUNKER, CEO. Frank Müller, JUNKER, Area Sales Manager Robert Huter, Bosch, Vice President Corporate Sector Purchasing Machinery and Equipment The Erwin Junker Maschinenfabrik GmbH has been honored with the “Bosch Global Supplier Award 2015” from Robert Bosch GmbH. JUNKER received the award in the Purchasing of indirect materials. In all, Bosch has given awards to 58 suppliers from 11 countries. This is the 14th time that the supplier of technology and services has given out the global supplier award. “The Bosch Global Supplier Award honors our top suppliers, who play such a key role in Bosch’s success,” said Dr. VolkmarDenner, chairman of the Bosch board of management, at the award ceremony on July 16 in
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Stuttgart. JUNKER CEO Rochus Mayer is proud of the award: “Working hand in hand with customers, we develop customized grinding machines for every conceivable application and all kinds of workpieces, regardless of their complexity. Out of this in-depth dialog, a unique source of problem-solving expertise has evolved making us the global frontrunner of the grinding industry. We
thank Bosch for the great trust and our employees for their extraordinary commitment.”
JUNKER – a member of the JUNKER Group The companies which make up the JUNKER Group develop, produce and sell precision grinding machines for the metalworking industry, as well as air filters for industrial air purification. A global workforce of 1400 employees is
actively working to secure the success of the JUNKER, ZEMA and LTA brands. JUNKER has been instrumental in shaping today’s grinding industry with highspeed grinding machines and ground-breaking inventions since 1962. Today, JUNKER is the world market leader in the manufacturing of CBN grinding machines. Their fields of application range from crankshafts to screw taps. The Group’s customers are located anywhere ultra-precise metal grinding is vital – predominantly in the automotive engineering and tool industries.
COVER STORY
Global Leadership With Technology Expertise Mr. Colin R Price, Director - Sales & Marketing (India), Renishaw Metrology Systems Ltd.
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COVER STORY www.mtwmag.com
Machine Hall Stonehouse
Q. RENISHAW has gain credible market share in computerized measurement technology industry, how did RENISHAW India managed this significant growth? A. Multi-task machines enable multiple operations to be completed in a single setting, reducing the need to move parts between machines and enabling new capabilities. Multi-task machines present more complex challenges in programming, setting and operating. Renishaw provide the solutions to over come everyday manufacturing challenges in all areas of manufacturing processes, from understanding machine tools capabilities to offering post-process inspection and verification and everything in-between. We consider ourselves a partner company where we work with companies to provide the full solution and not a sell-it and walk away company.
As such, automation is at the forefront of developments in machining technology. The need to get more out of machines by reducing human intervention and the causes of scrap is driving developments in machining technology.
Q. What are the market opportunities for RENISHAW products in India? How do you plan to position these products? A. Indian companies continue to pursue more production throughput and greater capabilities from their machining processes. These demands force manufacturers to identify and eliminate wasted cycle time and causes of poor performance. As such, automation is at the forefront of developments in machining technology.
Q. How about RENISHAW’s initiatives in measurement technology space? Which are your focus areas? A. Companies continue to pursue more production throughput and greater capabilities from their machining processes. These demands force machinists to identify and eliminate wasted cycle time and causes of poor performance.
South Wales Site of Renishaw
The need to get more out of machines by reducing human intervention and the causes of scrap is driving developments in machining technology. Renishaw employ over 300 people in India and we will continue to expand to match market demands and expectations. New product launches and technologies will also necessitate the need to increase resource when and as required. In Pune we have product manufacturing, software design and development and of course over 60 sales and support staff across our regional offices.
Q. Can you brief us more about RENISHAW’s top line product range? A. Renishaw’s metrology product demand remains strong around the globe and contribute to a large portion of our growth and turnover but the new technologies we have introduced such as Additive Manufacturing (3D metal printing) and healthcare ranges are also growing at unprecedented levels also.
Q. What do you think are the strengths of Indian measurement technology industry & How it is positioning itself against the global market? A. I have been involved in India since
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COVER STORY 2001 and coming regularly since 2005 and during this time I have seen a stepped change in the manufacturing culture throughout India and the demand for productivity and quality system improvement. Investment in machines and people has also been key in this change being effective. I believe the majority of Indian companies and business leaders see the tangible benefit in automation and process control and this will continue to drive the business and economy forward and stronger.
that when companies reduce spend on capital manufacturing equipment such as purchase of new CNC machine tools they strive to maximize output of their existing assets. Renishaw’s solutions are able to make this possible with a relevantly low investment with a typical quick return. As I mentioned earlier, Renishaw’s strength is our ability to provide our customers with manufacturing solutions to meet today’s demanding manufacturing challenges and having localized technical and service support.
Q. What are the key technological trends that are driving computerized measurement technology industry? A. We are seeing a vastly improved mar-
Q. What is your vision for Renishaw India for forthcoming years? A. Renishaw has been at the forefront
ket within India over the last six months. The last two years have been challenging due to the economic slowdown in key sectors such as automotive and power generation and of course the political changes in the Country. We continued our expansion and growth as a company and this can be contributed to the fact
New Mills dusk
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of innovation in its industry sectors for over 40 years, aided by its exceptionally high levels of investment in R&D and its global presence. The company is passionate about ensuring its customers benefit from the best technology and expertise available to maximise their potential. Renishaw announced back in October of our plans to set up India’s first Additive
Manufacturing Technology and Technical Centre based in Pune. We will initially have three AM machines processing different material powders. This move in itself will open up exciting opportunities for the Indian market and show that we are serious about this technology. I believe the additive market is relatively still new and the opportunities vast. There has been a real ‘buzz’ about the additive technology over the last two years and whilst it is an exciting technology the application of it is critical and should be applied correctly. Additive is not a replacement for subtractive manufacturing and radical new approaches to design should be applied to ensure that the component design is optimized to meet the true capability of what additive can provide. The applications and machines behind additive will develop and just as CNC did many years ago will evolve quickly as the technology becomes main stream and accepted across all the broad manufacturing fraternity.
INDUSTRY FOCUS
“
Indian market is very attractive to foreign capital
“
Joe T. Franklin, Jr., President, American Gear Manufacturers Association (AGMA)
“There are a number of companies both large and small who have operations or relationships in India. They view these as long-term relationships, not short-term opportunities to find a few things they can import into the US for resale. Many companies are enthusiastic about the opportunities of a growing Indian economy and a growing middle class,” says Joe T. Franklin, Jr., President, American Gear Manufacturers Association (AGMA) during an interaction with Nishi Rath. Q. Tell us something about AGMA. How does it empower gear manufacturers? American Gear Manufacturers Association (AGMA) is a US-based international trade Association representing the gearing and mechanical power transmission industry. AGMA has approximately 470 members with 25% of them representing companies outside of North America. We have members in more than 30 countries. AGMA members work together to create technical standards for the US and international markets. AGMA as an organization is the Secretariat international committee responsible for creating industry technical standards, ISO TC 60. AGMA was first elected to this position in the 1990’s and has been re-elected repeatedly since that time. In addition to technical standards,
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AGMA produces a technical conference for the industry, the Fall Technical Meeting, where many of the world’s gearing specialist come together to present research papers and network. Networking among all members is an extremely important benefit of being part of the AGMA. In addition to the technical activities, we have a number of business oriented and general management programs that are well received supported by members. Return members have a comfortable and productive environment to meet their peers and discuss industry issues. Lastly, AGMA produces the Gear Expo the fall of the odd numbered year that allows approximately 200 exhibitors to meet with several thousand attendees. Additionally the event host a number of educational programs. For the last sev-
eral years, Gear Expo held in conjunction with ASM’s Heat Treat exhibit. The next event will be in October of this year.
The present scenario of the global gear industry and the American industry... The gearing industry in the US and around the world needs economies and growing manufacturing sectors to be successful. Unfortunately today, too many of our economies are operating much slower than any of us would like. We have also seen a number of international rating organizations and forecasting companies have reduced their outlook for 2015 in future years. So most of the gearing activity around the world has unused capacity and is looking for opportunities to grow. Fortunately, there are a few strong
INDUSTRY FOCUS www.mtwmag.com
industries in the US, the automotive manufacturers are working at a very high level of activity industry sales are nearing a peek. Building construction has been slow following the recession in 2008, but is now on a good growth path for the next few years. The aerospace industry is still operating below capacity in the US but has a strong order book and extensive plans for capital investments that will lead to activity for the mechanical power transmission suppliers. Unfortunately for our industry, the decline in the price of oil has caused a significant slowdown for our members who supply the oil and extraction industries. Similarly, the decline in mining activities around the world have heard a number of our companies and, at this time, both of these seem to be longer-term slowdowns rather than short dips. I will also add that for US manufacturers. The strong dollar is making it more difficult to export products around the world and compounding this problem, is the fact that many of our target markets in Europe, Asia, Russia or Brazil are also facing slowdowns or outright recessions.
Q. What are the latest technology trends that you have come across in the global gear industry? We are monitoring several newer technologies for their near and long-term effect on the gearing industry. Innovations in sensors and data collection devices over the last few years will likely prove to bring significant productivity improvements in the global manufacturing of gearing and mechanical power transmission as we are able to work with customers to identify potential failures well in advance of a shutdown. We are able to
monitor things like tool life, bearing performance, effective lubrication than other elements of operating machinery that allow us to get the greatest productivity without working to failure. In a similar way, and especially for larger manufacturers, connecting, controlling and monitoring our manufacturing processes (called Industry 4.0 in Germany and other European countries, and the Internet of Things in the US) gives the owners of the manufacturing equipment much greater control over the means of production. In a connected factory, changes can be made very rapidly to accommodate individual customer demands and to get the maximum use from the equipment. Finally, in terms of gearing itself, innovations in materials, metallurgy and surface finish are allowing manufacturers to increase the power density of gears and drivetrains to the benefit of their customers and the ultimate users of the products being produced.
Q. How lucrative is the Indian market for the American companies? I have no data on the specifics of how lucrative or valuable the Indian market is for US gear manufacturers, but I do know that there are a number of companies both large and small who have operations or relationships in India. They view these as long-term relationships, not short-term opportunities to find a few things they can import into the US for resale. Many companies are enthusiastic about the opportunities of a growing Indian economy and a growing middle class. As you know, far better than I do, doing business in India is not always easy; there are a number of barriers including challenging infrastructure, heavy and
potentially intrusive regulations, the basic way business is conducted in India as compared to other countries and some historical views that don’t always support foreign companies coming into the Indian market. Even so, a number of our members and others recognize the great opportunity being offered by a young and growing population on the customer side and an educated and highly skilled workforce on the producer side.
Q. Do you think there is scope for growth/ improvement in the Indian industry? If yes, where/ how? I think there are opportunities for growth and improvement in all of our industries. And, yes, as an outsider, I am optimistic that your new government under Prime Minister Modi will live up to all of the high expectations of those who elected and support him. I certainly do not minimize the challenges that you face as a government and as a country to create good conditions for business to grow and thrive and at the same time continue to care for the citizens who through age or lack of education or other resources depend on the state for much of their survival. Certainly your own commentators and analysts have identified areas of your economy and society that they feel need to be addressed if you are to truly grow as an economy and as a country. But I will say that no matter how attractive a growing population is to people who manufacture goods and provide services, it is certainly possible that the difficulties of doing business can be so great as to kill the incentive that will lead to a withdrawal of foreign investments.
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INDUSTRY FOCUS Q. AGMA is a long time supporter of IPTEX, how has it helped you? AGMA has been a supporter of IPTEX from the beginning, largely because our members in India ask us to help. I mentioned earlier that we have members in over 30 countries, the truth is outside of North America, and the next country in terms of number of members is India. IPTEX is the trade show they developed with the organizer, Virgo Communications and Exhibitions. For AGMA, this event has helped a number of our members gain a deeper understanding of the Indian market and customers. In 2012, I brought about 20 member companies (from 7 countries) in a delegation to visit a number of Indian manufacturers in several regions of the country for just under two weeks. Additionally, the show is an opportunity for suppliers to the industry to meet a large number of customers and potential customers in a few days.
Q. Are American companies participating at the coming edition of IPTEX in 2016? If yes, how many? I will defer to Virgo Communications and Exhibitions to answer this. I do not know all of the companies who will be in the Show.
Q. Has the sluggish automotive industry affected the global gear industry? Auto sales in India may be sluggish
The future of the global gear industry... It is tempting to think we have seen the last innovation in an industry as old and as well established as gearing. But just when we think everything that can be invented has been, we learn that someone developed a way to cut spiral bevel gears with a milling machine or that bearings have intelligence and can warn the user that a failure will happen unless they take action now. I am optimistic about our industry’s future because we are keeping up with all the new innovations – condition monitoring, advanced automation, the connected factory – whether you call it Industry 4.0 or an application of the Internet of Things.
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currently, but this is not the case in other parts of the world or in the outlook for India. As I said earlier, the automotive market in the US is far from sluggish and is operating very close to all-time high records. Even with their weak economies in China and Europe, they too are benefiting from the strong US market, helped by a strong dollar. The Indian market is very attractive to foreign capital and your government is quite accommodating to foreign capital for auto production. Indian market is very competitive but one of the largest in the world. Your manufacturers sell both in India and in export markets.
Q. Market size of global and Indian gear industry? To my knowledge, there are no publicly available measures of the size of the Indian gearing market. You do have several internationally competitive manufacturers but no centralized way of collecting data. Also, I know of no gearing association in India.
Q. Which industry is the biggest consumer of gears and what are other emerging sectors for the gear manufacturers? The biggest user of gears is the automotive sector, accounting for as much as 70% of output in certain situations. The largest non-automotive users tend to be industrial gearing such as material handling and construction machinery.
Manufacturers and users are working together to eliminate unnecessary costs and add productivity. I have seen some fascinating applications in India and by Indian manufacturers to save massive quantities of electricity and to provide solutions in environments where solar power is the only way. We are blessed with ingenious, clever and thoughtful manufacturers who keep looking for ways to solve problems presented by customers. And they are not stuck in the old ways. As an industry we are embracing new technologies, applications and processes. Our collective job is to make life better for our customers and for their customers.
MGM-Pubblicità(210x297)_Layout 1 08/04/13 10.33 Pagina 1
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INDUSTRY FOCUS
“India is a major market but has not succeeded to realise its potential” “In India there’s still too much focus on cheap labour instead of automated, world class manufacturing systems. Also prices of raw materials are fluctuating and it is often difficult for manufacturers to maintain profit margins,” says Uli Kaiser, Business Development Manager South east Asia, EMAG Group. Q. How big is the global gear industry and where does India stand? The global gear industry is estimated to be about 180$ Billion across all industries - with, automotive, machinery, power tools, energy and aerospace being important markets. The analysts forecast the Global Gear Manufacturing Market to grow at a CAGR of 5.33 per cent over the period 2014-2019. India is a major market – both for demand as well as for manufacturing but has not succeeded to realise its potential.
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Q. What are the latest trends in the gear industry? In automotive you see that end products tend to get smaller and smaller driven by environmental issues. This results in new challenges for materials and assembly processes. Also the demand of gears per vehicle for transmissions will also increase as these products become more complex such as seven- and eight- and nine-speed automatic transmissions. Small but fast-growing markets like wind and solar energy also provide opportunities for gear manufacturers.
INDUSTRY FOCUS www.mtwmag.com
affects competitiveness, especially compared with international players, which uses higher quality automated equipment. In India there’s still too much focus on cheap labour instead of automated, world class manufacturing systems. Also prices of raw materials are fluctuating and it is often difficult for manufacturers to maintain profit margins.
Q. Where does India stand when it comes to automotive manufacturing?
Q. Automotive is the top user of gears, but for the last couple of years the industry has been lying low. How much has it affected the gear manufacturers? Over the last 5 years, China’s massive market entry in automotive has made a huge impact on the industry. Demand in Western countries has stagnated and is not expected to enjoy significant growth. China itself accounts for one-third of all additional gear demand and will surpass Japan to become the second-largest national market behind the United States.
Q. What are the latest technologies when it comes to gears? There are advances in raw material production – with continuous developments in sintering and cold forging. In manufacturing new methods aim at cost reduction whilst increasing the quality of the end product. Notable innovation are contour hardening resulting in uniform depth of hardened areas and hard turning and skiving to replace traditional grinding processes.
Major challenges for the automotive industry… Driven by price pressure, many suppliers decide to cut corners on quality of equipment and training of employees. This results in better short term profitability but
India has maybe the biggest potential for growth in automotive and other sectors and it’s clear that this is understood by the Government as evidenced for example by the ‘Make in India’ campaign. Whether it can turn the potential into economic reality remains to be seen. Focus has to be on high quality product - both from manufacturing equipment as well as from the end result. The ‘Nano-Strategy’ of a minimized product at the lowest price doesn’t resonate with consumers in developing markets. From the manufacturing side, the opportunity lies in development of advanced industry specific gears, which of course requires high technical expertise.
Q. Do you think automotive industry has shifted from western part of the world to the Asian Countries as we see Japan, India, Korea, Indonesia and China fast becoming the manufacturing hubs? There’s consolidation of the makers with Europe, US, Japan and Korea continue to be technology leaders with a stable local market and China trying to become a player with the rise of local brands such as BYD, Chery, Geely etc.
Q. Where do you see the automotive industry in the next 2 years? In terms of market growth, this decade will continue to be lead by Chinese growth followed by South East Asia and India as additional growth markets. Increasing personal income in these markets will be resulting in higher motor vehicle & other manufacturing output.
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COMPANY PROFILE
Brighter Solutions from Bright Burnishing About the Company :
“Bright” Roller Burnishing Tools Private Limited incorporated in the year 1994, is an ISO 9001 : 2008 certified company. With its Sustained efforts, Quality Products and After Sales Service it is enjoying its reputation in the field of burnishing for more than 27 years. Clientele :
They have a very wide clientele in India covering MNC, Corporate, Medium and Small Industries and Public sector undertakings. With long experience & satisfied customer base in India the company is exporting its quality products to countries like, USA, Iran, Australia, Thailand, Indonesia, UK, Singapore, etc. Applications:
Bright Burnishing Tools are being used in sectors like automobile components manufacturing, motors and pump industry, textile machinery manufacturing, hydraulic and pneumatic parts, home and office appliances, machine tool manufacturing, earth moving equipment manufacturing, railway parts, defense, aircraft parts and many more applications. About the product and its Advantage:
Burnishing is a cold rolling process on ferrous and non-ferrous machined components. Achieving superior surface finish (0.1 Ra to 0.3 Ra based on pre-burnishing condition) and close tolerance is easier with less cycle time and at negligible cost thereby eliminating finishing and quality problems, which are encountered
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in the day-today production process. Product range :
Product range includes burnishing tools for Internal Diameter, External Diameter, Internal and External Tapers, Flat circular faces, grooves etc. Internal Diameter Burnishing Tools: • Tools for through and stepped bores • Min. Internal Dia 5mm and above. • Designs available for Short bore length, Long bore length, Big internal dia • Tools with machine feed / self feed design available • Tools available with different shank options. Outer Diameter Burnishing Tools : • Tools for through and stepped bores • Min. External Dia. 2mm and above. • Tools available with different shank options. • Highly suitable for diameter less than 30mm and with short burnishing length. Taper Angle Burnishing Tools (Internal & External Angle / Taper) • Tools for Internal tapers and external tapers • Min. Minor Dia 5mm and above. • Highly suitable for mating taper assembly, like hydraulic end fittings. • Can be burnished directly after CNC turning. • Tools available with different shank options. Special Roller Burnishing Tools : Apart from the standard product range
COMPANY PROFILE www.mtwmag.com
surface finishes can be obtained (0.05 to 0.2 Ra) in single pass. This machine is highly suitable for both batch and mass production. New Introduction:
Bright also manufactures special purpose burnishing tools as per customer’s requirements such as • Single Roller Tool • Multi Surface Single Roller Tool • OD H Type tool • Face Burnishing Tool • Flat circular face burnishing tools • Groove Burnishing Tools Burnishing Machine
Apart from Burnishing tools Burnishing machines like Hydraulic OD Burnishing Machine, Pneumatic ID Burnishing Machine, Portable OD Burnishing Machine are also manufactured. • Portable OD Burnishing Machines can burnish plain shafts diameter ranging from 2mm to 30mm. These are highly suitable for achieving very close tolerances and high surface finish in plain shafts. This machine is highly suitable for mass production of
Mixi Shafts, Motor Shafts, Piston Rods, OD of Bushes etc. Separate
burnishing kits are supplied according to the components size requirement. These machines can be moved anywhere in the production line. • Pneumatic Internal Diameter Burnishing Machine is to achieve very high production, close tolerance and very high surface finish. The machine is provided with automatic spindle feed and rapid return control with pneumatic cylinder arrangements. The standard machine can burnish 40mm diameter maximum and has a spindle stroke of 80/100mm. • Hydraulic OD Burnishing Machine is constructed as per machine tool design standards. The standard machine can burnish outer diameter ranging from 6mm to 60mm. The machine is capable of burnishing both plain and stepped shafts. There is no limitation of burnishing length. The machine can be customized according to the customers production requirements. Auto part loading attachments can be designed and fixed in the standard machine for plain shafts. Very high
Tube expanders are made of special alloy tool steels carefully heat treated to withstand severe operating forces. These tools are produced by a highly skilled workforce using the latest machinery and state of the art manufacturing technology. Tube expanders are precision made tools. After rolling several tubes, submerge tools in solvent to clean and cool, then dip in light weight oil to lubricate. For best results in rolling tubes, it is suggested to use two or more tube expanders alternately.
Representation
The company has been widely represented throughout India by Regional Representatives, who handle both domestic sales and after sales service. To strengthen the domestic marketing base, the company has participated in numerous engineering trade fairs in India. Appreciation
“Appreciation is our strength and the same will help us to make our products better in all ways,” says Mr. C. Devaraj, Managing Director, Bright Burnishing Tools. “Many of our customers have sent letters of appreciation for quality of our products and after-sales service. It is a great source of encouragement. We always focus on continuous improvement and customer satisfaction,” adds Mr. Devaraj who has built this company brick by brick.
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INTERFACE
“I foresee India as an emerging manufacturing economy”: S. Ravishankar Walter headquartered in Germany is a world leader in cutting tools, serving the metalworking industry for over a century. With five competence brands under one umbrella, Walter offers around 49,000 tools for milling, drilling, turning and threading operations. It provides comprehensive tooling solutions for automotive, aerospace, energy, traction and general mechanical engineering segments worldwide. The company is upbeat about India emerging as a manufacturing economy in the nearest future. Hence it wants to partner Indian industry in its growth and help the industry achieve highest standards of manufacturing efficiencies. Mr. P.K. Balasubbramaniian converses with Mr. S. Ravishankar, Managing Director, Walter Tools India, to get deeper insights into its proactive initiatives and path-breaking innovations. Excerpts: Q. As a trendsetter in cutting tools, what are the path-breaking technological developments you would like to share with our readers? A. Today, process reliability, precision and
productivity are more important than ever – because cost pressure is continuously rising and the competition is keen. Walter has, for decades now, been providing its customers with intelligent tool solutions. Using this experience, we are driving forward total solution concepts in our customers’ value creation chain. The recently launched innovation in drilling and milling is one such example. Our new range of DC170 solid carbide drills represent a new icon of drilling on the market in terms of both performance
and design. This new range of DC170 drills is the jewel of Walter’s Development department and will be instrumental to set up a benchmark in drilling. The M4000 range is making high performance universal. Whether it is a shoulder milling cutter, a high-feed milling cutter or a chamfer milling cutter – the system indexable inserts can be used in all tools within the M4000 range. Walter uses these tools to show that high-performance tool systems are already being manufactured with 100 per cent CO2 compensation. Q. We understand you develop and demonstrate newer cutting solutions every 8 months. Why so? A. The unprecedented pace of technologi-
Mr. S. Ravishankar, Managing Director, Walter Tools India
cal change gives opportunities to businesses for creating growth through rapid conversion with newer technologies. Identifying customer’s needs – often before they realize it themselves and creating the right solution, drives business growth. For Leaders of innovative technology (like Walter) it is most important to leverage the voice of the market and respond to their dynamic requirements. For example, Walter launches new product innovations every 8 months. Every tool, every machining strategy, every solution is polished until it performs to perfection. Walter pioneers in offering Customers a complete machining solution backed with technologically innovative and advanced products.
Walter’s State-of-the-art Technology Center in Pune 34
MTW AUGUST 2015
INTERFACE www.mtwmag.com
Selecting a cutting tool supplier with such competence in product innovation, backed with local engineering support & availability of the entire spectrum of cutting tool products in a single portfolio helps customers to have an edge in the industry against the competition. Q. The world is moving towards lighter but tougher materials for making components for critical applications like automobile and aerospace. What are the challenges you face in developing cutting tools which are compatible? A. While the automotive segment contrib-
utes to a major share of Walter’s business, Walter has established its dominance in other resilient segments like railways, aerospace, power equipment and so on. Walter has experienced a very good growth in Energy, Railways and Aerospace sector in the last 3–4 years due to their focus on developing new tools, providing optimized solutions. The industry has a continuously evolving appetite for improvement which calls for challenging applications, surfaces & materials to be machined. On top of that, greater precision are needed to be achieved at an ever-increasing productivity rate with rock solid process security. Materials used in Thermal Blade, different Ti and exotic materials for Aerospace are difficult to machine. It demands extreme quality of the tools. Walter strives and delivers a strong product line and customized solutions for very specific machining needs of these emerging sectors. Walter India has a clear market strategy for these industries as our Engineers bring worldclass technologies with our Global Competence Center, to Indian manufacturers.
Q. Can speed, efficiency and economy go together? A. Today’s End users are demanding the
latest in technology at the most economical cost. These are challenging but interesting times, which calls for manufacturers to device processes and technology that not only address the markets requirement of price with profitability but also technological innovations that provide a competitive edge to meet the end user’s demand. It is thus an imperative obligation of technology leaders like Walter to be there for our manufacturing clients and provide them this needed competitive advantage through innovative cutting tool technologies, Product Quality and Expert Engineering Services. We at Walter concentrate with a holistic approach on the entire range of our client’s applications and on what they can achieve using our Specialized Process Optimization Solutions. Q. How do you educate the customer on the right selection and use of cutting tools? A. Empowering with knowledge is the key
to gain Customer trust. Walter believes in imparting trainings via seminar, technical trainings, various online applications & tools to educate customers. The state-ofthe-art Walter India Technology Center epitomizes Walter’s drive and dedication to superior customer service with the objective of cementing its reputation as the ‘Competence leader’. Prototype development, prove-out of new products and Process Optimization solutions along with Technology exchange and specialised training for Customers and Engineers are a few of the major deliverables of the Technology Centre. We conduct different levels of training modules to suit the customer requirements across functions from operators to super-
A riot of futuristic products from Walter Tools
visors and from foremen to manufacturing managers. These modules can be tailormade to address the varied training needs of different customers with the help of live demonstrations at the Technology Center. These live training sessions (on-the-job) are combined with classroom training to make it absolutely comprehensive. Q. How do you visualize the growth of machine tools industry in India and how do you hope to work in tandem to provide cutting edge technologies and solutions to the end-user? A. I foresee India becoming a major manu-
facturing economy in the times to come. Large MNCs have invested & are shifting to India. India is a growing economy with a large home market for the manufacturing sector. It has a huge demographic advantage of young, educated and ambitious workforce which is a key ingredient for growth in the manufacturing sector. And Walter wants to partner Indian manufacturers in this growth; we will continue to undertake initiatives that will help Indian industries to achieve the highest standards of manufacturing efficiencies. Walter India has ambitious growth plans through market share gain and distribution base expansion during coming years. We rely on a solid growth strategy, which enables us to provide our customers a competitive advantage through innovative technologies, premium product quality and expert engineering services. We have a very good Engineering team in India and possibly Walter has got the highest turnover by providing the Complete Solutions to its customers in comparison to its competitors. We have introduced new innovative products in the market at a faster pace. We have also introduced ‘Walter Multiply’ – a service brand to provide not only the tools but also the service to reduce the cost of machining. Process Optimization is a part of Walter Multiply service which aims to reduce the machining cost on the existing products and processes of the customer. We strongly believe that our customers will rely more and more on Walter products and services in the coming years.
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TECH UPDATE
All New Vertical Machining Centre for Speed, Accuracy & Economy From Lakshmi Machine Works (LMW), the 50 year old Engineering conglomerate JV Kraft-Vertical Machining Centre
LMW Machine Tool Division has introduced an All New Vertical Machining Centre “JV Kraft� in the X 800mm range which caters to the needs of diverse industrial segments from Aerospace to Job shops. The machine is equipped with robust spindle, constructed to minimize axial and thermal expansions and is dynamically balanced to ensure extremely low run-outs. The high precision feed mechanism provides high accuracy, rigidity and repeatability. The highly reliable swift Automatic Tool Changer (ATC) adds a new dimension to vertical machining. This state-of-the-art machine has been designed to meet the evergrowing demand for speed and accuracy of the user industry for high quality and high volume production. The machine is designed with the motto of best price-to-performance ratio and true to the goal of providing value creation through innovation, says I.N. Bhattacharya, General Manager-Marketing & Sales, MTD, LMW. For more information Lakshmi Machine Works Limited Machine Tool Division, Arasur Coimbtore 641 407 Tel : +91 422 3021300 E-mail: mtd_marketing@lmw.co.in
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TECH UPDATE
Coaxial inspection with QMmeltpool
3D
Active quality assurance is one of the most important requirements of additive production users. Monitoring the key data of a laser melting system regarding oxygen content, temperature, laser output and powder quality is part and parcel of the standards nowadays. However, a comprehensive statement about the quality of the part cannot be made simply on the basis of these machine parameters. Using in-situ process monitoring systems based on an on-axis system, however, it is possible to obtain information about defects during the build process. Concept Laser, a pioneer of LaserCUSING, now presents a tool for position-related real-time monitoring and three-dimensional visualization. The next quality level with QMmeltpool 3D will be available from 2016 onwards for the M1 cusing and M2 cusing machines.
I
n-situ process monitoring is one of the strategic technology areas of Concept Laser, and is one which the machine manufacturer is now expanding to include the QMmeltpool 3D for three-dimensional real-time monitoring. The LaserCUSING process is a highly dynamic one because of the high scanning speeds and significant laser outputs; it is influenced by a wide variety of process factors. In challenging areas such as medical technology, automotive as well as aerospace, the safety requirements are strict and high quality is a prerequisite. QMmeltpool 3D supplies quality-relevant data in real time for process monitoring and documentation. The system records position-related characteristics of the melt pool while the component is being built up (Figure 3). This data can be visualized in a threedimensional landscape, and analyzed by the user. According to information from the manufacturer, the analytical
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tool is comparable to the HD resolution achieved by computer tomography (CT). Process monitoring with QMmeltpool
The QMmeltpool system uses coaxial sensors to detect melt pool emissions that are created during the fusing process in the form infrared radiation. The coaxial structure allows restriction to a small region of interest with a high local resolution and rapid scanning rates (up to 50 kHz, depending on the detector type). This melt pool monitoring identifies two characteristic parameters: The melt
pool area and melt pool intensity. These characteristic parameters can be allocated to corresponding process errors. For example, a low melt pool intensity may indicate inadequate laser output or an excessively high scanning speed, i.e. insufficient energy input. Moreover, changes in the area of the melt pool may indicate a variation in the oxygen content within the process chamber. The part geometry also has effects on the thermal conditions in the process, which means that reference samples and a high level of process understanding are
TECH UPDATE www.mtwmag.com
with a high resolution level in terms of location and timing. Following that, these signals are correlated with the corresponding positional data of the laser. This comparison is what makes QMmeltpool 3D so ingenious: melt pools signals such as melt pool area and melt pool intensity can thus be visualized and evaluated in three-dimensions directly after the build process has finished. The user can trace the process of creating each part in terms of position. Local effects in the part during the build process can now be detected and analyzed better. Coaxial integration with QMmeltpool 3D: pinpoint accuracy with the on-axis approach
required for the variation in data during the process to be interpreted and analyzed correctly. In 2D melt pool monitoring, the signals are supplied as average values per component and per layer. This 2D perspective permits a restricted interpretation of localized defects. QMmeltpool becomes QMmeltpool 3D
The former time-related 2D monitoring of the build process has now become a position-related 3-D landscape. Instead of exclusively time-related data, the system now additionally delivers positionrelated signals for definitive allocation, comparable to computer tomography (CT) (Figure 3). These signals make it possible to generate 3D datasets of the part or its structure. A highly accurate 3-D landscape of the part is thus created. In detail, this means identifying characteristic properties of the melt pool. These include the area and intensity of the melt pool that can be investigated using two detectors, a camera and a photodiode,
The new approach is based on expanding the 2-D inspection into the 3-D space, with coordinate-related data acquisition of the melt pool values. It is possible to look at current quality assurance approaches available on the market to assess the new method of QMmeltpool 3D. Classic off-axis inspections have a lower resolution and lower detection rate. For example, an infrared-sensitive camera is used located in a position outside the build chamber – i.e. ex situ (Figure 2). The advantage of this ex-situ solution is that the system integration of the machine and camera system is rendered straightforward. An off-axis structure enables statements to be made about the overall fusing and cooling behavior. However, it is not possible to derive a detailed statement about the melt pool. The on-axis/in-situ structure is based on a two axial arrangement of detectors (Figure 1). The detectors used are a camera and a photodiode which use the same optic as the laser. This coaxial integration permits a high coordinaterelated 3D resolution of 35 µm. The detection rate results from the scanning speed. If it is 1,000 mm/s, the result is 100 µm, i.e. the distance covered by each shot. At 2,000 mm/s, the value is 200 µm. Concept Laser specifies the sampling rate of the camera as > 10 kHz and 50 kHz for the photodiode. The coaxial arrangement offers the advantage that the melt pool
MTW AUGUST 2015
39
TECH UPDATE (Figures 5 + 6). In-situ monitoring systems thus make a significant contribution to detecting process defects at an early stage and avoiding them in future. For the user, this represents a tool for optimizing the process. Possibilities and limits
emissions are always focused on one point of the detectors, and the frame size is reduced so that the sampling rate can also be increased. As a result, a detailed analysis of the melt pool characteristics is possible. Possible sources of defects during laser melting
Defects that occur during laser melting are due to an extremely wide range of influencing factors: Examples include the scanning speed or laser output (Figure 4). Process defects, for example, can be caused by scanning speeds that are too low or too high, having the effect of excessive or inadequate energy input. Inadequate energy input into the powder bed, for example, leads to unmelted powder in the form of irregularly shaped pores. If the energy input is too high, on the other hand, this can give rise to gas inclusions that are revealed as regular, round pores in micrographs. The process gas flow, the material and many other factors can also influence the process and part quality. In-situ monitoring systems can detect process characteristics in real time thanks to their high resolution and sampling rates (every 0.1 mm, depending on the scanning speed)
QMmeltpool 3D helps to minimize the work involved in quality assurance and to exploit time benefits. QMmeltpool 3D can supply local indications of defects in the part. As a result, subsequent inspections and tests can be reduced to a minimum. Furthermore, the data is available directly after the build process, resulting in savings in the amount of time taken. QMmeltpool 3D is unable to rectify defects during the build process. Due to the large number of influencing factors that can cause defects in the build process or on the component itself, and the highly dynamic properties of the process, developing a self-correcting control loop represents a significant challenge. Outlook
The practical added value of threedimensional visualization with QMmeltpool 3D is not just that it is an original way of providing active quality assurance. In production and process development, component jobs can be optimized through iterative variation of the parameters. Support structures can be adapted, and above all, the design of the part can be structured in a more efficient and production-friendly manner. Last but not least, new possibilities are opened up in material research and validation of materials. In 2016, the quality module is to be made available for M1 cusing and M2 cusing machines.
Characteristic data of the QMmeltpool 3D quality module
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Structure of the monitoring
In-situ
Inspection instruments
Camera and photodiode
Dimension
x, y and z
Resolution in 3D
35 Âľm
Camera sampling rate
> 10 kHz
Photodiode sampling rate
50 kHz
MACHINE TOOLS WORLD | 41 | August 2015
• ExactDress™ Dressing Control
© 2013 Schmitt Industries, Inc. All rights reserved. SBS DYNAMIC BALANCE SYSTEM is a registered trademarks of Schmitt Industries, Inc.
SBS PRECISION SYSTEMS (INDIA) PVT. LTD. Tel: 033-32920078, Cell: 9331140202, Email: enquiries@sbsindia.in | Web: www.sbsindia.in See us at EMO 2013. Hall 6 Stand C37. Fax: 033 24003097 • Kolkata • New Delhi • Pune • Bangalore
• AEMS Acoustic Emission Monitoring
• ExactControl™ Grind Cycle Management • SBS In-Process Balancing
Grinding Process Innovation
www.schmitteurope.com
TECH UPDATE
Complete System Competence for Maximum Productivity
Top customised engineering: DMG MORI Systems combines technology, machine tool, automation and peripherals in holistically coordinated 360° solutions for your production systems.
F
The future is automatic
and automation that is bundled within DMG MORI Systems GmbH. Added to this is the engineering expertise and strong partner structure that together with its experience enable DMG MORI Systems to configure and implement ideally aligned systems for every customer and every requirement. And it achieves this for a diverse range of workpieces, from a small precision part to tool moulds, and for a multitude of different lot sizes from single parts right through to serial production with automation solutions that range from standard to turnkey. The range is organised in four segments:
In the age of “Industry 4.0” the automation of manufacturing processes is gaining dynamically in importance. At the same time the merging of virtual and real production worlds demands an integral
Segment 1: Machine-integrated automation • Integrated in the machine • Universal production
lexible automation guaranteeing process reliability is an elementary factor of success for a universally digitalised production world. With this in mind DMG MORI Systems already offers its customers the possibilities and competences to produce successfully here and now. And this performance commitment applies to every segment of automation technology: to machineintegrated automation as well as standard automation and on to include flexible manufacturing cells and comprehensive turnkey production lines.
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communication capability of machines, systems and components. 360° system competence
DMG MORI Systems meets this challenge of the future actively by offering a holistic range of services from a single source for technology, machine tool and automation solutions. This diverse service offer is based on the unique experience of DMG MORI in the sector of techno-logy design
TECH UPDATE www.mtwmag.com
Segment 2: Standard automation • Solutions for tool, workpiece and pallet handling • Portal and robot solutions Segment 3: Flexible manufacturing cells • Implementation of customer-specific machining processes combined with automation of in-house machines and third party products Segment 4: Production lines
• Planning, simulation and implementation of turnkey solutions based on the DMG MORI corner-type solution Process reliability with maximum productivity in the turnkey sector
The interaction of different disciplines from technology, machine, automation and peripherals make turnkey projects the supreme disciple of automation and system technology. In addition to its wide range of products in the field of machine tools DMG MORI also offers proven expertise here in all fields – in the engineering of technological applications as well as in material flow and the required peripherals. This consistent integration is in turn the
basis for a high level of cost-efficiency, as Silvio Krüger, General Manager of DMG MORI Systems GmbH, explains: “The convincing features of the production lines include low unit costs, outstanding machining performance, a high system availability of over 95% and high output. They achieve the shortest cycle times and offer impressive flexibility where workpieces are concerned.” Parallel manufacturing processes are also possible and flexible programming leaves considerable scope in the production process. Reliability & process stability are ensured by the use of advanced and proven technologies and products on the one hand and the global presence of DMG MORI on the other. “As a supplier for the globally organised automotive industry its goes without saying that we draw on our worldwide service network and a specially setup top-level support team to help customers quickly whenever the need arises”, stresses Silvio Krüger, calling our attention to the new Technology and Competence Center in Wernau near Stuttgart. New Technology and Competence Centre in Wernau
With the aim of bundling and focussing
the system competences already mentioned with the resources of the DMG MORI SEIKI Group even more intensively for our customer we are currently constructing a future-orientated Competence Center for tool and equipment techno-logy, control system design and project management in Wernau. The company is building a completely transparent 47,000 m2 factory that has an air-conditioned production area of over 12,000 m², six independent central coolant systems, a central extraction system for emissions from the dry machining process and a measuring room for cmk and cpk production approvals of 450 m². Silvio Krüger sees the investment as a strategic milestone: “It is exactly here in the handling of turnkey projects that it is imperative to have the entire know-how ready to hand. The Technology Centre will allow us to optimise our structures and give customers the opportunity of getting a real impression of our engineering competence.” It will also be possible to coordinate the global activities of DMG MORI with Nara, Japan and Davis, USA perfectly from this central location.
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TECH UPDATE
Ceramic Coatings in Machine Tool Industry By P T Bindagi, Technical Director, Spraymet Surface Technologies Pvt. Ltd. , Bangalore
M
achine Tool Industry has undergone major developments in providing longer lasting life to spindles , arbors and bearings. Ceramic coatings by Plasma spray process have been in use since 1960 in many industries. Since last decade this process and ceramic coatings are used to provide hard surfaces to seal areas of spindles, contact faces of arbors and electrical and heat insulation to bearings. Apart from OEM level coatings, many user industries are using ceramic coating for refurbishing of spindles and other machine tool parts.
WHAT IS PLASMA SPRAY?
The plasma spray gun comprises a copper
anode and tungsten cathode, both of which are water cooled. Pressurised plasma gas (argonor nitrogen with hydrogen 15% as secondary gas) flows through the anode and passes the anode. The plasma arc is initiated by a high voltage discharge between anode and cathode which causes localized ionisation. The resultant heating from the arc causes the gas to reach extreme temperatures, dissociate and ionise to form a PLASMA. Plasma arc ( flame) extends down the nozzlewith temp upto 15000 deg C and velocity upto 600 mts/sec. Fine Powder is fed into the plasma flame through an external powder port mounted near the anode nozzle exit. The powder softens and hits the target( grit blasted job) in semi molten state with high velocities creating well bonded and dense coating. Typical spray materials used with Plasma Spray
Metals and its alloys : Steels, Ni alloys, Co Coating selection
Plasma sprayed Ceramic-coating on spindles and other machine tool parts (best-suitable for parts and areas that require wear and corrosion resistance) Tipycal Base material of spindles/Arbor high carbon chromium bearing steel (SUJ2) chrome molybdenum steel (SCM415, 435) carbon steel for machinery (S45C) martensite stainless steel (equivalent to SUS440C )austenite stainless steel (SUS303, 304)steel alloy for tools (SKS3, SK4) aluminum chrome molybdenum steel (SACM645)
Choice of ceramic Coatings Chromium Oxide( Black) : 72 Rc Very hard and low on impact Alluminum Oxide( white) : 62 Rc Good wear and thermal and electrical insulation Al oxide + TiO2 ( Grey/Black) 58Rc Widely used as it is easy to grind and less brittle and takes high finish ( 0.2 Ra)
Ceramic coating on New spindle or refurbish + coating procedure :
44
Under cut the diameter to be coated
Normally 0.4 mm on dia
Grit blast the surface
Get Clean rough texture
Plasma spray ceramic coating
To required thickness + Grinding stock
Finish by diamond grinding and super finishing
To required size and finish Upto 0. 1Ra finish can be achieved
MTW AUGUST 2015
Spindle bearing/seal area/parts coated with ceramics - Picture courtesy: Unionchemnitz
Arbor & sleeve ceramic coated – Al Oxide = Tio2
Split Babbitt or bronze bearing Thermal sprayed/ machined
alloys, Moly, bronze, copper, Babbitt, etc. Ceramics: Chromium Oxide, Aluminum Oxide, Al Oxide + TiO2 , ZrO2 , etc. Carbides: Tungsten carbide, Chromium carbide, TiC Hardness range of coatings: From SOFT 60 Rb( Bronze) to HARD 70 Rc ( tungsten carbide.) BENEFITS OF PLASMA SPRAYED CERAMIC OVER HARD CHROME
Environmental: Less hazardous as there is no Hexavalent chrome involved Dust disposal easier than bath liquid. Performance: 3-4 times wear resistance than Hardchrome Micro porosity holds lubricationSelective area coating is possible Higher thickness upto 300 microns per side is possible Limitations : Ceramics are brittle & to be handled carefully Process not as widely available as hardchrome
National Distributors:
Supra Industries
SP-106,MIDC Bhosari,'S' Block, Near Century Enka Ltd., Off Telco Road, Pune - 411 026 (India). Cell: +91 8888893791 / +91 8888837680 Tel.: + 91 20 30685648, Fax: +91 20 30685638 Email: info@supraindustries.com Website: www.supraindustries.com
TECH UPDATE
Steering pinions – efficient production of the basis for electromechanical steering systems
T
he future is one of driverless cars which will drastically change traffic and the experience of driving. This is one finding of a recent study by McKinsey & Company entitled “Autonomous Driving – 10 ways in which autonomous vehicles could reshape our lives.” McKinsey predicts various changes for manufacturers, including reduced development times, new competitors from high-tech and IT industries and the development of completely new business areas. Autonomous driving places very high demands on sensors, electronics and especially on the electromechanical components of current and future steering systems without which driverless cars would not be possible. Steering pinions are one of the standard components of these steering systems and are parts which must not only be manufactured in large volumes but also in top quality and at the lowest possible cost. The specialists at KOEPFER, a subsidiary of the EMAG Group, are very familiar with electromechanical as well as traditional hydraulic steering systems. Jörg Lohmann, Sales Manager at KOEPFER, is in a perfect position to report the following: “Our customers’ goal is reduce the amount of production outsourced due
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to various processes and to ultimately reduce overall cycle times. One solution is to offer complete production lines at one site for strategic components. This also affords one the chance to review current setups and, in some cases, completely remove steps no longer necessary from the manufacturing process, aiming, of course, to sink production costs.” EMAG KOEPFER offers such modular vertical solutions alongside its highly efficient horizontal hobbing machines known for maintaining quality despite high productivity. The solution provided depends, of course, on the manufacturing strategy of the customer. Large-scale steering pinion production
The K 160 features a high-speed portal loader with double rotary gripper to reduce the loading time to a few seconds. This challenge should not be underestimated when machining steering pinions, since the milling process often has to be carried out at a defined angle to existing slots, drilling templates or contours. A specially developed orientation device is the solution in this case. Lohmann continues: “Since the actual machining of the steering pinion only takes a few seconds, the idle times resulting from the loading and orientation processes can be reduced to an absolute minimum to maximize the machine’s efficiency. The high-speed loading solution we have developed enables production machining times of under 20 seconds to be achieved, which represents an enormous increase in productivity for an output volume of 100,000 to several million units.”
Complete production at a glance
EMAG also developed a steering pinion manufacturing system based the company’s modular machine portfolio. EMAG uses the VTC 100-4 vertical pick-up turning machine, the customized version of the well-known VT 2-4 for turning the raw parts. The gear hobbing technology on the VLC 200 H vertical gear hobber then produces the toothing. The VLC 100 IH vertical hardening machine is then used for the inductive hardening process and the VTC 100 GT vertical turning and grinding center delivers the perfect finish and perfect surfaces in the final stage of the process. Should any additional finishing be necessary to the tooth profile due to quench distortion, the VLC 200 H, with skiving capabilities, is suited for the task. Linking made easy – modular machines from EMAG
There are good reasons in favor of using EMAG’s modular machines in production lines, as the standard basic design delivers many major benefits. Each machine has a base made of Mineralit® polymer concrete, which has excellent damping properties to reduce vibration and improve component quality. EMAG’s typical
TECH UPDATE www.mtwmag.com
design includes an automation system and parts storage facility configured to suit specific requirements, both of which are just as integral to the modular machine concept as the pick-up automation system, in other words the automatic loading and unloading from this parts storage facility. The entire process takes place in just a few seconds to maximize the machines’ output. As the storage component is at exactly the same height on all the modular machines, transporting the workpieces between them is greatly simplified. Comparatively simple automation components, such as conveyor belts, pick-and-place units and changers make it possible to link the modular machines as required. These simple solutions not only guarantee low costs, but also require very little space – an entire EMAG production line for steering pinions can be installed on a surface area 15 percent smaller than other standard solutions. The lowered maintenance requirements compared to solutions with portal loaders or robots should also not be underestimated. The vertical design of the machines allows the spindle, slide and parts transport system to be arranged in a very compact form, which also helps to reduce the manufacturing system’s footprint. The machines in detail
The VTC 100-4 four axis vertical turning machine for shafts clamps raw parts between the central main spindle and the tailstock beneath it. There are two turrets
with twelve tool positions available for loading and machining processes with one of the turrets’ tool positions housing a workpiece gripper to transport the shaft in and out of the vertical turning machine. The turrets can be equipped with either turning or driven tools for machining operations. There are endless transport belts on both sides of the machining area. Next a pick-up spindle is used to load the VLC 200 H vertical gear hobbing machine. After the workpiece has been transported into the machining area, KOEPFER’s gear hobbing technology takes charge. The high-performance drive units, which deliver high torques and speeds to the spindle and hob cutter, ensure that toothing up to module 4 can be produced quickly and with high precision. The new VLC 100 IH is responsible for the hardening process. This combines the basic design of the modular machines with the induction hardening technology of eldec, another subsidiary of the EMAG Group. The finish machining of the steering pinions takes place on the VTC 100 GT turning and grinding center. This machine has a disk-type turret with eleven tool positions (the twelfth tool position houses a loading gripper) and a grinding wheel. The benefit of this machine becomes quite clear as the combination of turning operations such as hard or scroll-free turning together with grinding technology ensures a much faster machining process compared to classic final grinding, while still delivering the same quality. The workpiece spindle has a torque of 70 Nm and a drive rating of 17 kW to ensure that the machine has all the necessary power to effectively complete difficult machining processes. Regardless of how the automobile market develops, EMAG continues to prove that it is perfectly prepared to face future challenges with its products and production solutions. The wide range of technologies available in the EMAG Group allow the company to react flexibly to market developments and also develop unequaled, all-in solutions.
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1 metal 3D printed bicycle frame manufactured by Renishaw for Empire Cycles TECH UPDATE
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enishaw, the UK’s only manufacturer of a metal-based additive manufacturing machine that prints metal parts, has collaborated with a leading British bicycle design and manufacturing company to create the world’s first 3D printed metal bike frame. Empire Cycles designed the mountain bike to take advantage of Renishaw’s additive manufacturing technology, allowing them to create a titanium frame that would be both strong and light using topological optimisation - the new frame is some 33% lighter than the original. The frame has been additively manufactured in titanium alloy in sections and bonded together. This offers a number of advantages: Design freedom • Rapid iterations; flexibility to make design improvements right up to production • Ability to make shapes derived by topological optimisation (see over) • Ultimate customisation and tailoring make one-offs as easily as production batches Construction • Complex shape with internal strengthening features • Hollow structures
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• Built in features, such as the rider’s name Performance, titanium alloy • Seat post bracket 44% lighter than aluminium alloy version • Extremely strong - tested to EN 14766 • Corrosion resistant and long lasting Empire Cycles
Empire Cycles is a unique British bike designing and manufacturing company in the North-West of England. Passionate about using great British engineering to create elite products, the Company offers innovative designs to the world’s mountain bikers and downhillers. By working together, Renishaw and Empire Cycles optimised the bicycle design for additive manufacture, eliminating many of the downward facing surfaces that would otherwise have needed wasteful support structures. How strong is it?
Titanium alloys have a high Ultimate Tensile Strength (UTS) of more than 900 MPa when processed using additive manufacturing and near perfect densities of greater than 99.7% are achieved; this is better than casting and, as any porosity is both small and spherical, it has little effect
TECH UPDATE www.mtwmag.com
on strength. The project’s aim is to produce a fully functioning bicycle, so the seat post bracket was tested using the mountain bike standard EN 14766; it withstood 50 000 cycles of 1 200 N. Testing continued to 6 times the standard without failure. Testing of the completed bicycle frame will continue, both in the laboratory using Bureau Veritas UK, and on the mountainside using portable sensors in partnership with Swansea University. What is topological optimisation?
From the Greek word for place, “topo”, topological optimisation software is the term given to programs that are used to determine the “logical place” for material – normally using iterative steps and finite element analysis. Material is removed from areas of low stress until a design optimised for load bearing is evolved. The resulting model is both light (due to the low volume) and strong. The historical challenge in manufacturing these shapes can now be overcome with additive manufacturing, enabling physical 3D models to be realised. How light is it?
Titanium alloys are more dense than aluminium alloys, with relative densities of around 4 g/cm3 and 3 g/cm3 respectively. Therefore, the only way to make
a titanium alloy version of a part lighter than its aluminium alloy counterpart is to significantly alter the design to remove any material not contributing to the overall strength of the part. The original aluminium alloy seat post bracket is 360 g and the hollow titanium version is 200 g, a weight saving of 44%. This is just the first iteration; with further analysis and testing it could be reduced further. The original bike frame weighs in at 2100 g. Redesigned to make use of additive manufacturing, the weight drops to 1400 g, a 33% weight saving. There are lighter carbon fibre bikes available, but Chris Williams, Managing Director at Empire Cycles, has researched this already and says, “The durability of carbon fibre can’t compare to a metal bike, they are great for road bikes, but when you start chucking yourself down a mountain you risk damaging the frame. I over-engineer my bikes to ensure there are no warranty claims”. How was the project managed?
Chris had already produced a full size 3D printed replica of his current bike before he approached Renishaw, so had a good idea of what he wanted to achieve. Renishaw originally agreed to optimise and manufacture the seat post bracket only, but after this proved successful, decided the whole frame was a practical
Complete bike with 3D printed titanium alloy frame and seat post bracket
The entire bike frame was arranged in sections with the seat post bracket on one build plate & fabricated in one go
goal. Chris updated his design with guidance from Renishaw’s applications team on what would build well, and the frame was sectioned so that it would fully utilise the AM250’s 300 mm build height. The key benefit for Empire Cycles is the performance advantages that this construction method bestows. The design has all of the advantages of a pressed steel ‘monocoque’ construction used in motorbikes and cars, without the investment in tooling that would be prohibitive for a small manufacturer. The potential performance has not been completely explored yet, but we hope to continue to develop the project. As no tooling is required, continual design improvements can be made easily; and as the component cost is based on volume and not complexity, some very light parts will be possible at minimal costs. Research into bonding methods resulted in Mouldlife providing the adhesive, and technical specialists 3M providing test facilities. We will develop this further in partnership to look at iterative improvements in bonding methods, such as specific surface finishes. The wheels, drive train and components required to finish the bike were provided by Hope Technology Ltd. This project has highlighted that excellent results can be achieved by working closely with the customer. If you have a component that would benefit from additive manufacture please contact your local Renishaw office for further information.
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TECH UPDATE
Technology & trends driving the gear industry With the changing demands and requirements, the gear industry has undergone various modifications. Be it technology or the materials used, a lot has changed over the years. Taking a look at some of the major trends that have been doing the rounds in the industry today.
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ear manufacturing is a fairly complex metal cutting process and forms an integral part of many industrial products. Gears are used in various applications across industries such as automotive, machine tools, aerospace, heavy engineering, oil & gas, energy and general engineering among others. According to a report by TechNavio, the Global Gear Manufacturing Market is expected to grow at a CAGR of 5.33 per cent over the period 2014-2019. Earlier gears were made by conventional methods of casting and forging, but the industry has evolved over the years and so has the technology. But with a growing demand for better productivity and quality of gears, the manufacturers are now looking for machine tools and technology that can meet their requirements. Today, the customers look for better performance, cost effective-
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ness, efficiency and rapid development among others. In advanced countries, automated CNC gear cutting machines, finishing machines and CAD are increasingly being used in the production of gears. Indian gear manufacturers today are well aware of the developments and technology around the world and are coming forward to compete with the advanced countries. Gear manufacturing has witnessed various changes that has positively shaped the Indian industry. Innovative technologies and superior materials have made gear manufacturing process simpler and more productive. a) New generation cutting tools: Cutting tool technology has been evolving to meet the changing demands and there are several factors that are influencing the nature and use of cutting tools. According to industry experts, there are some challenging materials. Some
of them can be less than 25% as machinable as steel and can cost a lot more. Large component sizes also influences the nature of cutting tools. The high cost per part makes the machining demands more critical. Such factors are driving the new trends and leading the way for Indian companies. The Indian manufacturers are not just choosing cutting tools for greater life or speed, but are also looking for innovations to better the process. b) Developments in Gear Hobbing: Industry experts believe gear hobbing machines will focus on more on user-friendly operation, energy savings, functionality and low maintenance. Gear manufacturers are also focusing more on pre-grinding quality and higher process stability. One can also witness growing significance of ICI hobs for large gears.
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c) Grinding technology: Various industries have been trying to introduce gear grinding machines, backed by the increasing demands for low-noise gears in automotive transmissions and for high-precision large gears in construction machines, gearbox for wind turbine systems, and printing machines. It has been observed that gear finishing technologies are used after heat treatment to reduce vibrations and noise from automotive transmissions or to improve the efficiency and reduce the size of wind power generators. As for the techniques for finishing gears after heat treatment, gear grinding is commonly used in addition to carbide hobbing and honing. d) Automation: The automotive industry attracts the maximum gear manufacturers, resulting in a healthy amount of gear production. Technology used for gear production these days are highly automated. The chamfering and deburring operations on gear teeth have become more important and as quieter gears require more accurate chamfers, automation is highly recommended. From multitasking machining centers to Robotic Deburring System, a lot has been introduced to the gear manufacturing industry today. Automation has become more reliable and affordable than ever before leading to a huge demand surge from gear manufacturers. Worldwide sales of industrial robots reached an all-time high in 2013, according to the International Federation of Robotics. Gear designing & challenges
There are several challenges associated with the successful design of a new gear. A new gear design requires the knowledge and experience of several technical areas of engineering. Some problems that manufacturers face while working on a new design are mosty related to an inadequate evaluation the lubrication and cooling requirements, complete static and dynamic load analysis, evalua-
tion of materials and heat treatment and latest technology. The most common problem that is seen in the industry while designing gear is the wrong selection of the type of gear for a given application. Several important parameters should be considered when selecting a gear type for a given system. Selection of the right gear accuracy for an application is also very important as it effects the cost of manufacturing, the dynamic load and noise. Apart from this, taking into consideration the gear rim thickness is also mandatory. Import & export of gears
The Indian gear manufacturers are well equipped with imported gear cutting machines and testing equipments. From ball screws, gear boxes, speed changers and torque converters among others are imported to India. Today the quality of gears produced in India is at par the global standard and Indian manufacturers have carved a place for themselves in the global market. On the supply side, India also exports gears and gearing, ball screws, gear boxes, speed changers and torque converters. Winds of change
Globalisation has taught the manufacturers that in order to survive they can no longer be contented by doing business locally. As automotive, the most hottest industry segment witnesses a slow period, the gear industry will be driven by the growing demand in oil and gas industry. “Gears are used in every industry, yes automotive is the core segment that drives the demand. But there are various other fast growing segments like oil & gas, energy, heavy machineries and aerospace that are said to push the gear industry further. We expect to see a fair amount of growth in the auto industry in the coming future and so in the gear manufacturing segment,� said an employee of a well-known automotive company on condition of anonymity.
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TECH UPDATE
For maximum safety & precision. Backlash-free ROBA®- guidestop safety brakes available in new construction sizes The backlash-free, highly rigid ROBA®-guidestop profiled rail brakes guarantee maximum safety. In machine tools and machining centres, they additionally increase the process accuracy and machining performance. mayr® power transmission now offer this innovative brake concept in eight construction sizes, covering nominal holding forces from 5 to 34 kN.
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uspended loads present a substantial potential hazard in machines and systems – especially if people are positioned below them. Should an unintended fall or crash occur, the load must be brought to a standstill as quickly as possible in order to protect people and material reliably from damage. With the ROBA®-guidestop-type series, mayr® power transmission have developed a reliable safety brake and backlash-free clamping unit for profiled rail guides, which brakes movements safely and quickly, and which clamps the axes rigidly and backlash-free during the running process. The brake specialists are now expanding this triedand-tested concept to eight construction sizes, hereby covering nominal holding forces from 5 to 34 kN. The designs are dimensioned for four rail sizes made by established linear guide manufacturers. Also new are the compact design in short constructional design and the integrated switching condition monitoring with con-
tactless proximity switch. Safety for vertical axes
The innovative brake concept clamps with a high degree of rigidity and has a direct effect on the linear guide. The ROBA®guidestop brakes are directly mounted onto the masses to be braked or held. This creates a decisive advantage, especially for gravity-loaded axes, where the hazard risks to people must be minimised: Drive elements between the motor and the moving mass such as spindles, spindle nuts, shaft couplings or gearboxes, have no influence on safety – this differs from concepts featuring a motor brake, in which all drive elements transmit the braking torque up to the carriage. In addition, every element between the brake and the carriage has a negative effect on the rigidity. Therefore, ROBA®-guidestop safety brakes are significantly more rigid than motor brakes, which are often subject to backlash, and also pole brakes or band brakes. Maximum functional safety
Figure 1: The backlash-free safety brake ROBA®-guidestop guarantees maximum functional safety. Furthermore, the additional rigidity of the NC axis also ensures increased process accuracy and machining performance.
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The ROBA®-guidestop safety brakes work according to the fail-safe principle; this means that they are closed in de-energised condition. Pre-tensioned cup springs press the brake shoes onto the “midsection” of the profiled rail and the rail is clamped. The ROBA®-guidestop is released hydraulically with a nominal pressure of 70 bar. This is relatively low in comparison to the very high holding forces otherwise required. The brake mechanism is designed
Figure 2: Installation position of the ROBA®-guidestop in the carriage: The innovative brake concept clamps directly onto the profiled rail with a high degree of rigidity.
for relatively long stroke paths. This means the brake can compensate for manufacturing tolerances on profiled rails without losing its braking force. More accuracy and performance
The backlash-free clamping of the ROBA®guidestop directly onto the profiled rails provides even more advantages: The additional rigidity of the NC axis increases the process accuracy, improves the machining performance and can provide further technical advantages, for example in heavy machining. The machining process is less subject to vibrations, which has a positive influence on the surface quality of the part. When the axis is at a standstill, for example during machining, the ROBA®-guidestop brake takes over the load. This means that the drive motor can be switched off and removed from the control system during this phase. This eliminates the control movements and relieves the ball screw spindle. The closed brake absorbs axial forces. Downtime intervals and maintenance intervals are extended.
Solitaire No. 2 - 10" (250 mm) Precision Centerless Grinder
INDIAN ENTERPRISE
AMERICAN RIGIDITY
ITALIAN INNOVATION
Combined to give you Customized Centerless Grinders Solitaire Machine Tools Ltd. 292, Dharamsinh Desai Marg, Chhani Road, Vadodara - 390002, Gujarat, India Tel.: +91-265-2761776, +91-265-2773585 Email: sales@smtgrinders.com www.smtgrinders.com
TECH UPDATE
Improve your competitive Edge by Multitasking Machining
Mr. B.P. Poddar, Vice President : Sales + Marketing Fatty Tuna India Pvt. Ltd.
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et’s understand more about Multi Tasking Machining, need and development keeping the Indian industry in mind. Whenever you visit customers invariably they speak about the machine cost being high, interest cost of investment and duty structure among others. Buyers of machine tools are very conscious of cost of money i.e. interest rates and traditionally look for very high ROI (return on investment) i.e. about 25 to 30% which is far more if we apply internationally acceptable business norms. As a machine tool seller if we ask the customers – How many days inventory do you maintain? We generally do not get a clear an-
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swer. If we get answer, it is of the order of two to three months or even more. I am sure there are valid reasons for maintaining such levels of inventory. But as the Indian economy has opened out, Indian companies will have to achieve international standards in order to remain in the business. High interest rates kill you when you borrow money for longer periods, but that is not the case for short periods. In high interest rate economies, the trick is to turn around money very fast. As we all know inventory is divided into three parts - raw material, work-inprocess and finished goods. Generally, value of these inventory is an inverted triangle with raw material at the bottom. Sometimes control of inventory is sim-
ple and sometimes complex. We believe that to remain competitive, we must be serious about top heavy inventory i.e. work-in-progress and finished goods. Once we streamline these two, we must also divert to see how to reduce raw material inventory. In companies where manufacturing is simple i.e few operations to convert raw material to final products in short span, it may be simple to control inventory. However, if there are several operations involved, inventory control is a complex task. Historically, there are two major systems of manufacturing. If large volume of similar components, set up dedicated machines. Small volumes, batch production , standalone machines . In batch
TECH UPDATE www.mtwmag.com
production, determination of Economic Batch size is crucial to optimize the utilization of machines. Under such competition, efforts are to meet each and every customers demands. This to an extent means that mass production is over. One has to produce large variety in small numbers. To overcome this, one needs very flexible machines which handles large variety of operations and reduce the process time. Machine tool builders and experts carried out various studies in machine shops and invariably found that material waiting time / nonproductive time amounts to 30-40 % – be it in stores or on shop floors. Only 60%-70 % of the time, manufacturing process is actually carried out. Multi-Tasking
Multitasking may be defined as an ability to perform various operations efficiently without manual interventioncombination of - turning and milling operations in one set-up, first to second operation capability unattended. That means Multitasking machine which does both Turning & Milling operations must do Turning and Milling operations as efficiently as any specific TURNING & MILLING MACHINE does. WE have TURN-MILL centers which
are essentially turning machines with limited milling capabilities. These machines do not have true milling capabilities because of insufficient spindle clamping power and limited power on milling tool. Turret construction limits power transmission. Generally in any machining processes, there are invariably minimum two setup involved. In first set up , at holding area operations / machining cannot be performed. Machines with bar feeders , one can avoid this to some extent. However, sometimes internal operations are required of part off side. True Multitasking Machine should be able to change over from first to second operation and complete the part without manual intervention. The benefits of multitask machine are clear – one can simplify the manufacturing process and can manufacture only what can be sold thereby drastically reducing top of inventory. This also reduces raw material inventory as one can convert raw material to finished goods at the last minute. Development of Multi-task Machines
Generally Multi-Task Machines are based on following platforms 1. Turning Machine 2. Machining Centers Development From Two Axis Horizontal Lathe
1. 2 Axis CNC Lathe + Rotary Tools + C-Axis 2. 2 Axis CNC Lathe + Rotary Tools + C-Axis + Y- Axis 3. 2 Axis CNC Lathe + Rotary Tools + C-Axis + Y- Axis + B-Axis 4. 2-Axis CNC Lathe + Rotary Tools + C-Axis + Y- Axis + B-Axis + ATC+ automation features i.e. gantry loaders, work-piece measurement, tool life monitoring + gauging, in process gauging, post process gauging, feed force monitoring systems, automatic jaw changing etc. Just in Time – Fiction or Reality
The basic idea of Just-In-Time is rather
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TECH UPDATE simple. You reduce your stock of finished parts to an absolute minimum and add value to the part at the latest moment. This should reduce space for inventory and improve cash flow. The final result should be higher profits and be more competitive. Often Just-In-Time was realised in setting up machines, let it sit still and only turn it on when order came in. We have all realised that cost of frequent set-up of machine or the cost of all un-used machines waiting to be switched on only after order was received, eat into the cost savings we got from zero stock. To fulfill the basic requirement of Just-InTime production, which would really allow to reduce stock to minimum, new way of production machine would be required. Ideal would be combination of Milling Machine and Turning Machine which can be efficiently used as milling or turning machine as and when necessary. However, the modern Just-In-Time involves much more than only reducing stock. It is a concept where almost all departments are involved. Ways of Machining
Due to complex movement of the turret in X+Y+B-axis and movement of work-piece through Z1+C1 and Z2+C2, any tool can be brought into multiple angles and positions for machining. One individual turning tool can be used for facing on left spindle and OD turning on other spindle. For example, one live centering drill can be used to make centering operations within the work-piece for axial, radial, angular and off-center. Possible relative movements between -Tool +Work piece in three linear X+Y+Z and two rotary B+C provides possibilities for 5-axis operations made from bar or chuck clamping. Integrated second spindle-identical but opposite to first spindle allows secondary operation on 6th face. How Can You Beat Your Competitors?
To beat your competitors, you may consider the following possibilities :
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Network 1. Establish better sales network 2. Establish and maintain closer contacts with your customers 3. Establish better service.
solution is in sight. Ideal would be most flexible machine which can be changed within minutes to be able to adopt any combination of milling and turning operations.
Product 1. Product is of better quality 2. Product has more features 3. Product suits better customer needs.
Multi-Tasking
Production 1. You can easily integrate customers needs 2. You have shorter delivery schedules. 3. You can produce more cost efficiently.
To increase your competitive edge Multi-Tasking Definition
The ability to perform various manufacturing operations without manual intervention. The combination of Turning + Milling Operations in One Set-Up. First to Second Operation Capability Unattended. Multi-tasking Benefits
Therefore to beat your competitor a new type of machines are desirable - Multi Tasking Machines. Bottle Neck–What Can You Do?
Existing Methods To keep up with your demands, you often squeeze out machines and even the operators over their limits. But often forget to check if all the requirements are still needed today. Therefore following points must be checked and the following questions should be raised: 1. Why don’t we change the drawing to make the part simpler? 2. Why are the blank parts made in a such a way that the consequent operations are almost difficult to perform? 3. Why don’t we combine several operations onto one tool? 4. Are we using speed / feeds up to date? If we analyse these questions, probably the complete thought process will shift our manufacturing philosophy towards simplified design aspects from process point of view , using combined tools for improving process times,productivity possibilities The decrease in product life, increased variety of the product and smaller lot sizes, make it very difficult to make decisions for new investment until right
1. Ability to perform Turning + Milling operations in one set-up 2. Reduced In-Process Inventory 3. Reduced In-Process Time 4. Reduced Component Lead Time / Part Handling 5. Reduce Set-Up Time 6. Reduced Floor Space 7. Tolerances Minimized as a result of Few Clamping + De-Clamping and Handling 8. High Level of Flexibility 9. Unattended Operations 10. Multiple Job Capability 11. Multiple Operations can be performed. 12. Possibility of Angular Machining – Milling / Drilling with combination of “B” Axis. Summary
Unnecessary: Set-ups / Part Transfer / Inspections / Human Errors /Scrap / Tooling / Fixtures is wastage of time & money. As the name suggests, Multi-Tasking machine do more than a single machining task in a single setup. Conventionally, most complex parts required multiple setups on multiple machines. Upon examination, the labour cost associated with setup, part transfer and inspection for the additional operations is a wasteThese wastages can be eliminated using Multitasking Machines.
TECH UPDATE www.mtwmag.com
Winning at Titanium Machining Machine builder Fives Cincinnati finds Kennametal’s KM4X™ spindle connection key to achieving new levels of metal removal on industry-leading “super-profilers”
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hat does production superiority mean to aircraft manufacturers? In a word: billions. In the land of the giants, US-based Boeing beat European rival Airbus in net new orders and deliveries in the first quarter of 2015. While the first quarter is the traditionally slow quarter for new orders, it’s deliveries that generate the most revenue, and Boeing handed over a record number of jets for the period. For manufacturers of all sizes and types of aircraft, and their entire supply chain of components and parts suppliers working in difficult-to-machine materials, production delays can mean order cancellations, and cancellations can mean shifts to better-equipped builders. One technology provider that knows this better than most is Fives Cincinnati, whose Hebron, KY, plant produces Cincinnati machining centers, composites fiber-placement systems, and multispindle Cincinnati profilers. With over 650 profilers in the field all over the world, there isn’t a commercial aircraft flying that hasn’t been touched by a Cincinnati profiler, the company says. Available in three- and five-spindle
gantry configurations, the latest-generation of these powerful giants, the Cincinnati XTi Profiler, is impressive on many scales. Designed for manufacturers that process multiple materials, 7000-rpm spindles can cut aluminum and steel and high-torque (2523 Nm) spindles are available for processing titanium and other hard alloys. Called ‘the only multi-spindle platform available for titanium roughing,” company literature states the XT sets the MRR (metal-removal rate) record for machining titanium at more than 100 cubic inches per minute. These massive machines, with 4267 mm of X-axis travel (expandable in increments of 3658 mm), 3683 mm in Y, and 711 mm in Z, now are setting new records with optional KM4X100 spindle connections from Kennametal Inc. From Weakest Link to Strongest Feature
Whether profiling on large gantry machines or milling on smaller machining centers, processing tough material like titanium is a constant challenge. Machining hard alloys while adding the pressure of improving production efficiencies means maximizing metal removal in the face of
low cutting speeds and significant cutting forces. Machine tool builders like Fives have responded with specialty milling and profiling centers that feature improved stiffness and damping on spindles and sizable machine structures, all to minimize undesirable vibrations that deteriorate part quality, throughput, and tool life. Although these advances have added to greater productivity, the weakest point historically has been the spindle connection. The tool-spindle connection, the “handshake” between the machine tool and the cutting tool, determines how much material the machine can remove on a given operation. This is because this interface must withstand high loads and yet maintain its rigidity until tool deflection is too high or the onset of chatter is reached. Spindles may be able to transmit a considerable amount of torque, but cutting forces also generate bending moments that will exceed the interface’s limits prior to reaching torque limits. This becomes obvious in end-milling applications, where projection lengths are typically greater -- the limiting factor is the spindle interface’s bending capacity. As an example, an indexable helical cutter with 250mm (9.84 in.) projection from spindle face, 80mm (3.15 in.) in diameter generates 4620 Nm (3407.5 ft. lbs.) of bending moment and less than 900 Nm (663.8 ft. lbs.) of torque when removing 360 cm3/ min of Ti6Al4V at RDOC of 12.7mm and an ADOC of 63.5mm. By combining high clamping force and optimized interference levels, Kennam-
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TECH UPDATE etal’s next-generation spindle connection KM4X provides a robust connection, extremely high stiffness, and bending load capacity. For titanium processors, this means greatly improved performance in machining high-strength alloys and other materials, enabling extremely high metal removal rates and more completed parts per day. Adds More to Machine Design
Together with Kennametal senior account manager Mike Malott, Fives Cincinnati applications engineer Robert Snodgrass began evaluating KM4X approximately four years ago. “The engineering is impressive – it definitely allowed us to start thinking that there’s more to machine design, that a stiffer spindle helps meet customer demand for more effective metal cutting and increased throughput.” “Remember, typical aero structure components start out as forgings with much of the material being removed to achieve finished part specifications,” says Kennametal Vice President Mark Huston. “The “buy-to-fly” ratio -- the weight you buy in raw material vs. the weight that flies in finished form can be 4:1, 8:1 or more depending on the component.” First-generation Cincinnati profilers achieved an MRR of four cubic inches per minute in titanium, due to machine structure and tool-spindle connection limitations. With the XT-generation of Cincinnati profilers and face-contact HSK 125 spindle connections, the MRR increased to 50 cubic inches per minute. With the KM4X100, the MRR doubled to 100 cubic inches per minute. “Even at a 100 cubic inches per minute, our benchmark testing for the XT profilers using the KM4X were well below the machine’s theoretical limits for bending
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moment resistance,” Snodgrass adds. He noted that previous-generation tests employed large CAT60-taper toolholders that, when compared to 50-taper versions are like driving a tank versus an SUV. The KM4X achieved double the metal removal rates versus the 60-taper toolholder. Compared to CAT50, HSK100, or KM4X100 the CAT60 is almost twice the weight. “This changes spindle and machine design a ton,” says Ken Wichman, Fives Cincinnati product manager. “Many gantry machines have manual tool exchange even though automatic tool exchange/ storage is available. The enhanced bending moment resistance of the KM4X allows lighter tooling when compared to a CAT or HSK tool with an equivalent bending moment resistance. Ergonomically, this is a huge benefit to the operator. For customer’s choosing automatic tool exchange/storage, the smaller KM4X can accommodate more tools in a given footprint.” “We pride ourselves in keeping customers productive,” adds Fives Cincinnati Vice President Mark Logan. “Not only is a more powerful spindle connection like KM4X changing new machine design, it also can be a significant boost for existing machines in the field. This gives us the chance to offer a notable upgrade in retrofits while still pushing the limits on profiler models to come.” “The industry needs to set new standards for producing titanium parts at the lowest cost per piece, and the XT Profiler provides that capability and more,” says Chip Storie, Fives Cincinnati executive vice president. “With a massive cross-rail, robust spindle design, dedicated foundation, and high-pressure coolant system, we expect to exceed 100 cubic inches per
minute metal removal. This is going to change the way the industry approaches titanium machining.” SIDEBAR: Analyzing the Bobsled Cut
Mike Malott, Kennametal senior account manager, has spent years in the field to where he had been granted “family” status on the Fives Cincinnati production floor. He also has noticed that the FIVES “bobsled cut” for establishing cutting-tool performance has been making its way around the industry. “To truly put a new configuration through its paces, we had to develop an extremely challenging test – truly something for which the tool was not intended,” says application engineer Robert Snodgrass. The result was forcing a tool through a titanium workpiece following a deep and continuous curve, similar to a bobsled track. “We wanted to max out penetrating depth and torque in a simultaneousmotion cut, all the time subjecting the machine tool and the spindle/cutting tool to extreme forces in every possible way.” Experienced titianium processors may wince thinking of the screams that would come from the workpiece prior to either the machine tool or the cutter failing. But as the Fives video on YouTube proves (https://www.youtube.com/watch?v=0pcocy4IsE), a small mountain of chips from a deep and wide test cut can be processed efficiently at a pleasant hum, even on five separate spindles. The proof is in the performance, and further improvements are on the horizon.
TECH UPDATE
Quality Systems & Manufacturing Excellence in India By Ravi Kannan, Consultant & Trainer
M
anufacturing excellence in a competitive world means producing products of consistent high quality at the lowest cost. Quality systems will ensure that over time the quality does not deviate and the variation is within process capability limits. A product can be made consistently if the variation in input materials (M1) is limited to an acceptable range. The machine (M2) must also be operating as it would have been when it was new. The process methods (M3) laid down during the final product development stages must be followed without deviation and the men (M4) or women operators are fully trained in achieving the desired output. Finally the tools (T) used must also have been validated during the product development final stages and must be maintained as good as new. To sum up if variations in (M1), (M2), (M3), (M4), (T) are controlled, within limits defined in the original product design and development stage, using a robust design of experiments (DOE), then the product quality, manufacturing cycle time, tool consumption etc and finally product cost will be consistent. Ensuring that the variations are within set limits is the responsibility of the Quality Assurance team in an organization. Beware of Pitfalls
What seems a simple exercise in disci-
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pline and control is often a nightmare as the various people involved in the organization see things their own way. Let us see some examples of where things get out of control. This also gives us clues about how we can avoid these pitfalls. The purchase function in an organization is given the task of reducing the cost of procurement of materials. They receive a set of ‘required specifications’ conforming to some ‘standards’ as specified by their product development team. In reality the product development team first chooses a vendor and then does trials with the supplied material and uses the vendor specifications to arrive at the ‘required specifications’. Often the product development team is unaware if all the crucial input specifications have been mentioned by the supplier. (Suppliers do this so that their product is not easily copied by others.) The product development team locates vendors based on an incomplete specification and sources raw materials which are different from the original suppliers. The seriousness of the source change is often known when there are major rejections during manufacturing or product testing or during customer usage. (M1) has been compromised. Often critical product manufacturers in the automotive and aerospace domain define the source of raw materials to be used in their parts supplied to them to eliminate
this source of variance. It is therefore imperative that the product development and sourcing teams work together from the beginning to identify suppliers and negotiate to ensure consistent quality and cost with a clause stating that no change can be accepted in the supplier’s process without written approval by the buyer. (M2) is defined by the machine. Machine like humans do deteriorate with time. Wear and corrosion cause changes to accuracy and repeatability of machine systems. Bearings, slides and other moving parts wear out causing vibrations and widening of the process capability limits. It is imperative that there is a robust maintenance system in place to ensure that there is condition based monitoring of critical subsystems along with time based monitoring as well. Vibration monitoring, wear debris analysis in lubricants, lubricant quality and temperature changes are some of the techniques used. Finally the quality assurance team along with the maintenance team needs to do regular checks of machine process capability. A change from the original process capability is a clear indicator that something has deteriorated. Manufacturing excellence requires the right choice of machine for the required specifications. Buying machines of capability in excess of product requirement or machines with excessive features will
TECH UPDATE www.mtwmag.com
lead to higher cost of procurement of the machine and consequently the price per part produced. Extremely tight specification limits will require attention to many details including machine environment control (dust, temperature and humidity), cooling systems for spindles and control of tooling (T) also. Maintenance
The area of machine maintenance is often the most neglected area and leads to major deviations in product quality. Maintenance engineers and machine operators are often the least educated people in an organization and are also people who are least trained on quality. This leads us to (M4) variations due to human intervention. Every process variable has a mean (μ) and a standard deviation (σ). It is imperative that a machine is set such that the targeted mean value of the required dimension is achieved. The process capability is the specification band (Upper Specification Limit (USL) minus Lower Specification Limit (LSL)) divided by 3σ. If this value is above 1.33, we have a good stable process. The ultimate buyer may specify tighter ratios. Motorola recognized the danger of machines or processes not being centred. This led to the change in quality standards often referred to as “6σ”, meaning
a band of 12σ. A shift of mean of 1.5σ would still lead to a very high acceptance capability. Control charts maintained by the trained operator will help ensure that machine centring errors do not occur and a constant watch of the measured parameters gives an indication if an unacceptable trend is developing in the product variable values. When we refer to variable values we are referring to measured values. This leads us to another source of variation arising out of measuring instruments and human error in measurement. The subject of ensuring measuring instruments are calibrated properly and operators are trained to use measuring instruments properly is covered under the special topic called “Measurement Systems Analysis or MSA”. Cutting Tools, Jigs & Fixtures
We now come to the cutting tool and jigs and fixtures used to hold products during various stages of manufacturing. Like machines these too deteriorate with time due to wear and corrosion and mechanical damage. During the product development stage, care needs to be taken to ensure the right selection of cutting tools leading to the desired quality at the least cost. Depending on the specifications and tolerances of the product, tool wear and machine compensation for wear becomes critical.
Online non-contact gauging of tool and product dimensions can overcome this problem but at a higher cost compared to manual systems. Often machines and tooling go together. It is important to assess the total system of machines, holding fixtures, cutting tools, cutting tool holder and cooling systems. In very tight tolerance systems, sequence of machining, time of machining, number of products machined in a batch also becomes critical. Ball screws in guide ways are known to heat up and cause positional errors in machine tools. The Weakest Link
We now come to the crucial (M3) variations due to not following the detailed process instructions. It is often taken for granted that the product development team has produced a product after a robust design of experiments (DOE). When the DOE is done, the extreme limits of expected variance in input conditions must be simulated. Control surfaces must be mapped to understand whether there are regions in the control variable range which can lead to product or process instability. This is often the weakest link in the Indian Manufacturing Sector and prevents many products from becoming truly excellent. More focus on R&D and robust product development is needed in industry.
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TECH UPDATE
Application of Linear Encoders on Machine Tools By Abhilash Tripathi, General Manager (Sales & Service)., Heidenhain Optics & Electronics India Pvt. Ltd.
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he requirements facing industrial production of mechanical parts are steadily growing. Rising cost pressure is driving a trend towards dynamic machine tools that produce parts economically with very high accuracy even in small batches. The use of linear encoders to ascertain the slide position—also called “closed-loop control”—permits accuracy from the first to the last part. The effects of the feed mechanism, such as a difference weight of workpiece or the expansion of the recirculating ball screw, have no influence on the machining result and therefore on the accuracy of the machine. If the machine operates in a so-called “semi-closed loop,” the table position is measured through the pitch of the re-circulating ball screw and the angular position of the motor encoder. Changes in the feed mechanism, such as thermal expansion, cannot be detected in the closed loop. At higher traversing speeds,
however, the ball screw becomes significantly warmer. Figure 1 illustrates such heating with a thermal camera. The inhomogeneous temperature distribution with temperature peaks of up to 50.5°C is clearly visible. Positioning error up to 200 µm within a short time is unavoidable and cannot be compensated because of the unknown distribution curve. The test setup shown in Fig. 2 illustrates the effects on the accuracy in the production of 300 parts. One workpiece with three holes, 2 mm deep, and the corresponding outside contour was machined. After 30 more workpieces were “machined” without tool contact, ma-
Figure 3: Deviation between hole patterns in series production
Figure 2: Effect of drive accuracy on series production
Figure 1: Thermal behavior of a re-circulating ball screw
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deviations from the desired position are up to 200 µm. In contrast, the workpieces from machines with linear encoders provide the correct contour to within a few micrometers. (Fig. 3) The use of linear encoders therefore permits accuracy from
chining was repeated with 2 mm further infeed in the Z direction. This machining sequence was repeated to simulate the production of 300 individual parts. The workpieces show a considerable difference in the machining result of semi-closed loop control in comparison with that of a closed loop control. The
the very first part without protracted run-in cycles. Of course, this also applies for mold making. If, for example, two mold halves are machined, then form deviations due to machine error normally require extensive rework. This basic consideration applies both for linear and rotary axes. Here, too, positions can be measured with a speed-reduction mechanism connected to a rotary encoder on the motor, or with a highly accurate angle encoder on the machine axis, whereby angle encoders achieve significantly higher accuracy grades and reproducibility.
TECH UPDATE www.mtwmag.com
Linear encoders in various mechanical designs
Machine tools are usually equipped with sealed linear encoders, which are available in two designs.
Figure 4: Full-size and slimline linear encoders
The 100 series (with large cross section) is available up to a measuring length of 4240 mm. By fastening it every 200 mm with the machine base, a very high reliability is achieved against vibration conducted from outside. The 400 series (with small cross-section) permits measuring lengths up to 2040 mm and is used primarily where installation space is limited.The fundamental design of the encoders is identical for both series.
Figure 5 : Principle of design
A light source transmits light through the glass scale. The high-accuracy DIADUR graduation on the glass produces a precise pattern on the detector (photoelements), which is converted by the integrated electronics into electrical signals. With linear encoders for machine tools, the detectors function exclusively according to what is known as the single-field principle. These detectors, opto-ASICs developed by HEIDENHAIN, are optimized for application in machine tools. They are characterized by high tolerance to contamination and EMC interference.
This modern sensor technology is the basic prerequisite for very high reliability together with consistent signal stability. The housing protects the optics from heavy contamination and allows itself to be fastened to the machine base. The elastic sealing lips close the slot required for movement almost completely. In many cases, these measures do not suffice to ensure reliable operation. Under extreme exposure to liquid or condensation, the use of clean compressed air has proven to ensure reliability for many years of operation. A coupling between scanning carriage and mounting base permit the +/- 0.3 mm mounting tolerance to the machine components without impairing the accuracy of the encoder. Linear axes with direct drive
In the machine tool sector, too, the share of linear axes with direct drive is steadily increasing. This has been driving the continuously increasing demands on measuring technology with regard to signal quality and neutrality in the control loop. Besides small signal periods, a low position error within the period is also required in order to attain the required bandwidth in the closed loop. The absolute LC linear encoders with single-field scanning attain a max. error within the signal period of +/- 20 nm and therefore place no limit for the control bandwidth. Absolute measuring technology significantly facilitates finding the commutation angle after the machine tool is switched on, and allows simple implementation of feed axes with direct drive. Mounting the encoders
If the use of linear encoders is considered early in the design phase, fast and reliable mounting in only a few minutes is possible. For example, it allows the required alignment of the encoder to the machine guideway through milled stop edges.
Of course, pins can also be used to align the encoders. For the absolute linear encoders of the 400 series there are accessory “pins with clamping elements� that ensure a reliable connection of the scale with the machine base. They are recommended for measuring lengths of 640 mm and more. At 1240 mm measuring length or longer, the clamping elements or a mounting spar must be used in order to ensure the required stability of the encoder perpendicular to the measuring direction. The clamping elements have two advantages over the use of mounting spars. First, they can reduce cost, and second, they do not change the basic mounting conditions. It is therefore easy to implement a modular design with variable measuring length.
Figure 6: Installation via clamping elements for the 400 series Summary
A decisive factor for the productivity of a machine tool, besides accuracy (can I use this equipment to manufacture this part in a reliable process), is the availability of the equipment. High productivity with consistently high part quality is most easily achieved with linear or angle encoders. Today, their application is considered standard, not only on universal machines, but also on production machines. They are supported with numerous aids, beginning with 3-D models for simpler machine design, to special mounting accessories, fast and reliable mounting, and electrical testing equipment for initial servicing.
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TECH UPDATE
Automotive, Aerospace & Energy: Power boosters for the gear industry According to several reports the global gear demand is expected to grow to $217 billion by 2018. Different industry verticals are said to drive the gear demand in the near future. Taking a look at some of these sunshine industries...
G
ear finds its application in almost all the major industries. From small electronic companies to large oil & gas and heavy industries the demand for gear changes but it’s one of the key component of the manufacturing industry. Since gear industry is involved in all kinds of manufacturing activities, the demand for the same fluctuates as per the customer industries. For example, since the last few years automotive industry has not been is a great shape but aerospace has gained momentum. “Fortunately, there are a few strong industries in the US, the automotive manufacturers are working at a very high level of activity industry sales are nearing a peek. Building construction has been slow following the recession in 2008, but is now on a good growth path for the next few years. The aerospace industry is still operating below capacity in the US but has a strong order book and extensive plans for capital investments that will lead to activity for the mechanical power transmission suppliers,” says Joe T. Franklin,
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Jr., President, American Gear Manufacturers Association (AGMA). Irrespective of the slow growth, Automotive is still touted the number one industry for gear manufacturers. Automotive
Since its inception, the automotive industry has been one of the driving forces behind innovative high-power gear applications. Automotive industry is one of the largest consumers of gears and the growing global automotive market has given the gear industry a boost. As automotive industry is consumer driven, it also demands for most innovative gears which is keeping gear manufacturers focused on R&D activities. According to Franklin, “The biggest user of gears is the automotive sector, accounting for as much as 70% of output in certain situations. The largest non-automotive users tend to be industrial gearing such as material handling and construction machinery.” Aerospace
Aerospace is another important market
TECH UPDATE
for the gear industry. The global commercial aerospace landing gear market is expected to reach an estimated value of $5.3 billion by 2020. The growing demand for lightweight and sophisticated landing gear systems, growth in aircraft deliveries, and retrofitting and replacement of systems in aging fleets in mature markets are driving landing gear market. According to Lucintel, majority of the segments for landing gear market will grow moderately during 2013-2020. With the growth of commercial aircraft segment, increase in global air traffic and low-cost carrier market, there has been a growth in the global commercial aerospace landing gear market. The development of lightweight materials for the aerospace industry has also been growing fast. New materials are being utilized to achieve increased durability because they are more robust and are lighter. Industry experts say that lightweight landing gear is increasingly being used in aircrafts as weight reduction is necessary to achieve the optimum ratio between payload and range for an aircraft, and consequently, low fuel consumption. Ever increasing demand of aircraft from emerging economies like India, China and the Middle East countries is said to help boost the market. Liebherr, Goodrich Corporation, Messier-Bugatti-Dowty and Héroux-Devtek among others are the major players in the global commercial aircraft landing gear market.
Energy
Gears have huge application in energy sector as well. Sectors like wind power, tidal energy, generator, etc demands for fairly large size gears to move those large blades. In this sector the material becomes very important for manufacturing gearboxes. These are mostly customized gears that are made for specific requirements. Experts believe that gear usage in energy sector will continue to grow owning to the demand for renewable sources. According to Ministry of New and Renewable Energy (MNRE) current installed capacity of wind energy is 33645 MW that is expected to reach 60,000 MW by 202122. Also By 2030 – 35, energy demand in India is projected to be the highest among all countries according to the 2014 energy outlook report by British oil giant BP that will further propel the demand for gears in the country. Similarly, oil & gas is another industry that demands for similar types of gears. When drilling for oil, different applications require individual gear solutions, while processing demands high-speed pinion and bull gears for compressors. ‘Gear’ing up for opportunities
With the boom in aerospace and energy industry, and automotive industry showing signs of recovery, the gear manufacturers have something to rejoice. Experts say that regular innovation of products is very important right now & will help the gear manufacturing companies sustain their successful position in the market.
Industrial Gear Oils market to reach $5.8 bn by 2020 due to demand from manufacturing plants
Industrial gear oil is a lubricant fluid used in industrial gearboxes to reduce friction, protection against corrosion and to ensure efficient, low maintenance operation of gears at different speeds, temperature and oil contaminations. Industrialization is associated with rapid technological changes and manufacturing activities. Since the last decade, the BRICS countries are going through a
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phase of development in which industrialization has been an integral part. Due to the rising demand for various products, the manufacturing industry in BRICS countries is growing rapidly. This growth can be observed across industries like mining, steel, construction and others. A gradual shift from labour intensive manufacturing to capital intensive manu-
facturing like chemical, machinery, electrical, optimal equipment and so on has increased the consumption of industrial gear oil. Apart from the BRICS countries, Indonesia, Mexico and South Korea are also considered as the emerging markets where manufacturing activities are in the upward trend. Increasing industrial activities is a major driving factor for the demand of industrial gear oil.
TECH UPDATE
New ChaseAlu XEVT Line Chases Away Aluminum Challenges
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very machinist that works on aluminum knows the headache this alloy offers but its high strength to weight ratio make it an imperative and highly popular material in the automotive and aerospace fields. Yet, the main problems in machining aluminum remain the formation of built-up edges due to the adhesion of the materials used. To ensure excellence in aluminum machining, TaeguTec has tackled the primary tooling concerns when machining aluminum such as minimizing the tendency of aluminum to stick to the tool cutting edge, ensuring there is good chip evacuation from the cutting edge, and making sure the core strength of the tool is sufficiently durable in order to withstand the cutting forces thrust upon it without breaking. In this regard, TaeguTec has unveiled two new offerings under the ChaseAlu family that amalgamates the line’s power of machining aluminum with the hopes of machine shops to decrease their cost
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while increasing productivity. Servicing all industries, the Asian metalworking giant’s ChaseAlu’s two new offerings, the XEVT 16 – which is an upgraded version of the current XECT 16 – and the XEVT 22, come at a time when productivity, safety and cost needs to improve greatly for companies to be viable in today’s quickly advancing world. With high-speed machining requirements as the XEVT’s focus, both types are designed with a stable “V” shape bottom as well as a unique “stopper” for rigid clamping and stability. Both sizes guar-
antee high precision and excellent surface roughness in aluminum and non-ferrous machining due to their high positive helical cutting edges and polished insert surfaces. As such, both the XEVT 16 and XEVT 22 inserts always deliver outstanding productivity in demanding high-speed milling applications such as shouldering, slotting, face milling, step down milling, profiling, straight ramping and helical ramping. Moreover, both XEVT types are available in several corner radii and the XEVT 16 inserts are interchangeable with the current TE90XE and TFM90XE cutters in order to enhance the productivity of current XECT 16 inserts currently being used. The cutter’s simple screw clamping design ensures for proper seating and rigidity during machining in order that the tool stays firmly in place when handling high feeds and speeds on aluminum and non-ferrous materials. Cutters are available as end mills, modular types, face mills and HSK type face mills. In extensive real-world tests, TaeguTec’s ChaseAlu XEVT 16 clobbered the leading competitor’s similar offering by increasing productivity by an amazing 329 percent while also increasing tool life by a very respectable 33 percent on an aluminum workpiece. In another test, but this time on aluminum alloy, TaeguTec’s XEVT 16 increased productivity and tool life by 27 percent and 33 percent respectively.
EVENT GLIMPSES
MTW Magazine Participation @ India Machine Tools Show 2015, New Delhi : 4-7th July,2015
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EVENT GLIMPSES www.mtwmag.com
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PROJECTS
Defence Larsen and Toubro Ltd
DEFENCE LUBRICANTS
PROJECT
MANUFACTURING MECHANICAL WORKS PORT & SHIPPING TRANSPORT
UPDATE
POWER
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Bagged an order from Ministry of Defence for the design and construc- tion of a foating dock for the Indian Navy (FDN). The dock will be capable of docking Naval Ships and Subma- rines of up to 8000 T displacement with draughts up to 7 m, day and night. The FDN complete design and engineering will be undertaken in-house at L&T’s Warship Design Centre.
Place: Mumbai Contacts: Morata Deepak, V.P (Corp Comm), L&T House, Ballard Estate, Mumbai - 400001. T: 022-66965270, 67525656, 67525840, 61817577, F: 67525893.
Lubricants
Manufacturing Henkel Adhesive Technologies India Pvt Ltd Germany-based Henkel AG is setting up an adhesives plant at Kurkumbh near Pune with an operational area of 20,000 sq mtr. The production capacity would be about 80,000 metric tonnes of adhesives and surface treatments per annum. This unit will start production by early 2017.
Place: Maharashtra Contacts: Surendra Mehra, Project Manager, Kesar Solitaire, 10th Floor, Plot No. 5, Sector - 19 Palm Beach Road, Sanpada, Navi Mumbai- 400705, T:022-39296768,39296600, F:39296602, E:surendra.mehra@ henkel.in,
Mechanical Works
Balmer Lawrie
Bridge And Roof Co.(I) Ltd.
Plans investment on its lubricants and warehouse businesses in the next few years. The company aims to ravamp its speciality lubricants business and for building multi-product warehouses.
The company has awarded contract to Zillion Infraprojects Pvt Ltd for the mechanical work of offsite area at IREP,BPCL-Kochi. The completion is targeted by November 2015.
Place: Kolkata West Bengal
Place: Kerala
Contacts: Mohar Mukho-
Contacts: H.Karmakar,
padhyay, Head (Corporate Communications), 21, Netaji Subash Road, Kolkata-700001, West Bengal. T: 033-22225218, 22225305, E: sinha.v@balmerlawrie.com
DGM, 2/1, Russel Street, Kankaria Centre, 5th Floor, Kolkata - 700071. T: 033-22174469 to 4473, F: 22172106, Ext.-416 E: bridge@bridgeroof.co.in
PROJECTS www.mtwmag.com
Ports & Shipping Ganga- varam Port Ltd. The private port has signed an agreement with Petronet LNT Ltd for setting up of an LNG terminal. The clearance is in place from the Ministry of Environment and Forests. A land-based LNG terminal with a capacity of 5 MTPA will be developed in frst phase. The LNG terminal will comprise facilities for receiving, storage and re-gasifcation of LNG.
Place: Andhra Pradesh
Gujarat, T:079- 23238346, 47, F: 079-23234703, E: info@gmbports.in
Malabar Ports Pvt Ltd Kerala Government is all set to develop the port at Ponnani through private investment. Chennai-based Malabar Ports would undertake up this project.. The government has acquired 29.3 acre of land for the project that would be leased for a period of 33 years to the company. It is likely that the foundation stone would be laid soon.
Place: Kerala Contacts: New No 84 Old No 50, Dakshin Appartment, First Avenue, Indira Nagar Chennai - 600020, T: 044-42607368
Gujarat Maritime Board (GMB)
Karaikal Port Pvt Ltd
The state board has identiied stretches for developing greenield ports include Bhavnagar to Ghoga, Jamnagar and Bharuch area. The sites identiied for developing shipyards include JakhauMandvi, Dwarka-Porbandar, Porbandar-Mang- rol, Mangrol-Veraval and Mahuva. The process of appointing the consultants is on.
Plans to set up a LNG Terminal inside the port. The talks with three multina- tional companies is in advanced stage. This terminal will be
Place: Gujarat Contacts: Kalpesh Vikhlani, GM (Projects), SAGAR BHAVAN’ Sector 10-A, Gandhinagar - 382010.
The consortium of NMPT, ONGC, BPCL and Mitsui is setting up LNG terminal with 2-3 MTPA capacity.
Contacts: Pranav Chaudhary, CFO, Hansa Plaza, Plot No.798, Road No.36, Jubilee Hills Hyderabad - 500033, T: 040 23519999, F: 040-23519990, E: secretary_cfo@gmail.com
(NMPT)
ready in 24-30 months.
Place: Tamil Nadu Contacts: G R K Reddy, CMD, MARG Group, Chettinad Chambers, 3rd Floor, No.39, RK Salai, 5th Street, Near AVM Rajeshwari Marriage Hall, Chennai – 600004, T: 044-45622000, F: 044-45622080 New Mangalore Port Trust
Place: Andhra Pradesh Contacts: R.Thipayya, PRO, Panambur, Mangalore-575010, D.K. District, Karnataka, T: 0824-2407259 Andhra Pradesh Gas Distribution Corporation (APGDC) APGDC, GDF Suez, Shell and GAIL is setting up a 5 mtpa foating LNG terminal at Kakinada.
Place: Andhra Pradesh Contacts: S. Narayanan, MD 2nd Floor, #5-9-58/B, Fateh Maidan Road, Basheerbagh, Hyderabad- 500004, Andhra Pradesh, T: 040-67304930, F: 67304951, E: info@apgdc.in Petronet LNG Ltd. The company is setting up LNG terminal with 5 milliontonne at Gangavaram Port.
Place: Andhra Pradesh Contacts: Peter Fernandes, Chief Manager(Project), 1st Floor, World Trade Center, Babar Road, Barakhamba Lane, New Delhi - 110001. T: 011-23472525, 23413130, F: 23414271
Indian Oil Corporation The company is setting up a 5-million tonne per annum LNG import, storage and regasiication terminal at Ennore Port.
Place: Tamil Nadu Contacts: Anjali Bhave,Sr. Manager (Corp Comm), 3079/3, J B Tito Marg, Sadiq Nagar, New Delhi - 110049, T: 011-26260140, 26260000, E: anjalib@indianoil.in Karaikal Port Pvt Ltd MARG Karaikal port has a cargo handling capacity of 28 million tonne per annum. The port is being devel- oped in three phases and currently has ive berths and plans to have a total of nine berths capable for handling 47 MMTPA by 2018.
Place: Tamil Nadu Contacts: G R K Reddy, CMD, MARG Group, Chettinad Chambers, 3rd Floor, No.39, RK Salai, 5th Street, Near AVM Rajeshwari Marriage Hall, Chennai – 600004, T: 044-45622000, F: 044-45622080
Transport BEML Ltd Defence Public Sector Undertaking & major manufacturers of Metro Cars in India, BEML has received order
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PROJECTS
from DMRC for the design, manufacture, supply testing and commissioning of 74 no’s broad guage Metro Cars for their RS-13 project (Rolling Stock).
Place: Delhi
Place: Haryana
Place: Delhi
Contacts: A.K Ahuja,
Contacts: B L Manjunath,
Sr.VP (Projects), 2nd Floor, Ambience Corporate Tower, Ambience Island, NH # 8, Gurgaon - 122001, Haryana. T: 0124-4302550, 4716300.
CGM (Metro), BEML Soudha, Bengaluru-560027, T: 080-22963240, 25242414, F: 22963278, E: ofice@pr.beml.co.in, rd@beml.co.in
Contacts: S.Ramanand, Asst GM (Corp Comm), BEML Soudha, 23/1, 4th Main, SR Nagar, Bangalore-560027, Karnataka. T: 080-22224457, 22963210, E: bemlpr@gmail.com
Kochi Metro Rail Ltd
Place: Chhattisgarh
The company has submitted an alignment and land plan to the Revenue Department for acquiring land on the stretch between Jawahar- lal Nehru Stadium to Kakkanad as a part of the extension of Kochi Metro corridor. As per the approved proposal there will be 11 stations-Palarivattom Junction, Palarivattom Bypass, Chembumukku, Vazhakkala, Kunnumpuram, Kakkanad Junction, Kochi SEZ, Chittethukara, Rajagiri, Infopark I & Infopark II - on the 11.2-km stretch.
Contacts: Shiv Raj Singh,
Place: Kochi Kerala
Rashtriya Ispat Nigam Ltd. The company is laying a 450km slurry pipeline all along the NH-43 from Nagarmar in Chhattisgarh to Visakhapatnam avoiding forest areas to ease congestion on Kothavalasa-Kirandul railway line.
Civil Engineer, Near Sales Tax Offce, Ratan Muni Rd, Jaipur House Colony, Agra, Uttar Pradesh-282010, T: 0562 2811009, M: 9639004477
Rapid Metro Rail Gurgaon
Contacts: Reshmi C R, Sr DGM (Communication Manager), 8th Floor, Revenue Tower, Park Avenue Kochi. 682011 Kerala. T: 0484-2380980, 2350355, 2350455, 2350955, F: 2380686, E: reshmi.cr@kmrl.co.in
Ltd. BEML The implementation of second phase of Rapid Metro is in progress.The service from Sikanderpur to Sector 55-56 along Golf Course Road will be achieved in time.The project is likely to complete by September 2016.
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Bagged an order from Delhi Metro Rail Corporation (DMRC) for the design, manufacture, supply, testing and commissioning of 74 nos broad guage metro cars for their RS13 project (Rolling Stock).
Power Rashtriya Ispat Nigam Ltd The company is contemplating plans to set up a 500 MW thermal power plant on the premises of Visakhapat- nam Steel Plant in collaboration with NTPC.
Place: Andhra Pradesh Contacts: B.S. Satyendra, Corp Comm (Asst. General Manager), Administrative Building, Visakhapatnam Steel Plant, Visakhapatnam - 530031 E: satyendra_ban@vizagsteel. com, T: 0891-2518431,2518226, F:2750569 Gujarat State electricity Corpora- tion Ltd (GSECL) GSECL has taken up decision to replace existing old and ineffcient units by new supercritical technology units. The frst phase of this project will see the replacement of 120 MW units at Ukai, Gandhinagar & Sikka thermal power plants.
Place: Gujarata Contacts: I M Patel, Chief
Engineer, Gandhinagar Thermal Power Station,, Vidyut Bhavan, Race Course, Vadodara-390007, Gujarat. T: 079-2321566, F:079-23217673, E: gsecl@gebmail.com
Rashtriya Ispat Nigam Ltd. The company has signed an MoU with Power Grid Corporation of India Ltd for setting up a transmission tower and tower parts manufacturing unit. The completion is targeted in 24 months.
Place: Visakhapatnam Contacts: B.S. Satyendra, Corp Communica- tions (AGM), Administrative Building, Visakhapatnam Steel Plant, Visakhapatnam - 530031 E: satyendra_ban@vizagsteel. com T: 0891-2518431, 2518226, F:2750569 Telangana State Power Generation Corporation Ltd The company plans to set up a 4,000 MW ultra mega power project at Damarcharla in Nalgonda district. MOU is signed in this regard with BHEL. The Yadagiri thermal power station is likely to have 5 units with 800 MW capacity each.
Place: Telangana Contacts: Bala Raju Chief Engineer (TPC), Vidhyut Soudha, Kairapabad, Hyderabad - 580082, M: 09440817003, E: cetpctgenco@gmail.com
PRODUCTS
PRODUCTS
PRODUCT SHOWCASE
www.mtwmag.com
CC 10 - 22 Straight Cutting Oils • • • • • •
CC series oils are Chlorine-Free CC series oils are Non-Staining CC series oils can be used safely on all materials Non-Toxic, Non-Irritating, Non-Corrosive Easy to recycle and waste treat Lower misting and fewer residues
Hangsterfer’s CC oils are designed for light and medium duty metal cutting and metal forming operations. These economically formulated oils are manufactured under the same quality control standards set for all Hangsterfer’s products. Offering superior lubrication for the machine tool as well as the cutting and forming operations. CC oils provide benefits in productivity, equipment life and environmental compliance. CC 10 = This is the lowest viscosity in the series. CC 10 is ideal for high speed turning, machining and stamping. The low viscosity enables better flow rates and allows for more heat removal. CC 22 = This oil is ideal for use in CNC Swiss-style turning centers, especially on those requiring chlorine free oils. It has enough lubricity for the more demanding operations and materials, including lubrication of the guide-bushings.
APPLICATIONS CNC Swiss-style Turning
High Speed Turning and Machining
CNC Machining
General Turning and Machining
Multi-Spindle and Cam-style
Tapping & Threading
Stamping
Forming
Broaching
Gear Hobbing and Shaving
Grinding and Honing
Punching and Blanking
MATERIALS For Product Enquiry Contact Hangsterfer’s Laboratories, Inc.USA Sanjay Tools & Adhesives Mobile : +91 9822028518, +91 9892516810 E-mail: hangsterfers@sanjaytoolsnsk.com Web : www.hangsterfers.com
Carbon Steels, Low, medium and High
Stainless Steels
Nickel Alloys
Copper and Brass
Aluminum
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PRODUCTS
Versatile and Cost effective Three Axis CNC Gun Drilling Solution for Die & Mold Industry Precihole’s XYGVN Series Three Axis Knee Type Gun Drilling Machines cover all major requirements needed in a Deep Hole Drilling solution: high precision, high productivity, compact footprint, affordability and reliability. These Machines can be tooled up for a wide range of components and cover the whole spectrum of gun drilling range from Φ 2 mm to Φ 40 mm with drilling depths of up to 1000 mm
Some highlights of these machines include:
For Product Enquiry Contact Precihole Machine Tools Pvt. Ltd. A 180, Wagle Industrial Estate, Road no 16Z, Thane (W), Maharashtra 400604 Tel: +91 22 399 1444 / 45 Fax: + 91 22 25824862 Email: sales@precihole.com Website: www.precihole.com
• Modular Construction that allows high level of flexibility for standard components • Option for 1 spindle or 2 spindle configuration provides higher productivity • These machines are designed with prime focus on operator safety & ease of operation • The setup change-overs are quicker and extremely operator friendly • CNC Controls for precision positioning of horizontal and vertical axes • Compact footprint and ease of use for operator • Fixturing capabilities to stack and drill multiple components • Different levels of automation can be incorporated to satisfy custom requirements Precihole Machine Tools was established in 1988 and has more than 700 installations of machines all over the world. The company manufactures state-of-the-art machine tools and special purpose machines. Precihole also provides precision machining and component manufacturing services for the engineering industry.
Nine9 i-Center Drill Nine9, Taiwan developed the world’s first indexable Center Drill “i-Center” (patented) with high-efficiency which not only promotes cost reduction but also improves process performance. “i-Center” is a unique solution in the world to upgrade the center drill process into indexable generation leaving HSS and Solid Carbide centering as ancient history. The most significant feature of this tool is that indexable insert can be replaced when the holder of a machine is installed well whereas for the previous generation tools the machine must be adjusted for replacing the center drill.
For Product Enquiry Contact Stitch Overseas Private Limited Plot No: 179 & 180, Industrial Estate, Udyog Vihar Phase-VI, Sector-37, Gurgaon-122 004. Haryana, India. Tel.: + 91-124-4755400; Fax: + 91-124-4755430; Helpline No. +91-9313361202 E-mail.: stitch@vsnl.com; Website: www.stitchtools.com
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FEATURES: • High Speed, High Feed Rate New I-Centre to drill alloy at 6000 r.pm with a feed rate of 6000mm/min with considerable ease. • NO Re-setting or Re-sharpening By eliminating re-sharpening with a simple insert changeover, the I-center drastically improves process performance. • Easy Tool Length Setting The axial position accuracy of the insert is 0.05mm, not necessary to reset the tool while changing the insert. • Excellent Repeatability The positioning repeatability of the insert is within 0.02mm in radial direction, thus ensuring conformity to over larger cycles of time. • Remarkable tool life and performance The new I-Center delivers remarkable tool life and performance with coolant supplied directly through the tool holder to the cutting edge.
PRODUCTS www.mtwmag.com
CPS Automotive Torque wrench attachment A device is to be use for enhance the tightening accuracy with row accurate tools i.e. Air Tool/Impact Tool/ Oil pulse Tool to ± 3%. 3 to 4 second time save per bolt tightening by eliminating the use of torque wrench for correction.
Available Range of this attachment:
For Product Enquiry Contact 3m Solutions Rakesh Goel M-09718363730 E-mail raakeshgoel2000@yahoo.com
• • • •
2 to 12Nm 5 to 25Nm 10 to 50Nm 20 to 100 Nm
*** Shown Torque wrench not the part of this device Applied for Patent
Brother’s Speedio Compact Machining Center The SPEEDIO - Compact Machining Center series is an evolution of BROTHER’s legendary CNC Tapping Center series. The SPEEDIO’s are built using BROTHER’s revolutionary design concepts that combine the best of mechanical and electrical technologies to give users unmatched productivity and cost advantages. The enhanced structural rigidity, selection of machine elements, the high torque spindle option, the overall build quality and a host of controller features makes the SPEEDIO a formidable machine in the production shop floor.
Major Features : HIGH PRODUCTIVITY • Non cutting time is greatly reduced due to higher rapids (50/50/56) (X/Y/Z) at 2G acceleration and Spindle acceleration 0~10000r.p.m in 0.15 sec. • Tool change is minimized to 0.8sec (Tool to Tool) and 1.4 sec (Chip to Chip) resulting in faster component cycle time. • Fastest pallet changing time of 2.9 sec results in faster set up time. HIGH MACHINING CAPABLITIES • Enhanced machine rigidity. • Use of high power spindle motor to allow the machine to demonstrate broad machining capabilities from high speed, high efficiency to heavy duty machining(high torque spindle specs gives maximum torque 92Nm)
The Speedio series includes: For Product Enquiry Contact Stitch Overseas Private Limited Plot No: 179 & 180, Industrial Estate, Udyog Vihar Phase-VI, Sector-37, Gurgaon-122 004. Haryana, India. Tel.: + 91-124-4755400; Fax: + 91-124-4755430; Helpline No. +91-9313361202 E-mail.: stitch@vsnl.com; Website: www.stitchtools.com
a) Table Traverse Type Compact Machining Center SX series (S300X1/ S300X1/ S700X1/ S1000X1). b) Pallet Changer Type Compact Machining Center RX series (R450X1). c) 5-Axis Vertical Turn Mill Center MX series (M140X1). Owing to its inherent advantage of “cost saving” by virtue of enhanced productivity and saving in power this family of machines is very popular in the high volume component manufacturing industry worldwide like Automotive , Faucets , IT & many more.
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Flap wheels LSV, Grinding wheels of abrasive fleece (special manufacture) These wheels with various bore dimensions can be used on both hand-held and floorstand type machines. The LSV consists of abrasive impregnated fleece flaps. A special type of fleece gives flexibility to the tools which easily conforms to the individual workpiece profile. Examples of application: • matting • conditioning • polishing • finishing • final surface finishing LSM, Flap wheels of abrasive fleece with abrasive cloth (special manufacture) These wheels with various bore dimensions can be used on both hand-held and floorstand type machines. Due to the combination of coated abrasive and abrasive fleece greater stock removal is achieved compared to the product type LSV. Please take note of the rotational direction! Examples of application: • preparation work • de-rusting • pre-finishing • graining • keying LSL, Flap Wheels of abrasive cloth (special manufacture) These wheels with various bore dimensions can be used on both hand-held and floorstand type machines. The type LSL consists of individual flaps imbedded radially into a very substantial resin-based core. Please take note of the rotational direction! Examples of application: • preparation work • deburring • de-rusting • prefinishing • graining • keying
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
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LSL, Flap Wheels of abrasive cloth for angle grinder Advantages: • Fits onto standard angle grinders • Replaces the use of shaft mounted flap wheels (where no straight grinder is available) • No flange needed • Ideal for welding seams on Stainless Steel (tanks) Examples of application: • de-rusting, removal of surface coatings and oxidise layers • cleaning of welding seams • grinding in the tank industry • grinding in the assembling industry Application info: Only to be used on the periphery of the wheel
ADVERTISERS INDEX COMPANY NAME
PG. NO.
GRIND MASTER MACHINES PVT. LTD.
B BRIGHT BURNISHING TOOLS PRIVATE LIMITED
25
C CNC SOFTWARE, INC.
BACK PAGE
DOWEL ENGINEERING WORKS
19 59
E
1
JYOTI CNC AUTOMATION LTD.
INSIDE BACK COVER
L
29
RENISHAW INDIA (PUNE)
INSIDE FRONT COVER
SANJAY TOOLS & ADHESIVES
37
SBS PRECISION SYSTEMS (INDIA) PVT. LTD.
41
LAKSHMI MACHINE WORKS LIMITED
11
SOLITAIRE MACHINE TOOLS LTD.
53
65
SPRAYMET SURFACE TECHNOLOGIES PVT. LTD.
21
SUPRA INDUSTRIES
45
LAKSHMI RING TRAVELLERS (COIMBATORE) LIMITED
ERWIN JUNKER MASCHINENFABRIK GMBH
3
M
13
MGM-VARVEL POWER TRANSMISSION PVT.LTD.
PG. NO.
S
J
67
GLEASON
COMPANY NAME
R
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ENGITECH EXPO - 2016
G
PG. NO. 5
HAAS AUTOMATION INDIA PVT. LTD.
D DMG MORI INDIA
COMPANY NAME
MACHAUTO EXPO - 2016
69
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MARPOSS INDIA PVT. LTD.
17
UNITY CONTROLS PVT. LTD.
2015 - 2016
MACHINE TOOLS WORLD |
79 | August 2015
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Inside Story
Mr.
Colin
R Price
Director - Sales & Marketing (India), Renishaw Metrology Systems Ltd.
My Life’s Goals
Aim & Ambition: My ethos in life is be driven and motivated and successful in my professional career but to maintain a level head throughout the journey. Treat others as I would want to be treated myself and stay true to my morals and believes at all times. Whilst it is nice to be important I is equally important to be nice as well. My ambition is to reach my potential in career and life without compromise to the personal / family or professional balance. Vision: To make the best of myself as possible and to always have the interest of my company at heart and influence others to act accordingly through good leadership and mentoring. Social Goal: To give back to the local communities and network with other businesses to make a positive impact whenever possible. Business Goal: To give my 100% and work hard and make the difference. Effect positive change through structure and experience and mentoring others. Make a positive impression and deliver whenever possible and most importantly to never avoid the challenges and difficult aspects of the job at hand, either externally or internally.
My Leisure Choices
Favourite Tourist Spot: Caribbean Islands & Thailand. I love the crystal clear waters and music vibe of the Caribbean and the natural beauty and friendly people in Thailand. Music I Like: I like all types of music genre, from Soul R&B, Motown, Reggae to Johnny Cash. It depends on my mood and situation. Sports I Love: Rugby Union, Boxing and Scuba Diving. I am a national diving instructor and have been fortunate to dive a good number of the dive sites around the World and this in itself opens up a brand new World in itself.
Ask my Taste Buds
Favourite Food: Thai, Caribbean and Italian. And I have to mention my wife’s home-made cooking. Not that it tastes nice but I have to mention it!
In Awe of
I Admire: Lots of individuals but people who fight and stand by their beliefs in order to encourage change for the right causes and reasons. The Nelson Mandela’s and Martin Luther Kings’ of this World and on a sporting level Richie McCaw of the New Zealand rugby team who leads by example and commits 100% each time and every time – truly inspirational player to watch & learn from.
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BE DYNAMIC!
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