Machine Tools World September 2015 by Divya Media Publications Pvt. Ltd.

Absolute Rotary Encoders with Integrated Diagnostics

The HEIDENHAIN rotary encoders ECN/EQN 1300 with optical scanning have become the industrial standard in feedback systems for incorporation in servo motors. The integrated diagnostics and sturdy components ensure very high signal quality and availability, which are necessary prerequisites for use in safety-related applications. Also, they provide all information necessary for commissioning, monitoring and diagnostics. The result: guaranteed system availability from start to finish.

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Angle Encoders

Linear Encoders

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Contouring Controls

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Position Displays

Length Gauges

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Rotary Encoders

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Volume 1 Issue 4

Contents

Vol 1 Issue 4 | September 2015

Publisher

TECH UPDATE

Shirish Dongre

CEO

Shekhar Dongre

Editor

When it’s impossible to take actual Measurements, Multiphysics provides the answers

Shilpa Dongre

Marketing Team Ladoji Pendurkar, Amol Powle, Bhavin Shah, Bharat Shah, A.Purohit, Vinod Surve, Kavita Chaudhari

Designer & Layout Arun P. Shinde, Pradeep M. Pillalamarri, Nandan S. Moghe, Dinesh S. Gawade

Circulation Executive

JUNKER Group exhibits new grinding technologies at the EMO

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

22 “We expect to see a rise in the demand for sophisticated machines” Dr. Jens Hardenacke, Asia Pac Head of DMG MORI

WEST (Maharashtra & Gujarat) Pune S.Kadam - 09833373371 Gujarat Dinesh Shah - 09327344559 Rajkot (Saurashtra) Swapnil Bhatia: 09227909005

BUSINESS NEWS

INTERFACE

Mastercam X9 & Dynamic Motion on Display at WESTEC 2015

Replace manual gauges with new INTUOTM software for EquatorTM 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

MTW SEPTEMBER 2015

Sandvik Asia to set-up a world-class manufacturing facility at Chakan

Grind Master celebrates Success of Crankshaft Dynamic Balancing Machine

Customised CNC upgrade simplifies railcar axle grinding

EAST (Kolkata & Other regions) S. Roy - 09433097806

Recent developments in metalworking fluids

Achieve “better than new” machine accuracy & extend machine life by advanced ballbar training

Additive manufacturing with a digital process chain in the Blok Group

KREBS & RIEDEL : Grinding Perfection for Every Process Plasma & Automated sheet metal cutting

IN FOCUS

High Insulation Gate-Drive Transformer to Control MOSFETs in Automotive DC/ DC Power CVs

Delcam: Leading the way through excellence

PROJECTS

PRODUCTS

PRODUCTIVITY ACROSS THE BOARD

CENTERLESS CYLINDRICAL GRINDING The centerless grinding machines of the JUPITER series offer significant production benefits: The patented CNC height adjustment of the support rail minimizes tooling times, automatic adjustment of the grinding gap geometry optimizes the grinding process, and the inclined bed guarantees outstanding dimensional accuracy.

www.junker.in JUNKER PREMIUM-SERVICE: • Guaranteed servicing • Fast and competent • 24 hours a day, 7 days a week • Worldwide service network

Hall: 14 • Booth: N06

Erwin Junker Maschinenfabrik GmbH India Branch Office Office No. 104, City Square 29-2, K.M. Gandhi Path, Bhamburda Shivaji Nagar, Pune 411 005 +91 20 255 33 896 info@junker.in

Editorial Board

Editorial Index A

Industries

Ador Welding

36 N

NUM Group

CNC Software, Inc.

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

(Mastercam)

6, 9

Concept Laser

Precihole Machine

D Delcam

16, 24

DMG MORI

Erwin Junker

Grind Master

H Hypertherm

Effica Automation Ltd.

Renishaw Metrology Systems Ltd.

Mr. MIHIR Baxi President – Global Sales Jyoti CNC Automation LTD

R Systems

8, 46

Ms.Samina Khalid Marketing Manager

Premo

Renishaw Metrology

Mr. Arjun Prakash Managing Director

Tools

Sandvik

Sanjay Tools & Adhesives

Sciaky, Inc.

Supra Industries

K Komet Group

Krebs & Riedel

TAITRA

Mitsubishi Heavy

Unity Controls

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

MTW SEPTEMBER 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

BUSINESS NEWS

Mastercam X9 and Dynamic Motion on Display at WESTEC 2015 WESTEC 2015 attendees will get to see and experience the most powerful Mastercam machining software yet. Stop by booth # 1715 at the Los Angeles Convention Center in Los Angeles, CA, September 15-17 for a look at Mastercam X9 which introduces Dynamic Motion improvements, Multiaxis enhancements, and many Design and System features to make your job easier. There will be live presentations every 30 minutes on Mastercam products, available in both English and Spanish. This year at WESTEC, attendees have the opportunity to register for a Mastercam X9 Rollout Event, hosted by CNC Software and local Mastercam Reseller, to learn about the latest tools in Mastercam X9. Also available are three Brew & View breakout sessions located at the main stage of the show floor. Topics are: • The Evolution of CAM: An Introduction to Mastercam’s Dynamic Motion

• Machining Way Too Fast: A First Experience Jumping into Mastercam Dynamic Motion • Speed vs. Power: Maximizing Material Removal with Mastercam’s Dynamic Motion

Dynamic Motion Technology Dynamic Motion toolpaths follow a proprietary and sophisticated set of rules that take into consideration a broad data set. To create the most efficient cutting motion possible, Dynamic toolpaths calculate not only the area where metal will be removed; they also take into account the changing condition of the material throughout various stages of machining.

Design and Multiaxis Features Dynamic Xform allows you to switch between gnomon manipulation and geometry manipulation mode at any time. Solid Disassemble is a new Model Prep function that takes an assembly and lays each body

out in a single pane. The associativity between solids and toolpaths has been greatly improved. Now when bodies are edited, only the toolpaths directly affected by the change in the solid body are marked dirty. The new Multiaxis Link ensures reposition moves between 2- through 5-axis operations are safe and collision-free. Multiaxis Link is an operation that takes a list of toolpath operations and a safety zone shape as input. Mastercam X9 introduces improved processing logic for advanced multiaxis toolpaths. Select Multiaxis toolpaths now process in the Multi-Threading Manager, streamlining your 2- through 5-axis workflow experience.

Also available in Mastercam X9: • Preview Toolpaths support for select Mill operations to see your results before closing the toolpath parameters dialog. • Surface High Speed Hybrid now supports dedicated flat processing, making Hybrid even more intelligent and efficient. • The efficiency of the 3D HST Rest Roughing Linking has been improved. The moves are closer to your model,

MTW SEPTEMBER 2015

eliminating costly excessive air motion. • Mill Tooling introduces two new tool types, as well as changes to two existing tools.

About Mastercam Developed by CNC Software, Inc., Mastercam is Windows®based CAD/CAM software for 2- through 5-axis routing, milling and turning, 2- and 4-axis wire EDM, 2D and 3D design, surface and solid modeling, artistic relief cutting, and Swiss machining. CNC Software is a privately owned corporation founded in 1983. The U.S.based company provides Mastercam CAD/CAM solutions to more than 200,000 installations in 75 countries in industries including mold-making, prototyping, automotive, medical, aerospace, and consumer products. Mastercam runs under Windows 7 and Windows 8, and is compatible with all other CAD/CAM systems. For more information about CNC Software, Inc. and its Mastercam family of products, contact CNC Software, Inc., M - F, 8 AM - 5 PM EST at (800) 228-2877 or (860) 875-5006,—671 Old Post Road, Tolland, CT 06084. For more information, Website: www.mastercam.com

Taming power quality is now child's play

When you use DigiVolt Stabilizers, Tranquil Ultra Isolation Transformers and Powercon Power Conditioners from Unity Controls, power quality is under total control and would no more hamper your production and product quality. These silent sentinels protect your sophisticated, high precision production equipment from the ill-effects of voltage, spikes, surges, transients, sags, noise and harmonics affecting AC power lines. Thus ensuring continuous uptime and enhanced productivity and consistent quality.

Intelligent Microprocessor-based, High Efficiency, Energy Savers specially designed for CNC machines

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BUSINESS NEWS

Replace manual gauges with new INTUOTM software for EquatorTM Highly repeatable process control on the shop floor - create simple gauging routines in minutes and eliminate user error The Renishaw Equator™ flexible gauge is now offered with the new INTUOTM gauging software, combined with a range of industry standard Renishaw probes. INTUO simplifies and automates the gauging of a wide variety of parts, removing dependence on the skill of manual gauge users. Reducing gauging inconsistency reduces scrap, whilst ensuring parts that are out of tolerance are always identified. Renishaw is also launching the Equator Button Interface (EBI), with simple push-button controls for shop-floor operators, removing the need for a mouse and keyboard.

Replace manual gauges, reduce ongoing costs INTUO with Equator is an ideal alternative to multiple manual devices such as vernieror digital

callipers, micrometres and plug gauges. Equator is highly repeatable and runs fast automated routines, meaning significantly reduced labour costs. With many workshops using hundreds of manual gauges this cost saving can be considerable. INTUO, with minimal training, uses intelligent functions to help the engineer set up gauging of parts in a matter of minutes. Shop-floor operators then select and run those programs using the user-friendly Renishaw Organiser front-end software.

Gauging routines in minutes INTUO allows the programmer to create gauging routines using just a part with an engineering drawing. With the Feature Predict function activated, the programmer uses the joystick to take points on each feature while INTUO does most of the work, by predicting the type of feature, the nominal value and a

possible tolerance band. It is then easy to adjust the program to change the number of points taken or to space them evenly, and match nominals and tolerances to the engineering drawing.

Easy manual input of master part actuals It is a simple task to input the actual values for features on the master part, which does not need to be a ‘perfect part’. In fact it is preferable that a production part manufactured with the same method and material is used. First the features required are measured on a certified device, like a calibrated manual gauge or any co-ordinate measuring machine (CMM). The values from this master part inspection report can be manually added to a table in Organiser or to the corresponding field in INTUO – changing one will update the other.

Programmer training in one day

INTUO allows engineers to create simple gauging routines on Equator in minutes, with easy input of master part values. With Equator Button Interface shop floor operators can start routines with a single button, & control other basic functions

MTW SEPTEMBER 2015

INTUO has gone through extensive development to make it as simple to use as possible, which means that programmers only need a training course lasting a few hours. Training is ‘handson’, using the joystick to take points while interacting with icon based menus and a graphical workspace to rapidly build up the features to be gauged. In just a few hours programmers will learn the four stage INTUO process of Align – Measure – Dimension – Report, and be ready to inspect production parts.

Equator Button Interface In many shop-floor environments simple operator controls are essential. Customer feedback has shown that an alternative to the keyboard and mouse is required, so Renishaw has introduced the Equator Button Interface (EBI), which works directly with the Organiser software. EBI uses large push buttons which can be operated by operators wearing gloves. It is not affected by shop-floor contamination and can be mounted on the front of the Equator or on the framework of a table or enclosure. At the most basic level it can be used to start gauging programs, but can also be used to stop those programs midcycle, select other programs and navigate the Organiser environment. Equator can be moved using the jog keys if necessary and there are buttons for initial alignment, switching between master/measure modes, changing view screens and easy error recovery.

Control your process Equator has various reporting options, including simple pass/fail, a more detailed view in Process Monitor (a process monitoring window for the user interface), or automatic data capture for updating machine tool offsets. Process Monitor provides a chart showing the history of feature measurements, and an easy graphical view of proportion of tolerance for each feature. Being able to view the inspection data history of

BUSINESS NEWS www.mtwmag.com

Process Monitor also enables shop floor management of the mastering process according to temperature, time or number of parts measured. Use of a calibrated master part allows the system to be re-zeroed whenever shop-floor conditions change, meaning Equator can cope with a rapidly changing thermal environment.

Global support

a part is an invaluable function for controlling manufacturing processes. This is not possible

when using a Go/no-go gauge, which can only indicate the state of each feature.

Reflecting the international nature of many modern manufacturing organisations, Equator customers have been able to take advantage of Renishaw’s extensive network of Equator support engineers. Projects initiated in one country or region can be easily transferred and locally supported in multiple

locations. Renishaw now has over 70 regional support offices and multiple approved partners, covering every industrialised area of the world.

The versatile gauge Equator is unique in its design and method of operation, and has already changed the thinking of thousands of production engineers, making it their new gauge of choice. The versatility and repeatability Equator offers is re-defining the world of gauging, and now with INTUO and the Equator Button Interface an even wider range of capabilities is offered to manufacturers globally. For more information. www.renishaw.com/gauging

CNC Software, INC reorganizes educational division CNC Software, Inc.’s dedicated educational division recently underwent organizational changes designed to better align it with the needs of the industry it serves. Effective July 1, 2015, the group of four representatives housed in the Gig Harbor, WA office report to divisional leaders located in the Tolland, CT headquarters. “This is an exciting quarter as it marks the official integration of our educational division into our corporate office. It is more important than ever that we continue to respond to the needs of the educational industry since they are helping to develop the future of manufacturing.” President Meghan Summers West said. “We made

a strategic decision to align this division even closer with the rest of our company. Previously, our educational group worked as a standalone department, but now it has been integrated into our main organization, allowing us to allocate even more resources to our educational ventures.” Dan Newby, who had previously served as the Educational Sales Manager for over 27 years, will report to Doug Nemeth, Director of Sales for North America and Europe, and will continue his work as Educational Territory Manager. He will now have additional and increased support combining efforts from the entire corporate sales department. Other staff

onsite in Gig Harbor will report to respective department managers in Tolland, CT. “I’m excited about this change because it means we’ll be able to better understand and respond to the needs of all of our customers – whether they are in the educational or industrial arena,” Doug Nemeth said. “By integrating both divisions, we can leverage the expertise and experience of our entire staff and continue to lead the way when it comes to preparing students for jobs in manufacturing.” CNC Software’s commitment to the educational industry is evident in its devotion to exciting and engaging educators and students to help develop

future machinists, engineers, and programmers. According to the most recent analysis of CAM software seats produced by CIMdata, Inc., CNC Software’s Mastercam is the world’s most widely used CAM software in both industrial and educational settings. With over 100,000 paid, installed educational seats worldwide, Mastercam has nearly twice the installed base of the closest competitor.

For more information, Website: www.mastercam.com

MTW SEPTEMBER 2015

BUSINESS NEWS

Taiwan Machine Tool Exports to India surges over 11% in first six months of 2015

Trade between India and Taiwan is increasing rapidly with Taiwan’s machine tools exports to India growing by 11.6 % in the first two quarters of 2015 (January to June ). This comes in the wake of, the overall Taiwan– India bilateral trade touching $ 2.108 billion in the first five months of 2015. Taiwanese exports to India contributed USD 1.28 billion while imports from India touched US$ 828 million. “There is a clear cut synergy between the needs of the Indian manufacturing sector and the special characteristics of the Taiwanese machine tool industry. As the world’s fourth largest exporter of machine tools and component, machine tools in Taiwan can offer products to a broad range of industries, including aerospace, automobiles, computers, energy, medical equipment as well as precision mold. The strengths of Taiwanese machine tools products include excellent quality, reasonable prices, integration and constant innovation, and continuous value addition. In the future, we truly expect Taiwanese products to help speed up India’s manu-

MTW SEPTEMBER 2015

facturing energy and make a significant contribution to the Make in India initiative,” said Mr Lee, Guann-Jyh, Director of the Taipei Economic and Cultural Center in India, Economic Division. He was speaking at a press conference at Pragati Maidan on August 20 ,2015 in the backdrop of the Delhi Machine Tools Expo 2015 (DMTX). The event christened “Taiwan machine tools speed up a better India”-was organized by the bureau of Foreign Trade and implemented by the Taiwan External Trade Development Council (TAITRA). Taiwan now has become increasingly keen on investing in India. At present there are more than 80 Taiwanese companies in India. Many Taiwanese companies have successfully expanded their business in the fields of electronics, machinery, food and textiles. “Establishing good economic and trade relationships with India has always been the goal of Taiwan. We are optimistic that India’s future economic growth will be stronger given its 1.2 billion population and the

demand driven by its young and aspirational middle class. The huge, upcoming public-private sector infrastructure projects is expected to drive growth further. No doubt, the Indian market holds enormous potential for Taiwanese companies,” Dr Lee added. At the Expo five Taiwanese companies Tongtai Machine & Tool Co, Ltd; She Hong Industrial Co. Ltd., Chien Wei Precise Technology C0., Ltd ; MEGA Machine Co., Ltd. and Fair Friend Enterprise.Co.,Ltd launched their products. Indian industry can benefit from the Taiwanese machine tool industry as it is extremely innovation focused. This industry is concentrated in clusters along the Dadu Plateau of central Taiwan which has been christened the Golden Valley. This region which is home to over 1000 precision machinery manufacturers and over 10,000 downstream suppliers employs more than 3,00,000 people and accounts for $ 3 billion in revenues. It has the highest output value per unit area and the highest density of any machine tool industry cluster in the world. Without this cluster, Google’s solar farms in the desert would be unable to follow the sun. The top four equipment suppliers for the global semiconductor and display panel industries also use components from here and without them, the semiconductor and display panel industries

would find their supply chains cut. Car components for the German and Italian manufacturers, as well as gears for General Motors, Porsche and Hyundai, all come from this industry cluster. Even China, the world’s largest car market, principally depends on this Golden Valley of precision machine tools for its mold processing equipment. The Taiwan machine tool industry is even able to meet the stringent requirements of Apple and help it create its unique and innovative products. Taiwan machine tool industry has emerged as the preferred supplier to Apple in the face of stiff competition from traditional technology powers like Germany and Japan.

About TAITRA Taiwan External Trade Development Council (TAITRA) is globally recognized as Taiwan’s foremost non-profit trade promotion organization, with over 60 overseas offices around the world. For more than 40 years, TAITRA has been highly commended for its professional and outstanding services, offering a host of trade related services that cater to a variety of business needs. Partially supported by the government of Taiwan and various commercial and industrial associations, TAITRA has been entrusted to spearhead numerous government projects including the launch of the Taiwan Industry Image Enhancement Plan.

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BUSINESS NEWS

Hypertherm expands robotic capabilities with purchase of Jabez Technologies, creators of Robotmaster Software Jabez Technologies, creators of software to simplify complex robotic programming, is joining Hypertherm, a U.S. based manufacturer of plasma, waterjet, and laser cutting systems, to make it easier for companies to utilize robots for manufacturing applications. Simple offline programming is a key barrier to the wider utilization of robotics in manufacturing. Hypertherm and Jabez believe combining Hypertherm’s cutting expertise with Jabez’s skilled engineering and support staff will make it easier for robotic programmers and integrators to achieve optimal results. At the same time, Jabez can enhance its support for a wide variety of robotic programming applications, including those beyond cutting, by leveraging Hypertherm’s global infrastructure and strong engineering community. “A growing trend toward lean and flexible manufacturing is resulting in the expanded

MTW SEPTEMBER 2015

use of robotics in our served industries. Manufacturers realize that robots are increasingly critical to producing higher quality products at a lower cost, and to achieving the speed and flexibility needed to remain competitive,” Evan Smith, Hypertherm’s President and CEO commented. “Adding Jabez to the Hypertherm team will enable Hypertherm to bring even greater value to our robotic customers, and at the same time provide Jabez with the support and resources to achieve its wider vision, which we share.” Hypertherm is not making any major changes to Jabez’s operations, leadership structure, or distribution channels. Chahe Bakmazjian, founder and president of the privately held company, will continue to lead his team as part of Hypertherm’s newly established Robotic Software group. Jabez’s current offices in the Montreal area will remain intact, with no consolidations or reductions

planned. Support for nonHypertherm cutting systems, non-cutting applications and previously planned investments in engineering and support resources will continue. In addition, Jabez Associates will receive all Hypertherm benefits, including profit sharing and full participation in the company’s employee stock value plan. The transaction was structured as a purchase of substantially all assets of Jabez Technologies. Financial terms are undisclosed. “We are excited to join the Hypertherm family. Hypertherm’s vision regarding the future of industrial robotics as well as the cultural alignment between our companies made a perfect and natural fit,” explains Chahe Bakmazjian. “Additionally, we can leverage Hypertherm’s global service, support and logistics resources to better serve our rapidly growing base of robotic integrators and end users to accelerate the growth of Robotmaster.” Jabez Technologies specializes in simplifying complex robotic programming for 3D shapes, particularly in high-mix manufacturing environments. With the ability to program many different robots across multiple processes, and by providing tools for easy cell setup and configuration, its Robotmaster software delivers the flexibility required to sup-

port a wide variety of robotic applications. Built-in simulation tools, on-the-fly calculation capabilities and unique optimization and collision avoidance tools allow programmers to quickly prepare their jobs with confidence. Hypertherm designs and manufactures advanced cutting products for use in a variety of industries such as shipbuilding, manufacturing, and automotive repair. Its product line includes plasma, laser and waterjet cutting systems, in addition to CNC motion and height controls, CAM nesting software, robotic software and consumables. Hypertherm systems are trusted for performance and reliability that result in increased productivity and profitability for hundreds of thousands of businesses. The New Hampshire based company’s reputation for cutting innovation dates back nearly 50 years to 1968, with Hypertherm’s invention of water injection plasma cutting. The 100 percent associate owned company, consistently named a best place to work, has more than 1,400 associates along with operations and partner representation worldwide.

For more information, visit Web: www.hypertherm.com

BUSINESS NEWS www.mtwmag.com

Sandvik Asia to set-up a world-class manufacturing facility at Chakan

L-R - Mr Dinggui Gao, President, Sandvik Construction; Mr. Parag Satpute, Managing Director, Sandvik Asia; Mr Scot Smith, President, Sandvik Mining As part of its continued growth in the country and to leverage India’s position as one of the best cost countries in its operations, Sandvik had recently announced a commitment to set-up a world-class manufacturing facility at Chakan, which is part of the Maharashtra Industrial Development Corporation (MIDC) Industrial Park near Pune. Development of the site commenced today with the ground-breaking ceremony held at the site. The facility will be operational by end of 2016. The company has made an initial investment of $45 million (approx. 275 crore) towards the 53 acre plant. To develop the facility, the company will make strategic investments in a phased manner over the next 5 years. In the first tranche, it has announced a USD 45 Million commitment to commence development of the site by mid-2015. The new world-class manufacturing facility will help

the company further innovate and create solutions for India’s emerging needs under the visionary ‘Make in India’ initiative. Sandvik is a global industrial group with advanced products and world-leading positions in selected areas – tools for metal cutting, equipment and tools for the mining and construction industries, stainless materials, special alloys, metallic and ceramic resistance materials as well as process systems. In 2014 the Group had about 47,000 employees and representation in 130 countries. Sandvik Asia is the Indian subsidiary of the Sandvik Group and a strategic growth engine in its emerging markets footprint.

For more information, Website: www.sandvik.com

MTW SEPTEMBER 2015

BUSINESS NEWS

Sciaky, Inc. reaches structured reseller agreement with EFESTO, LLC Sciaky, Inc., a subsidiary of Phillips Service Industries, Inc. (PSI) and leading provider of metal 3D printing solutions, announced that it has entered into a structured reseller agreement with EFESTO, LLC that includes the sale of Sciaky’s Electron Beam Additive Manufacturing (EBAM) systems and services to targeted countries and named accounts. Under terms of the agreement, EFESTO will provide exclusive sales representation and resale of Sciaky’s EBAM solutions to Australia, Brazil, China, India, Japan, Nigeria, Poland, Russia and South Korea, along with named accounts in the Middle East and the U.S. oil & gas sector. EFESTO is a rapidly growing advanced technology enterprise, committed to engineer-

ing an industrial revolution in the field of 3D printing of metals and metal composites. It has deep knowledge and experience in Directed Energy Deposition (DED) technologies and their industrial applications, and an extensive track record of marketing premium ‘best-in-class’ metal 3D printing equipment around the globe. EFESTO is also establishing premium service bureaus that will utilize the largest and fastest metal 3D printers available. “This relationship with Sciaky has compelling synergies, providing EFESTO a remarkable technology and product line to bring to its global customers, as well as the opportunity to utilize in its own service bureaus,” said Ashok Varma, CEO & Chairman of EFESTO, LLC.

“Sciaky is proud to bring EFESTO aboard for key countries and accounts around the world,” said Mike Riesen, general manager of Sciaky, Inc. “Sciaky’s EBAM process is the fastest, most scalable metal 3D printing process in the world.” Sciaky also provides industryleading electron beam and advanced arc welding systems, as well as affordable job shop welding services, for the aerospace, defense, automotive, and other manufacturing industries.

About Sciaky, Inc. Sciaky, Inc., a subsidiary of Phillips Service Industries, is a world leader in metal 3D printing solutions. Our exclusive Electron Beam Additive Manufacturing (EBAM) process is the fastest, most cost-effective metal 3D printing process in the market, allowing manufacturers to save significant time and money over traditional manufacturing and prototyping processes. Sciaky also provides industry-leading electron beam and advanced arc welding systems, as well as affordable job shop welding services, for the aerospace, defense, automotive, healthcare and other manufacturing industries. Our welding equipment meets rigid military specifications to manufacture items such as airframes, landing gear, jet engines, guided missiles and vehicle parts.

For more information, Website: www.sciaky.com

MTW SEPTEMBER 2015

BUSINESS NEWS

Grind Master celebrates Success of Crankshaft Dynamic Balancing Machine

Grind Master builds Crankshaft Dynamic Balancing Machine in Technical Collaboration with Balance Engineering of USA. The CRH_MQL600 (for Automotive Crankshafts) is first amongst a range of machines that will include lighter and heavier models for a variety of Crankshafts. Balance Engineering, Global Leaders in dynamic balancing, have cooperated with Grind Master in a Joint-Engineering exercise to develop a Flexible yet highly accurate Balancing Machine. “Crankshaft is the heart of an engine, and Balancing is a ‘Mission Critical’ operation critical for engine life and smoothness”, says Sameer Kelkar, responsible for Engineering of the machine. “The machine gives the customer KEY PROCESS ADVANTAGE in terms of accurate balancing under 10 gm cm. Using MQL and Vacuum chip extraction

MTW SEPTEMBER 2015

systems, it is also a very ECOFRIENDLY system.” “Grind Master is known for its Crankshaft Microfinishing Machines, which it supplies to leading Global Automotive OEMs. Adding Crankshaft Dynamic Balancing Machines to our portfolio of products leads us a step closer to providing our customers with a Complete Crankshaft Finishing Solution. We have built more than 7 machines in the first year of this product. All machines are performing really well, including the first two delivered to Netalkar Power Transmissions Belgaum, which has produced over 50,000 parts.”

For more information Web: www.grindmaster.co.in

Delcam hosts Asian Technical Summit in Bangalore Delcam held its 2015 Asian Technical Summit in Bangalore earlier this month, where the company presented its latest technical and financial news to the media, customers and academics fromboth India and the wider Asian region. Headline sponsor for the meeting, the fifteenth in the series, was again HP, which presented its latest hardware developments to the attendees. The meeting was the first Summit to be held since the appointment of Pete Baxter as Vice President in February. The audience was, therefore, especially interested hear his presentationon Delcam and its part in parent companyAutodesk’s philosophy on ‘The Future of Making Things’. The main focus of the other presentations at the Summit was on the latest versions of Delcam’s range of CAM systemsthat are due to be presented at the EMO exhibition in Italyduring October. Updates were also included on the other software in the Delcam portfolio, including the company’s design, reverse engineering and inspection software. The programme also featured presentations from several of Delcam’s Indian customers. These included companies from Delcam’s traditional markets in toolmaking and subcontract machining, such as Godrej Ltd – Tooling Division, Ashcraft Engineers and Shree Engineers, as well as Mr. Vijayragavan from Titan Company Ltd,

who described his company’s use of Delcam’s PowerMILL and ArtCAM software in the manufacture of watches. In addition, speakers from IMTMA and TAGMA detailed how their associations were working with Delcam to improve skills and productivity within Indian manufacturing. International customers that presented at the Summit were Jason Hogan from 360 Knee Systems, who described his company’s use of Delcam software in the manufacture of bespoke systems for knee replacement surgery, and Craig Tanner from ASPETAR Sports Hospital, who talked about his work producing custom orthotic insoles for elite athletes with Delcam’s OrthoMODEL system. Even so, the presentation that received the most interest from the audience was that by Prof.Karunakaran, from the Mechanical Engineering Department at IIT Bombay. He covered several projects on hybrid layer manufacturing using PowerMILL to program both additive manufacturing with different welding techniques and the subsequent machining of the welded structures into finished parts.

For more information, Website: www.delcam.com

BUSINESS NEWS www.mtwmag.com

MHI to Collaborate with Sugiyama Mecharetro in Remodeling of Large-scale Machine Tools -- New Arrangement Will Enhance Total Solutions Business -Mitsubishi Heavy Industries, Ltd. (MHI) has concluded an agreement, and signed a memorandum, with Sugiyama Mecharetro Inc. on collaboration in the machine modification of large machines. By combining the two companies’ respective strengths - MHI’s response capability in terms of technology and quality cultivated through its business in large machines, and Sugiyama Mecharetro’s cost competitiveness achieved through its robust track record in machine modification - the aim is to generate a broad array of new untapped market needs. Initially the collaborative operations will target users in Japan. Applying the areas in which the two partners respectively excel, services will encompass all aspects of machine modification, including

overhauling and retrofitting*. MHI will primarily contribute in terms of specialized technology and quality control knowhow as a machine tool manufacturer possessing expertise accumulated in all types of large machines, including double-column 5-face milling machines and horizontal boring mills. Sugiyama Mecharetro will mostly take charge of the actual modification work applying its abundant expertise and technologies cultivated over its many years of operation in repair and modification - capabilities enabling the company to respond stably to modification jobs that are too difficult for other firms to handle. Sugiyama Mecharetro, based in Motosu-City, Gifu Prefecture, was established in 1945. Since its founding the company has

performed overhauling and retrofitting of machine tools, its unique knowhow extending even to remodeling of highly superannuated machines and machines of foreign origin. In addition Sugiyama Mecharetro undertakes the design and manufacture not only of machining tools – machining centers, turning mill and grinding machines, etc. – but also rocket component machining systems as well as dedicated machines for a broad range of manufacturing industries, including aviation and aerospace, automotive and nuclear power. Taking the opportunity of new collaborative relationship with Sugiyama Mecharetro, MHI looks to further strengthen its business in total solutions, pursuing differentiation by offering solutions that will

make use of its knowhow as a machine tool manufacturer having strengths in engineering, machining technologies and tooling technologies, to meet newly created demand for diverse manufacturing systems. *Overhauling refers to mechanical modifications and repairs that restore, and in some instances, enhance, a machine’s functions, performance, productivity, quality, maintainability, etc. Retrofitting involves the replacement and repair of NCs and other control devices in order to improve functions, performance, productivity, quality, maintainability, etc.

For more information, Web: www.mhi-global.com

MTW SEPTEMBER 2015

TECH UPDATE

When it’s impossible to take actual Measurements, Multiphysics provides the answers Extreme heat in a blast furnace makes it impossible to take measurements during certain parts of the process. At TRB we are using simulation along with actual outer temperatures in a blast furnace roof runner to find out how hot it gets inside. BY SIMON CHIARTANO, TERRES RÉFRACTAIRES DU BOULONNAIS (TRB)

last furnaces, where molten metal reaches temperatures near 1500 °C, create an environment where every possible precaution must be taken to keep workers and production equipment safe. One potential hazard is when the molten metal first leaves a furnace through a taphole and travels through a runner where the slag is separated out (see Figure 1). If left totally exposed, the molten metal could splash and present great danger to operators and tools, or cause a halt in production. To contain splashes and provide protection, sections of the runner have a roof whose outer shell is made of cast iron with an inner lining made of concrete. This lining is necessary because, without it, splashing molten metal would quickly melt holes in the cast iron. The concrete liner is subject to thermal shock as well as corrosion and erosion. A typical operating life for a roof runner is one month, after which time it must be relined. Given that a blast furnace can have two or three or even four taps, and we at TRB have hundreds of blast furnaces, it is clearly to our advantage to design them as economically as possible while maintaining overall safety. Designing runners has traditionally been an inexact science because we cannot

FIGURE 1: Molten metal exits a blast furnace (left) and travels through a runner where slag is separated from the cast iron (right). The cross-section being studied with COMSOL Multiphysics (see Figure 2) appears in the middle zone as indicated.

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take accurate measurements of what is going on inside them. In the past we used trial and error methods to come up with the best type of concrete for liners and to determine the best thickness. If a liner got damaged too quickly, we simply tried a new combination. Much of these decisions are based on the heat the liner is exposed to. However, until now we have had almost no idea of these temperatures. Are they 300 °C, 1000 °C? We just didn’t know! We can’t place sensors inside because they would be exposed to extreme heat and splashing molten metal, which would destroy these expensive devices. Instead, we turned to simulation with COMSOL Multiphysics and its Heat Transfer Module. Pre-Heat the Oven

Under normal operating conditions, the molten metal doesn’t enter a runner at room temperature. Thus, the first stage of our simulation was used to pre-heat the simulated runner based on a gas burner at 500 °C. This model also provides the cross-section 2D geometry we used for all further studies (see Figure 2). In the figure, note the two shades of brown, which correspond to two different types of concrete. One is in contact with molten metal and must resist the fluid, corrosion and thermal shocks. In this model, we only consider this inner layer of concrete. The second type of concrete never comes in contact with molten metal and serves as a mechanical frame. To study the preheating effects on the concrete, we set the simulation to only use conductive heat transfer, ignore air convection, and to assume a fixed temperature for the gas burner. The results now set the starting point for further investigations.

FIGURE 2: 2D geometry of a roof runner. The molten metal comes in contact with a concrete liner, and the outer shell is of cast iron.

Is the Air Under the Roof Moving?

Following the pre-heating simulation just described, the next stage of the model studies the first time the molten metal in the blast furnace is tapped and sent through the runner. At this point we obtain the temperature of the air underneath the cover and see how it changes over time. For this, we modeled what happens when we tap the blast furnace and send molten metal through the runner for 75 minutes. Here we did couple the heat transfer by conduction in the solid components of the surface with the flow of the air due to natural convection. In the model it took us 300 seconds of simulated time for the walls in contact with the fluid to reach the same temperature of the metal

FIGURE 3: Simulation results show that after 300 seconds, the correct condition of 1500 °C is reached and heat transfer occurs mainly by conduction.

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TECH UPDATE (1500 °C). Once we reached this condition, conduction took place slowly through the layers, as shown in figure 3. It is interesting to note that at roughly 500 seconds, the air profile is almost still (see Figure 4), a fact that plays an important role into the subsequent modeling steps. Specifically, we simplify some of those steps by not including the effects of moving air, which would not add significant information.

FIGURE 4: During the first tap, the simulation performed with COMSOL Multiphysics shows that after 500 seconds air under the roof runner is almost still Simulating a 7-Day Heating Cycle

Studying the first tapping, however, does not allow time for the entire runner to heat up and thus does not provide results we can verify in practice, which was our ultimate goal. To approximate how an actual blast furnace operates, the next stage consists of having molten metal flow through the runner for 75 minutes, then having it remain empty for 75 minutes, and cycling through this for seven days of simulated time. As just mentioned, this stage does not include air convection; we set the temperature on the inner walls that are in contact with air to the temperature determined in the previous step. However, there was one assumption we made thus far that could affect results, so we wanted to refine our model. Specifically, in the previous model we set the temperature of the air interface to the liner at a fixed value of 500 °C. However, when the metal stops flowing, the temperature of the bottom liner does not instantly drop from the 1500 °C of the metal to the 500 °C we had specified. We went to yet another simulation stage like the previous one with one big difference. When there is molten metal, we set the temperature at the fluidliner interface to 1500 °C; when there is no metal, instead of setting it to 500 °C, we made it thermally insulated. We then ran this model for 24 hours of simulated tapping and pauses. The results

MTW SEPTEMBER 2015

are shown in Figure 5.

FIGURE 5: Results for 24 hours of simulated time. Trace 6 and 7 follow the temperature of the air at the interface with the molten metal and the top inner liner, respectively.

Trace 6 follows the temperature of the air at the interface of the molten metal where it reaches (top dotted line) the set level of 1500 °C; without molten metal the temperature of the air alone drops off until it reaches roughly 750 °C (bottom dotted line). We can note that this temperature is much higher than the 500 °C from previous models. Trace 7 follows the temperature of the air where it comes in contact with the top inner liner, and that temperature starts to level off at roughly 430 °C after 24 hours. Finally, we extended the study to a full week to see what temperature the outer cast iron shell would eventually reach. To make simulation time reasonable, we simplified this by setting the air temperature to the value found at the end of the previous stage; this is valid because Figure 5 shows that the interior air temperature has essentially stabilized. Similarly, we set the temperature at the fluid contact edges to the results in Figure 6. After another six days of tapping and breaks, we saw that the outer shell reaches a temperature of roughly 80 °C. Verify Our Simulation to Optimize the Roof Runner

To verify the model, we took thermal imaging photos of an actual roof runner (see Figure 6). We found that its temperature, 76 °C, was in reasonably good agreement with the model. Next, we opened up a roof runner and used imaging techniques to

FIGURE 6: Thermogram of an actual roof runner.

FIGURE 7: Thermogram of the inside of a roof runner (top) and a standard photograph from the same angle (bottom).

measure the temperature of the liner (see Figure 7). We realize that when you open the cover, the temperature inside will rapidly drop, so the actual temperature inside during operation will be higher. In Figure 7, the hottest temperature is 300 °C, which gives us reasonable confidence that our simulated temperature of 430 °C (Trace 7 of Figure 5) is sufficiently accurate for our immediate purposes since we estimate a temperature drop of around 100 degrees. We had no idea whatsoever what this temperature was going to be and now, thanks to simulation, we reached an accurate calculation within 10 °C. The simulation has given us considerable understanding of what is going on inside the roof runner. We were surprised when we found the temperature inside the cover is between 400 °C and 500 °C; we had expected it to be much higher. Until now, our concrete liners have been very thick, but thanks to simulation we have learned that we have likely overengineered them. Although we haven’t factored in the roof wear mechanism, simulation provided us with great insights: we know now that we can reduce the thickness of concrete on roof runners. Besides saving the cost of raw materials in future roof runners by making the liner thinner, if they are lighter they will also be easier to maneuver, which will improve production rates.

COVER STORY

“We expect to see a rise in the demand for sophisticated machines”

Dr. Jens Hardenacke, Asia Pac Head of DMG MORI

Q. Please tell us about DMG MORI’s journey in India? A. We have a two digit market share in India at the moment and we would like to double the same within the next three to four years. At present there are a couple of things we are looking at. We are currently focused on making more and more industry related solutions, for the same we have several centres of excellence in in Germany and Japan. For example, a centre of excellence for aerospace, centre of excellence for medical, we also installed a centre of excellence in Japan. We are planning to come up with a centre for automotive as well. Our company has plans to get the same concept into India in the next couple of months. In India, we see lot of very specific requirements for different industries and we would like to serve these requirements in a better way by having specialists on the engineering sites taking care of special requirements. By this we think we can increase our market share in each segment we are present in. We are not focusing on one segment in specific looking at the problems

MTW SEPTEMBER 2015

In an interaction with Machine Tools World, Dr. Jens Hardenacke, Asia Pac Head of DMG MORI talks about the company’s vision, Indian machine tool industry and latest industry trends.

COVER STORY www.mtwmag.com

was not because of the Indian ecomony or the Indian machine tool market. Now with the new atmosphere, new prime minister and this can do attitude, we hope that the Indian machine tool market will over perform the global machine tool market in the next 3 to 5 years.

faced during the 80s and 90s of the last century when the industry focused too much on the automotive sector. By being present in different industries and segments, by serving them in an adequate way we think, we put our eggs in enough baskets so that we can participate in the growth in each segment.

Q. How is the current scenario of the machine tool industry in India compared to the global industry? A. For us as a company India is a sleeping giant which is in a stand still for the last couple of years. While the world wide machine tool market has seen growth, specially in the US & Japan, India did not participate in the growth because of some elementary structural problem that it faces. But with the new government there is lot of hope that this will change dramatically. We expect huge two digit growth rate in three to four years where we somehow can compensate for the recent disappointing years. Even though we have seen some growth for our company, this

Q. Which are the key segments you are targeting? A. We want to have the biggest share in the automotive market in India and increase our market share in the aerospace sector. We also see potential in the medical sector where we want to further grow. The die mould market in India is also bouncing back. One interesting market that does not really exist at the moment but we want to build up, is the market for additive manufacturing, it has lot of potential for growth in India.

Q. Please describe some of the latest trends that you have witnessed in the recent times... A. I already mentioned about additive manufacturing, it basically fits into the concept of DMG MORI. We are a very strong R&D driven company and at present we are mixing different technologies, for example combining milling and turning, but we found some additional possibilities where we can combine for example laser technology with 5 axis, which means we have machines that are able to work kind of a 3D printer but also additionaly work as a 5-axis machine. In India, we see more and more customers moving from 3-axis to 3+2 axis

to 5 axis. We also see that in the turning industry more companies are undertaking complex tasks by switching from normal 2-axis lathe to turning machines with live tools. Simple milling operations are also done by turning machines . These trends have been there but the economic condition could not do justice to the same. But now in 2015-2016 we see big signs of these trends to gain momentum.

Q. How do you position your products in the price sensitive Indian market? A. First of all, we have a complete range of machines which include price sensitive and more simpler machines in 3 axis machining centre and turning machines. We also see that the Indian customers are expecting more, the requirements of the Indian customers with regards to accuracy is changing tremendously. Customers are no longer happy with the normal machines. We expect to see a rise in the demand for sophisticated machines.

Q. Any new products or solutions from the company? A. In India we are trying to streamline our product range, so we are bringing different product lines together. But we also launched new generation machines. We are not targeting any specific models at present, we are just continously working to improve our product line. Every year we bring around 30 - 40 new products to the market, which will also happen in 2015 and 2016.

Visions for the company... We see ourselves as the trend setter in the Indian market. At the moment I would say 10% of the customers are using 5-axis machines and 20% are using multi tasking machines. We would like to be the trendsetter in at least doubling the share of these technologies. We would like to accompany the Indian machine tool market in its strength and also make sure that with our national and international network we are able to get more indian customers to use these technologies.

MTW SEPTEMBER 2015

IN FOCUS

Delcam: Leading the way through excellence Q. Delcam has gained substantial market share in machine tool industry, please brief its journey from the inception & share some its milestones? Delcam has roots in Cambridge, when in 1965, Donald Welbourn, Director in Industrial Co-operation at Cambridge University, had the vision to see the possibility of using computers to assist pattern-makers to solve the problems of modelling difficult 3D shapes. We take 3D modelling for granted. In 1965, only crude 2D drawing systems were available using terminals linked to large main-frame computers. Initial work at Cambridge was sponsored by the Science Research Council but finding money to support the development was a constant problem for Donald Welbourn. In 1973, Donald persuaded his friend Lord Caldecote, then chairman of the Delta Metal Group and an ex-Cambridge engineer, to send Delta graduate engineer, Ed Lambourne, to Cambridge to work on the development of the software, which had been christened DUCT. The link between Cambridge and Delta Metals ultimately lead to the transfer of the system into industry. In 1974, Donald obtained additional sponsorship from Control Data in Europe in the form of access to its powerful time-sharing computing resources. Control Data offered DUCT initially on its time-sharing bureau service, most successfully to two of its largest German customers, Volkswagen and Daimler Benz. In 1982, mini computers with much more power at lower cost started to appear. This was a major step forward and, by 1984, the technology began to be competitive with traditional methods in many more applications. For many years, aircraft had been designed using computers but now it was becoming possible to economically design saucepans and other domestic products with complex 3D shapes using a computer. When Donald Welbourn retired in 1983,

MTW SEPTEMBER 2015

in 1991 and moved to a new purpose-built DUCT development continued both at building in Small Heath, Birmingham, in Cambridge and by the small team estabOctober 1991. lished at Delta in Birmingham. By 1984, Until then, DUCT had remained the the Birmingham team was larger than that company’s sole program. However, in at Cambridge and the unique features of 1993, Delcam introduced its first new DUCT began to be recognised. It was one software, ArtCAM. This was a different of the very few systems developed from type of software aimed at artistic applicathe beginning to design and machine tions rather than the engineering indusproducts. Indeed, Donald Welbourn had try. It subsequently became popular in a arranged the first public display of comrange of industries including signmaking, bined CAD and CAM technology at the woodworking, engraving and jewellery Machine Tool Exhibition held in Olympia, manufacture. London, during June 1972. The equal Overseas activities had continued to emphasis on design and machining made develop in the later years DUCT different from its competitors and within the Delta Group this was appreciated by the users. Most but this was exother systems had developed 2D panded significantly drafting first, followed by 3D modelafter the company ling with machining added later. became independSince 1977, the demonstration ent. There was a activity in Birmingham had gradustrong emphasis on ally been developed with additional forming subsidiaries machine tools being installed and a and joint ventures in sub-contract programming service the most important being added. This was now a separate countries, incommercial activity, Deltacam Systems Ltd, which by 1985 employed 15 people. This direct practical experience was very helpful in defining customers’ needs of the software and in testing new developments. In 1989, Deltacam Systems Ltd was bought from the Delta Group in a management and employee buyout led by Hugh Humphreys, the Managing Director, and Ed Lambourne, Technical Vineet Seth Director. The comManaging Director – South Asia & Middle East, pany was renamed Delcam Ltd., UK, ASEAN Business Development Delcam International

Director, Delcam Professional Services Ltd., UK

IN FOCUS www.mtwmag.com

cluding a wholly-owned subsidiary in North America, to sell to the region’s massive manufacturing market. The success of its international business saw Delcam win the first of its six Queen’s Awards for Industry, with an Award for International Trade in 1991. Delcam has since won five more Queen’s Awards, for International Trade in 2005 and 2010, and for Innovation in 2003, 2004 and 2011. In July 1997, Delcam plc was floated on the Alternative Investment Market (AIM). In preparation for this, Delcam UK was established to focus on UK sales and customer support. The funds generated by the floatation were used to increase the size of Delcam’s headquarters in Birmingham, to recruit more staff to the development team, and to grow Delcam’s sales and marketing teams. The increased investment in software development allowed Delcam to develop a new range of stand-alone products to replace DUCT. The first of this new generation of software was PowerMILL, which soon became established as the world’s leading stand-alone milling software. It was followed by the PowerSHAPE CAD program and the PowerINSPECT inspection software.Despite being affected by the Asian economic crisis in the late 1990s, Delcam continued to increase its market share. By 2000, the company’s sales had grown to the extent that Delcam was ranked as the world’s leading specialist supplier of NC software and services by the US analysts, CIMdata. Delcam held its leading position for the remainder of its thirteen years as an independent company. In 2005, Delcam consolidated its position with the acquisition of the US-based CAM software specialists Engineering Geometry Systems, the developer of the FeatureCAM CAM software line. Introduced in 1995, FeatureCAM was the world’s first feature-based programming system. In the following year, Delcam further expanded its range of software with the acquisition of the business and fixed assets of another US-based company, International Manufacturing Computer Services Inc., the developer of the PartMaker suite

of CAM software. The PartMaker range includes the industry-leading applications for the programming of multi-axis lathes, PartMaker SwissCAM (for Swiss type lathes) and PartMaker Turn-Mill (for turnmill centres with live tooling). A third important addition followed shortly afterwards with the acquisition of Crispin Systems Ltd., one of the leading specialist suppliers of software to the footwear industry. This acquisition confirmed Delcam’s position as the world’s leading supplier of CADCAM systems to the industry. The expanded company continued to grow at a rapid rate. Having taken until 2004 to reach 10,000 customers, Delcam announced its 20,000th customer in 2007 and its 40,000th client in 2012. Delcam was acquired by Autodesk, Inc. on February 6th, 2014. Delcam now operates as a wholly-owned, independently-operated subsidiary of Autodesk. Autodesk, Inc. is a world leader in 3D design, engineering and entertainment software. It has more than 8,000 employees worldwide and is headquartered in San Rafael, California. Similarly, Delcam India too had very humble beginnings. After initially being represented by various well known technology companies like Wipro & EDS Technologies, Delcam set up direct operations in India in the year 2000. I was the first employee of Delcam in India and I started off with a small but highly competent team of four professionals as a branch office of Delcam International. In 2002, we registered as a private limited company and soon became a wholly owned subsidiary of Delcam plc. Delcam India has had a consistent growth since it was established. From a team of five to the current strength of 125, we have come a long way. In due course we have also set up 15 direct offices across India and are proud to have a - sales to technical staff ratio of approximately 1:4. Our success is largely due to our support & close collaboration with customers. As of date we have more than 3000 customers and counting, in the Automotive, Aerospace, Toolmaking, Energy, Consumer Goods and Woodworking domains – amongst others.

Q. Please brief us about company’s global reach & what are the global alliances that have been made in order to out-front the competition? Delcam has 300 offices across 80 countries. One of the most important reasons to have direct presence across the globe, is to maintain consistency in support, training and co-operation with technology partners. Long standing employees help build and maintain long term relations with customers and partners, which speaks volumes of stability of the company as far as knowledge capital is concerned. In order to keep ourselves well differentiated from competition, we have done many things that are viewed as trend setting in retrospect. As a company we have always believed that investing continually in research and innovation is the way forward – and to this effect, we still continue to invest a substantial amount (25% of our revenues) into further development of our products. We also work with many industry partners including - but not limited to - Machine Tool Manufacturers, Cutting Tool Manufacturers, Industry Clusters, Consortia etc., to develop innovative solutions in CNC machining, metrology as well as emerging trends like Additive Manufacturing & Robotic Machining. We have also been working regularly with Academia and Technology training centres to research new methods in NC manufacturing. All of the above factors have helped us engage with & address the practical aspects of our technology far better than our competition. The very fact that we have our own Advanced Manufacturing Facility in Birmingham allows us to try our software in-house before supplying it to customers. This added confidence and reliability of our software also make it a system of choice for many in the businessl.

Q. What are the market prospects for the Delcam products in India and how do you plan to position these products? In the CAD/CAM scheme of things, India is largely dependent on the Automotive sector for Manufacturing growth. As a re-

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IN FOCUS sult, Toolmaking industry tends to be one of our largest focus areas, followed by the Aerospace segment. Packaging, General Machining, Medical Component Machining, Woodworking are other areas of focus which have been growing steadily in the past 5 years. Aptly, we have different products for different markets and market requirements. PowerMILL, is Delcam’s core 3, 4 and 5 Axis milling product, a stand-alone CAM system that produces NC toolpaths from CAD models quickly. It is extremely powerful, yet easy to use, and generates roughing and finishing toolpaths which optimise the productivity of CNC machine tools, while ensuring the highest quality machining of models and tooling. Delcam has been at the leading edge of High Speed Machining technologies for many years, helping customers such as Magna Automotive, TATA Group and First Auto Works machine components in the shortest possible time. PowerMILL is used in the following industries – aerospace, automotive, energy, electrical appliances, footwear, ceramics, packaging, toys and sports equipment. PowerINSPECT is the world’s leading hardware-independent inspection software. It can be used with all types of measuring devices, including all major makes of CMM, as well as with portable measuring equipment and machine tools. It provides a single platform for all inspection needs, boosting flexibility and minimising training costs. PowerINSPECT is used in the following industries – aerospace, automotive and energy. PowerSHAPE, Delcam’s Tribrid Modeller, provides a complete solution for both product design and toolmakers. Whereas designers are primarily concerned with the design of a finished product, often ignoring the features required for manufacturing, mold and toolmakers require a complete model. It is also a complete point data manipulation solution, enabling engineers to quickly and accurately bridge the gap between the physical and digital world. PowerSHAPE is quick, simple and interactive, offering even casual users the power to quickly solve engineering

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problems, from copy milling to feeding free form organic surfaces into the design process. PowerSHAPE Pro places Reverse Engineering in the hands of designers by offering a CAD based approach to capturing the design intent of a part or tool. PowerSHAPE is used in the following industries – aerospace, automotive, energy, electrical appliances, footwear, ceramics, packaging, toys and sports equipment, jewellery and signmaking. ArtCAM is a unique software program designed to produce decorative products directly from 2D artwork quicker than you ever thought possible. It can output to over 350 machine tools, enabling one to choose the right machine for their business. ArtCAM is used by 1000’s of users, worldwide, across a vast range of industries, successfully enhancing their product ranges and their profits. ArtCAM is used in the following industries – automotive, footwear, ceramics, packaging, jewellery, woodworking and signmaking. FeatureCAM offers the ultimate in programming automation for production machining.Introduced in 1995, FeatureCAM was the world’s first Windows-based and feature-based milling system. The product range has grown significantly to include turning, wire-EDM, mill-turn packages and feature recognition for imported CAD files. FeatureCAM is used in the following industries – aerospace, automotive and consumer goods. PartMaker SwissCAM is a patented system that defies comparison in automating the programming of Multi-Axis, Sliding Headstock Swiss-type lathes. PartMaker applies a Patented Visual Programming approach with “divide and conquer” programming strategy to simplify the programming of CNC Swiss-Type Lathes. The software helps the operator break a complicated part surface into a set of planes or faces. Machining tasks, such as turning, plane milling and cylinder milling are carried out separately for each face in an intuitive manner. This software is typically is used in the medical and electronics industry. Crispin FootwearCAD suite is a

PC-based system which is made up of several software modules. Each module can be used independently of the others and combined give a full Shoe Design to manufacturing solution, including a comprehensive production instruction system. CRISPIN provide the only complete footwear CADCAM solution that is designed to help speed up footwear design and manufacturing processes and reduce product time to market. CRISPIN offers a comprehensive, powerful, yet easy-to-use footwear design and manufacturing solution that requires minimal training. This is majorly used in the Footwear and Medical (orthotic & orthopaedic) industries.

Q. Can you brief us about the marketing strategies that were applied in order to stand out in the competition of the industry? Delcam has always tried to lead the way in our every offering. Whether it is the speed and efficiency of our CAM products or the innovative methods of our artistic CAD/ CAM product or the versatility of our tribrid modelling & metrology products, we have been the fore runners in innovating. Alongside this innovation, we have always believed that we need to partner with our customers and associates in order to educate the market about the innovations that we are working on and their subsequent benefit to the industry. We have made every effort to showcase our technologies at seminars, technology workshops, trade fairs, academic conclaves etc. Events like our European & Asian Technical summits showcase developments in our products in the previous year to journalists, academicians, technical partners and participatingcustomers. We also have a dedicated website www. delcam.tv that runs on-demand videos of customer & partner testimonials as well as success stories. To compliment these, we also have an on-demand learning zone for customers, where interactive video lessons demonstrate technical innovations that help users and managers in being more efficient. We also work with leading maContinue on page no.28

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MACHINE TOOLS WORLD | 27 | September 2015

IN FOCUS Continued from page no.26 chine tool partners during trade shows to demonstrate interesting case-studies –live on their machines. This practical exposure helps potential prospective customers in making on-spot decisions about commercial purchases and it leaves with a lasting impression of our collective capabilities.

Q. Brief us about the R&D and Quality policy for your business? While this question is more appropriate for manufacturing businesses, Delcam does follow a strict quality policy for software development. Keeping software bugs to a minimum by world-wide testing through application engineers and the practical implementation of our software in our Advanced Manufacturing Facility in Birmingham, we ensure that we don’t treat our customers as testing sites – which is what most others end up doing eventually. As far as the R&D policy goes, both Delcam and Autodesk have firm belief that increased investment in R&D as well as innovation will help us in being industry leaders – thereby making sure that our customers are more likely to succeed in their business by using our software and services.

Q. What are the key technological trends that are driving your industry? The CAD/CAM industry, as I had mentioned a few years back, is currently undergoing consolidation. A very big reason for this is that CAD/CAM software will not continue to be used as they are currently being used in the near future. Manufacturing technology is undergoing many disruptions and CAD/CAM needs to be in a position to support any changes that result out of this. The key technological trends in our industry currently are Multi-Axis & Multitasking machining, Robotic Machining, Bespoke process automation, Unified manufacturing process, Flexible manufacturing systems and Adaptive manufacturing. A new and upcoming trend would be that of 3D printing or additive manufacturing and it holds a lot of promise for high value component manufacturing such as those

MTW SEPTEMBER 2015

in Aerospace. We are also looking at beyond these trends ahead into the future. Autodesk’s Future of Making Things is a good example of how we as an organisation are laying the foundation for integrated and smart manufacturing methods connected via IoT amongst others.

Q. Could you brief us on Indian & Global perspective of machine tool manufacturing industry? What are the distinguishing factors? The biggest differentiating factor between the global perspective and Indian perspective of the machine tool industry is Innovation. Where global machine tool companies look at expanding the envelope, many Indian companies are still trying to make “similar” products. There are a few Indian companies that are an exception and are on par with global manufacturing innovations, but the former are a larger crowd. Also, there is a big focus on high precision machine tools as also the reliability of such machines by Machine tool manufacturers outside of India – very specifically in US, Europe & Japan. The positive side is that there is a huge potential for growth for Indian machine tool manufacturers and they are currently gearing up for this.

Q. Please comment on the current machine tool scenario in India? On the commercial front, it is a field day for most Indian machine tool manufacturers due to the parity in dollar exchange rates. Save a handful of well known companies, most machine tool manufacturing companies in India are on their growth path now and are in the learning phase. They are now focussing more on quality issues, reliability and stability issues amongst others. This will have a positive impact on their brand in the near future.

Q. In your opinion how can the Indian machine tool industry become globally competitive? In order to be globally competitive, Indian machine tool manufacturers need to offer the best quality at affordable rates, deliv-

ered quickly and followed up closely by post-sales support. Maintaining delivery timelines, product service & support should be the focus at the moment. Since this state is true for all, the only thing that would set an organization apart is its ability to not just supply... but to adequately support customers as well. In addition to this, it is a great time to “educate” the market on “technology of the future” - as that would help companies get branded in the right perspective. Also a great time to “Collaborate” with industry associates/partners that have similar synergies and provide a unified solution system to the customer. We should make good use of the Make-in-India campaign to launch a new revolution which will make a positive impact on customers buying Indian machine tools.

Q. How do you perceive the future of the Indian machine tool industry? The future of the Indian machine tool industry is bright. The IMTMA’s commendable efforts in unifying manufacturers under a single umbrella, providing training and testing facilities at various centres across the country as well as sharing best practices through international forums will certainly ensure that quality and productivity will get a boost in the years to come. Also with the emphasis on training, young engineers are being groomed to take on the challenges in the industry and I’m sure that they will be armed with better knowledge through training and experience of their peers alongwith technological advancements in computer science to conquer these challenges.

Q. What is your vision for Delcam? Delcam is a company with a rich culture and knowledge capital. As part of the larger Autodesk organisation we look forward to contribute our experience and knowledge to the bigger picture – Future of Making Things.

TECH TRENDS www.mtwmag.com

Recent developments in metalworking fluids By Ashok Kumar With the growing rate of industrialization, metal working fluids, commonly known as cutting fluids, continue to be extensively used in machining industries even after the development of advanced processing techniques such as MQL and dry machining.

etal working fluid (MWF) is the name given to a range of oils and other liquids that are used to cool and/or lubricate metal workpieces when they are being machined, ground, milled, etc. MWFs reduce the heat and friction between the cutting tool and the workpiece, and help prevent burning and smoking. Applying MWFs also helps in improving the quality of the workpiece by continuously removing the fines, chips, and swarfs from the tool being used and the surface of the workpiece. Swarfs are the small pieces of metal removed from a workpiece by a cutting tool. With the growing rate of industrialization, metal working fluids, commonly known as cutting fluids, continue to be extensively used in machining industries even after the development of advanced processing techniques such as MQL and dry machining.

The mechanics of metalworking

The mechanics of metalworking which governs the requirements for metalworking fluids includes (i) the bility of the fluid to provide a layer of lubricant to act as a cushion between the workpiece and the tool, in order to reduce friction, (ii) functions as a coolant to reduce the heat produced during machining or forming, (iii) prevent metal pick up on both the tool and workpiece by flushing away the chips as they are produced, (iv) produce the desired finish on an accurate piece-part. The impetus in the days of the industrial revolution, is to machine or form part

at the highest rate of speed with maximum tool life, minimum downtime and the fewest possible part rejects (scrap), all while maintaining accuracy and finish requirements, which can only be achieved by metalworking fluids properties. In metalworking processes, the use of mineral, synthetic and semi-synthetic cutting fluids have gained widespread acceptance. However, the harmful effects and high risk of life threatening occupational hazards to the machinists as well as causing environmental degradation is discouraging to continue its use in the near future. As mentioned above, MWFs are primarily used for three reasons â&#x20AC;&#x201C;viz; to remove heat during machining operation, to provide lubricating effect and to facilitate faster chip removal from the machined zone. While MWFs enhance the tool life and reduce the cost of machining operation, it is posing a very serious threat to the health and safety of machinists as well as to the environment. As a result, there is tremendous pressure from global energy authorities and environmental protection agencies to develop bio based alternatives or any other alternative to the presently cutting fluids. It has also gained worldwide importance, making green manufacturingâ&#x20AC;&#x201C;a philosophical process. The entry and dominance of new, modified, cost effective petroleum and synthetic chemical based cutting fluid has still worsened this condition. A study conducted by the Occupational Safety and Health Administration (OSHA) agency reveals that the detrimental effects of

the conventional lubricants, till date, has given rise to sixty three identifiable health hazards such as skin infection, allergy, acute respiratory disorders etc. Another major problem associated with this, is the disposal of cutting fluids to the environment. The discharge of these nonbiodegradable cutting fluids can widely affect the environment due to hazardous metal carry-off, reduction of nutrients in the soil and oxygen depletion. Research & Development

Research and development efforts are going on throughout the world to find metal-working fluids that eliminate these problems. One proposed solution is to develop a cutting fluid from microalgae oil. Although there are a large number of vegetable oil based cutting fluids available in the market, the sustainability of its production is questionable due to factors such as farm land utilization where food crops are cultivated and soil fertility depletion. The susceptibility of MWFs to biological contamination and the potential for this to lead to health risks associated with bio-aerosols and infection from hazardous microbial species calls for new technology to detect microbial growth in real-time. The fast response is especially important since microbial outbreaks can occur faster than dip-slides can detect harmful microbial species. In the future, we believe that applications of flow cytometry will offer the opportunity to conduct real-time analContinue on page no.32

MTW SEPTEMBER 2015

TECH TRENDS

Continued from page no.29 ysis of microbial species and total biomass load. These challenges have encouraged researchers for the development of a more sustainable bio based alternative. The use of algae based third generation biolubricants allows effective utilization of industrial waste water and sewage sludge material, which is otherwise hazardous to the aquatic fauna when discharged to the surrounding environment. Minimum quantity lubrication (MQL) techniques represent another growing class of EALs (environmentally adapted lubricatns). MQL typically involves sprays of compressed air and a small amount of oil to provide the function of a MWF without the large volumes of aqueous waste. However, air is an inefficient coolant and today’s oil-in-air MQL systems are only suitable for mild machining operations that do not require significant heat removal. Therefore research is currently focused on developing new approaches that extend the reach of MQL to more intense machining processes. MQL technologies are relatively new and therefore face technical and economic barriers to implementation. They require new delivery systems dissimilar to those used for aqueous systems. Pilot-scale implementation has shown that MQL systems are less expensive to operate but require significant capital investments in both infrastructure and expertise. Unless environmental and health costs are considered, many companies have considered these costs too high to warrant switching from current systems. Still some manufacturers are making significant investments in MQL due to cost savings and higher performance, as well as for environmental and worker health reasons. Several other large OEM and supplier companies are currently following suit. The environmental, health, performance, and economic benefits of switch-

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ing from water-based systems to gasbased MQL systems have been observed in industry. The cost savings mostly arise by eliminating major infrastructure components in the plant, which represent a significant fraction of water-based MWF system costs. This is important since life cycle MWF costs can represent 10-17% of metals manufacturing costs. Delivery of minimum quantities of lubricants using a spray of air (also called near dry machining) reduces purchase and operational costs while dramatically reducing energy consumption at the MWF system level. MQL systems are even claimed to increase safety and operator morale, largely from the elimination of mist and other oily waste associated with flood delivery of water-based MWFs. To date however, MQL has only been adopted on a limited basis because most workers are not familiar with how to design and implement MQL systems. Technical questions also remain about how to achieve sufficient cooling using MQL in challenging machining operations involving advanced materials. Some form of contaminant control and chemical addition is almost always performed in recirculating MWF systems, driven by costs of MWF acquisition and disposal. In an ideal MWF system, such control systems would achieve a perfect separation of contaminants and return the MWF to its “as new” state. However, contaminant removal on its own cannot address issues such as accumulation of hardness ions, evaporation, pH reduction due to microbial growth, and loss of surfactants. Therefore, even under ideal separation, direct chemical maintenance and biological control is required to extend the life of the MWF. Microfiltration is a membrane-based separation technology that can not only remove microorganisms, but can also remove contaminant particles and free oil from MWF to produce a high quality

recyclate. A major difference between conventional filtration and membrane filtration is that conventional filters operate by capturing particles within a filter matrix, and the filters cannot be regenerated after use. Membrane filtration is typically performed with filtration tangential to the channels of bulk fluid flow. This crossflow mode of operation discourages the accumulation of particles within the filter matrix, and the separation takes place at the surface Membranes can be cleaned and re-used for long periods of time, and essentially indefinitely for ceramic membranes. Therefore, rather than filter clogging with contaminants, the principal limitation to high filtration rates in microfiltration and ultrafiltration is the physical-chemical interaction of MWF ingredients with the membrane surface. Membrane filtration processes, while challenging, have proven to be able to restore the MWF to “good as new” condition. For instance, research has demonstrated the technical feasibility of using ceramic microfiltration membranes to supplement or replace biocides and other treatment technologies as a means to control MWF contamination and create a recycled MWF indistinguishable from new MWFs. However the primary limitation to wider application of membrane filtration technology is its sensitivity to MWF formulation design, particularly to the selection of oils and surfactants and their application concentration. While we know how to design semi-synthetic MWFs to greatly increase their flowrates through microfiltration membranes, no commercially available MWFs have yet used this sustainable MWF design approach, even though it leads to more stable microemulsions regardless of whether they are recycled using membranes. This makes membrane filtration as an approach to improve the sustainability of MWF systems less profitable than it should be.

TECH TRENDS

KREBS & RIEDEL : Grinding Perfection for Every Process

REBS & RIEDEL is a family owned company and has been in operation in Bad Karlshafen Germany since 1895. With over 190 dedicated employees and an annual turnover of â&#x201A;Ź21 million is one of Germanyâ&#x20AC;&#x2122;s leading manufacturers of advanced grinding wheels. An export share of approx 40% demonstrates the international orientation of the company with exports being a major part of their sales programme.

Products include conventional grinding and cutting wheels using corundum and silicon carbide abrasives. Super abrasive (CBN and diamond) tools with a vitrified bond have been manufactured with ever rapidly growing sales since 1985. The production of grinding wheels takes place on modern machinery and profiling of the grinding wheels on the CNC machines PM280T & PM550TC with automatic tool change manufac-

Grinding Wheels in Vitrified Bond

MTW SEPTEMBER 2015

tured by M/s Burri Werkzeugmaschinen with the very latest profiling techniques. The process and the organisation of production guarantee the highest standards of quality to their customers concerning the steady structural property and the tightest hardness tolerances. The grinding wheel compounds are based on our innovative MULTO vitrified bond system and, in conjunction with the grinding media used (highgrade aluminium oxide, micro-crystal-

TECH TRENDS www.mtwmag.com

line sintered aluminium oxide and the new aluminium oxynitride), guarantee low thermal effects on the workpiece, good retention of profile, and cutting ability with high dressing cycle speeds and high efficiency. We are certified in accordance with ISO 9001:2008 and produce the grinding tools in accordance with the internationally valid standards EN, ANSI and JIS. KREBS & RIEDEL is member of the GEAR RESEARCH CIRCLE of the Laboratory for Machine Tools and Production Engineering (WZL) at RWTH Aachen University (Germany). Gear Grinding wheels offered by Krebs & Riedel:

The range held in stock includes grinding wheels in white high-grade aluminium oxide and sintered aluminum oxide. Due to their selective porosity and grain compound, the grinding wheels guarantee a cool grind with high profile and abrasion resistance. Most recently, the application of dressable vitrified CBN grinding wheels to gear grinding has also intensified. For this purpose, KREBS & RIEDEL can also

offer you a product program that we are continuously developing and perfecting. Gears are among the most important machine elements in the construction of transmissions, vehicles and machinery. The requirements placed on these products in terms of power transmission or running smoothness continue to rise steadily. Grinding is therefore one of the most important methods for fulfilling these high quality demands. The grinding wheel dimensions are specified by the grinding machine systems being used or by the particular task. Working speeds lie between 40 â&#x20AC;&#x201C; 63 m/s, on the newest machines even as high as 70 â&#x20AC;&#x201C; 80 m/s. White high-grade aluminium oxide, special aluminium oxide mixtures or sintered aluminium oxide mixtures are preferably used as the grinding media. KREBS & RIEDEL have been developing and producing aluminium oxideand silicon-carbide-based grinding wheels for more than 100 years, and CBN tools for more than 20 years. This experience and vision forms the basis for their ongoing innovation. Their service is driven by the determination to provide you always with the best possible solution for your tasks. Their sound knowledge of materials, processes and machinery enables their application technicians to advise and assist you with great precision, including in the planning phase. This they do using every means of communication that they and you possess, and at all times. Unusual cases are a challenge that the company particularly relish. If necessary, they will perform testing together with you until they have developed a solution that exactly meets your requirements. KREBS & RIEDEL in India is represented by the machine tool manufacturer Burri India Pvt Ltd Pune which is a subsidiary unit of Burri Werkzeugmaschinen GmbH & Co.KG Germany.

For more information, Website www.krebs-riedel.com

MTW SEPTEMBER 2015

TECH TRENDS

Plasma & Automated sheet metal cutting Q. What Is Plasma & Plasma Cutting?

Plasma is a state of matter like a solid, liquid or gas. Adding heat to material causes the molecules in it to vibrate or move more quickly. When a solid is heated, the molecules start to vibrate more vigorously. Eventually the solid turns to a liquid and the molecules actually move around and collide with each other. As more energy or heat is added the motion becomes faster and more vigorous still and eventually the molecules move so quickly and collide so energetically (violently) that they separate and form a gas. If still more energy is added to the gas the molecules travel faster and thus collide with each other more violently and the gas changes to a plasma. An atom consists of a positively charged core and is surrounded by negatively charged electrons. The molecules in a gas can be either individual atoms or collections of such atoms that are very closely connected. When plasma is formed, the collisions between the molecules eventually get so violent that,

MTW SEPTEMBER 2015

at first, the molecules will break up into the individual atoms and eventually some of the atoms will separate from, or lose, some of their electrons from their outer shell. The gas changes to plasma when a critical number of atoms lose electrons. When kinetic energy in a gas is increased, some of the electrons are freed from the atoms outer shell and plasma is formed. When an atom releases electrons it becomes an ion. When enough energy is added to a gas that there is a balance between the number of atoms releasing electrons and those naturally recombining with free electrons, the gas is said to be ionized. This ionized gas is plasma. In plasma, there is an important fraction of ionized atoms at any given time, so there are always ions and electrons that are separate and free. The energy input into the gas has to be ongoing otherwise the gas will eventually cool enough that the electrons will mate back with the ionized atoms. When this happens, the plasma returns to a gas state. Plasma is a thermal, very hot, electrically conducting gas, from positive and negative ions, electrons and excited and neutral atoms and molecules. In physics, we often talk about the 4th state. As the plasma gas a monatomic argon or diatomic hydrogen, nitrogen, oxygen gases and air can be used. The plasma gas is ionized and dissociated by the energy of the plasma arc. By a recombination of atoms and molecules outside the plasma jet of the system, plasma rapidly releases the received energy and enhances the effect of thermal plasma beam on the machined object. Plasma jet is usually additionally cooled with water. This allows the energy density of the plasma beam reach up to 2106 W/cm2. Due to the high temperature, the plasma

TECH TRENDS www.mtwmag.com

expands and flows with supersonic speed in the direction of the machined object (anode). In the plasma arc, temperatures rise to 30 000 Â° C; in conjunction with high kinetic energy of the plasma beam, a very high cutting speed can be used, depending on a material and a thickness of all electrically conductive materials.For the cutting process, a pilot arc between the cathode and the nozzle is first ignited by means of high voltage. This weaker energy pilot arc prepares partially, by ionizing, the path between the plasma torch and the machined object. By touching of the pilot arc and the machined object (cursory incision and cursory piercing) the power of the main arc is automatically increased.All kinds of steels, brass, aluminium, copper, stainless steel and other metal alloys can be cut. Road to plasma-cutting automation

Fabricators note several reasons for considering the move from manual plasmaarc cutting (PAC) to automated cutting. A basic reason to automate is simple: manufacturers need quality cut parts at a reasonable price and at high rates of productivity.

ty, and the machine produces good, clean cuts. Further, a dramatic reduction takes place in the amount of cut-edge finishing. Quick Switch from Automated to Manual

While most users largely dedicate their PAC system to automated cutting on its table, arrangement can be made to quickly switch to manual cutting, by a quick-disconnect torch feature. This allows the user to efficiently switch from the setupâ&#x20AC;&#x2122;s 180-deg. mechanized cutting torch to a 70- or 90-deg. manual torch. Software automatically detects the selected torch to switch between automatic and manual modes. Technical Tips For Better Plasma Cutting

Over the years, the air plasma arc process has been greatly refined so that plasma provides good quality cutting, gouging and piercing at very high speeds for a much lower cost. This cutting process is truly perfect for many industries. Plasma arc cutting is a process where an open arc can be constricted by passing through a small nozzle, or orifice, from the electrode to the workpiece. Although the technology behind the plasma arc may seem complicated, the process itself is very easy to learn and perform.

Purchasing the right system

Facilitating the transition to automation requires a number of decisions. First, purchasing the right type of automated PAC setup needs a complete understanding of how the part requirements would apply to automation in terms of money. High-precision dual-gas cutting systems cost many Lakhs of Rupees, often accompanied by an equally expensive controller. While these setups provide very high cutting speeds, it is difficult, if not impossible, for a small fabricator to justify such an investment. Automated plasma table

For cutting the same shape multiple times, using an automated plasma table saves hours of post-cut grinding, which enables Cornfield Customs to maintain price competitiveness. The move to an automated system increases productivi-

Plasma - a cut above oxyfuel

While oxy-fuel was the most common method of cutting carbon steel in the past, plasma cutting is gaining favour because it provides numerous advantages. Plasma cuts faster than oxy-fuel; a pre-heat cycle is not required; the kerf width (the width of the cut) produced is small; and, it has a smaller heat-affected zone, which prevents the surrounding area from warping or damaging paint. In addition, plasma cutting can be used on any type of electricityconducting metal (the oxy-fuel process cannot cut stainless steel or aluminium). Moreover, plasma cutting is a cleaner, less expensive and more convenient method of metal cutting because clean, dry air is used for most plasma cutting applications. A properly installed air plasma arc

MTW SEPTEMBER 2015

TECH TRENDS cutting setup is safer than oxy-fuel gas cutting. This is because there is a chance of flashbacks and the danger of flammable gases in exposed hoses with oxy-fuel torches. Plasma cutting is easier for hole piercing due to the plasma jet. The plasma jet is the swirling force of air around the arc, in combination with the arc attachment, which focuses the heat into the metal. In addition, plasma arc piercing does not require the metal to be preheated, which saves production time. The plasma jet also makes for a better choice when cutting stacked materials. Plasma cutting applications

The plasma process can be used to cut any material that is a good electrical conductor. Unlike chemical cutting, it can be used on any metal for applications such as stack cutting, beveling, shape cutting, gouging and piercing. Plasma cutting can be successfully performed on a variety of material sizes as well. Plasma can be used to cut anything from thin gauge aluminium to stainless and carbon steel up to several inches, depending upon the power of the cutting machine. Setting-up a plasma arc cutter

To set-up a plasma arc cutter, simply hook-up the compressed air to the plasma cutting unit. Three choices of air are available: bottled, in-house air supply or a small air compressor. Most plasma units have a built in regulator to maintain the proper flow of air for the system. To set the amperage, or heat, of the cutting unit to the proper level, make a few practice cuts with the amperage set high. You can then adjust the amperage down according to your travel speed. If the amperage is too high or your travel speed is too slow, the material you are cutting may become hot and accumulate dross. Travelling at the right speed and using the right amount of heat will produce a very clean cut with less dross on the bottom of the cut, as well as little or no distortion to the metal.

MTW SEPTEMBER 2015

Operating a plasma arc for cutting

Begin cutting by placing the torch as close as possible to the edge of the base metal. Press the trigger to initiate the pre-flow air; the pilot arc will then light, followed by the cutting arc. Once the cutting arc starts, move the torch slowly across the metal. Adjust your speed so that the cutting sparks emerge from the bottom of the metal. You should be able to see the bottom of the workpiece and the arc should be directed straight down. If the sparks are not visible at the bottom of the plate, you have not penetrated the metal. This is because your travel speed is too fast, you have insufficient amperage, or the plasma stream is directed at an angle. At the end of a cut, angle the torch slightly towards the end of the cut or pause briefly to completely finish the cut. The post flow air will continue for a short period of time after the trigger is released to cool the torch and consumable parts, however cutting can be resumed immediately. Operating a Plasma ARC for Gouging

Plasma arc gouging can be accomplished by placing the torch at approximately a 40-degree angle to the base metal. Press the trigger for the pre-flow air and pilot arc. When the cutting arc ignites, form the arc length a short distance from the workpiece. Further adjust the arc length and travel speed as needed. Do not gouge too deep, as several passes may be needed to accomplish the necessary gouge. Again, after releasing the trigger, the post-flow air will continue for a short period of time, but gouging can be resumed immediately. Operating a plasma arc for piercing

Piercing - creating a hole - can be performed by placing the torch at a 40-degree angle to the workpiece. Press the trigger. When the cutting arc is initiated bring the torch tip to a 90-degree angle and the arc will pierce the base metal. A good rule to follow is that you can pierce up to 1/2 of the maximum cutting thickness provided by the machine.

MACHINE TOOLS WORLD | 39 | September 2015

• ExactDress™ Dressing Control

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• AEMS Acoustic Emission Monitoring

• ExactControl™ Grind Cycle Management • SBS In-Process Balancing

Grinding Process Innovation

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TECH UPDATE

JUNKER Group exhibits new grinding technologies at the EMO

â&#x20AC;Śor grinding a step drill blank made of carbide Unveiled for the first time in Europe: Grinding machines from ZEMA

The JUNKER Group takeover of ZEMA in March caused quite the stir in the grinding sector. At the EMO MILANO 2015 (October 5th â&#x20AC;&#x201C; 10th), the grinding machine manufacturers will be exhibiting together for the first time in Europe: ZEMA will be demonstrating a cylindrical grinding machine for shaft grinding and JUNKER will be featuring no fewer than three different grinding machines at its Booth N06 in Hall 14: for grinding rolling elements, tool blanks and internal threads on ball screw nuts.

MTW SEPTEMBER 2015

screw nuts - with a minimal space requirement and short cycle time. Grinding rolling elements using centerless plunge-cut grinding

The JUPITER 125 centerless cylindrical grinding machine ensures the perfect concentric grinding of cylindrical workpieces, using either corundum or CBN depending on the application. Centerless grinding enables high metal cutting output coupled with a long grinding wheel service life, allowing for substantial production advantages in large volume processing.

Grinding internal threads on ball screw

Consistent quality during the cylindrical

nuts

grinding of tool blanks

Grinding specialist JUNKER has radically reduced downtimes on the JUMAT 1S/30 KGi by integrating the longitudinal and radial positioning fixtures in the loading gantry. This move has enabled the grinding machine to achieve a good surface quality finish in the internal thread of ball

The JUNKER Lean Selection speed is able to realize several grinding operations on tool blanks in a single clamping set-up. One or two high-performance grinding spindles mounted at the swivel-action wheelhead (B axis) work using the QUICKPOINT grinding method. An in-

TECH UPDATE www.mtwmag.com

The JUNKER Group was present at the last EMO in Hanover, unveiling a range of innovations to the grinding industry

genious automation concept ensures short loading times. Grinding crankshafts with corundum

At the EMO MILANO 2015, ZEMA will be demonstrating how its Numerika GH-1000 machine grinds the flange and journal of crankshafts with the utmost precision. This durable cylindrical grinding machine, with its hydrostatic X and Z axis and hydrostatically mounted grinding spindle, is ideally suited for grinding an array of workpieces for the automotive industry such as cardan or transmission shafts. In addition, the operating element of the GH-1000 is extremely simple and convenient to use. 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 groundbreaking inventions since 1962. Today,

At the JUNKER Group booth, visitors will be able to witness a number of live demonstrations of grinding applications, including the grinding of internal threads on ball screw nuts…

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 ultraprecise metal grinding is vital – predominantly in the automotive engineering and tool industries. ZEMA, founded in 1953, employs a workforce of over 80 and produces CNC grinding machines with corundum grinding wheels. The traditional Brazilian company draws on ingenious machine concepts for grinding transmission, turbocharger and cardan shafts as well as grind-

ing the flange and journal on crankshafts. Its customers come predominantly from the automotive engineering industry and its suppliers, as well as from tool building. ZEMA has been part of the JUNKER Group since February, 2015 and utilizes the Group’s worldwide sales and service network accordingly. LTA Lufttechnik GmbH is a technological leader in filtration solutions. The air flow specialists research, develop and manufacture filtration systems for industrial air purification. For more information, Website: www.junker.in

MTW SEPTEMBER 2015

TECH UPDATE

Customised CNC upgrade simplifies railcar axle grinding novel task-oriented HMI simplifies control of plunge grinding operations

comprehensive upgrade of classic high power centreless grinding machine tools is helping a leading railcar axle manufacturer to greatly simplify precision grinding operations on axle forgings. A key element of the project – which has been managed by APeC Integration Services, Inc – is the retrofit of customised CNC control based on NUM’s powerful Flexium platform. Based in Wattsburg PA, APeC is an electrical systems integrator specialising in upgrading machine tools with modern PLC and CNC control systems. Established in 1989, the company has built a reputation for enabling clients to maximise the longevity and performance of their

MTW SEPTEMBER 2015

machine investments. Key retrofit services include upgrading servo and spindle motors and drives, PLC integration and custom machine controls, and complete CNC replacement. The machine tools in this particular project are high capacity Landis centreless grinders, which utilise a dressable grinding wheel and a plunge grinding cycle to create precision profiles on railcar axle journals. During grinding, both the axle workpiece and the grinding wheel rotate in the same direction, which means that the two surfaces are moving in opposite directions at the point of contact, resulting in smoother operation. Once the machine is up to speed, the grinding wheel is fed

– or ‘plunged’ – into the workpiece and makes continuous contact with a single point along its length. The plunge action is controlled by a servo-driven axis grinding at several feed rates, with transition points monitored by in-process gauging. A builtin automated two-axis dresser system with a diamond tipped tool is used to dress the grinding wheel whenever necessary. This is the second time that APeC has improved the performance of these grinders with control systems based on NUM CNC kernels. The original machines were hydraulically actuated and equipped with tracer type wheel dressing systems. In the mid 1990’s, APeC performed a full Continue on page no.44

TECH UPDATE Continued from page no.42 mechanical and electrical upgrade on each machine that included retrofitting a modern CNC system and in-process gauging instruments. On that occasion, the company based the upgrades on NUM’s Power 1060, which at the time was regarded as one of most flexible and userfriendly CNC systems on the market. After a further 20 years’ full-time service in a busy production environment, the machines became due for another mechanical and electrical upgrade. APeC had supported the machines and worked closely with their operators throughout this period, during which time it had also developed a number of ideas for making the machines even easier to operate and more productive. The upgrade program offered the ideal opportunity to put many of these ideas into practice. To expedite machine upgrade and minimise the impact on its customer’s production schedules, APeC managed a threeway development partnership. All major mechanical re-design, hydraulic, lubrication, and geometrical rebuilding aspects of the project were handled by EURO Machinery Specialists, Inc., a company with some 45 years’ experience of refurbishing and modernising high value metal cutting machine tools. On the control side, APeC collaborated with NUM USA to develop

MTW SEPTEMBER 2015

a unique and intuitive human machine interface (HMI). This enables operators to learn how to use the machines very easily and quickly – even if they are unfamiliar with these types of grinders. Customer benefits include improved worker satisfaction, less need for training and increased machine productivity. According to Dave DeCoursey of APeC, “A key project goal was simplifying machine operation as much as possible. NUM’s open Flexium CNC platform provides the control flexibility and HMI customisation facilities that we needed to develop individual, task-oriented screens. The user interface is consequently now much more ergonomic. Most operations, such as offset calculations, calibration, dressing and automatic grinding cycle initiation, are now performed using single, virtual pushbuttons that are only displayed when appropriate.” Each machine upgrade uses several NUM products, including the CNC kernel, touch-sensitive operator panel, servo drives and motors. The Flexium CNC system uses EtherCat I/O communications, making it simple for APeC to implement an advanced plunge depth control architecture. The in-process gauging instrumentation previously used for this aspect of machine operation has been replaced by a linear encoder, which facilitates fast and accurate depth control, as well as providing real-time feedback to the operator throughout the grinding cycle. The main control screen features two large analog-style dials, supported by digital displays, which derive their input data from separate measurement probes located along the length of the axle journal, allowing the operator to monitor taper tolerance very easily. The client- and application-specific HMI software that APeC has developed for the grinding machine upgrade is task oriented. It uses individual screens that are tailored to the application, with clear context-sensitive functions that help to prevent human error. By using the Extended NCK Access (ENA) facilities of the Flexium CNC controller, each custom PLC-driven visualisation can control and

monitor the CNC functions directly. This form of control approach is specially useful for automated teach type functionality, such as guiding an operator through machine start-up and preparing for automatic cycles. For example, the start-up screen initially displays only the status of the CNC system and a single ‘Shutdown’ button. As soon as the CNC system indicates that it is ready, the start-up screen displays two additional buttons: Home Screen and Manual Operation. When the operator touches a displayed button and causes a change of screen, the software automatically alters the CNC mode accordingly and selects the corresponding part program if applicable. By confining the operator’s available options to just those that are appropriate at the time, the software helps to ensure consistent and efficient machine use. Another major advantage of this type of control approach, with extended access to the NCK, is that it can be used to help the operator with tool offsets and adjustments to part program dimensions. When the grinding wheel or dressing tool is replaced, the operator can manually position the tool on the desired surface of the wheel, access a password-protected screen and then simply press a button. The offsets are calculated and pushed into the dressing program automatically, using the ENA facility. This same facility allows the operator to alter dressing dimensions and sparkout setpoints simply by adjusting a value up or down – these are then pushed into the corresponding part program. Steven Schilling, General Manager of NUM Corporation in Naperville, Illinois, says, “The open architecture and advanced functionality of Flexium CNC systems enable engineering companies to implement innovative machine control solutions for retrofit or new machine tool projects. In this instance, APeC and Euro Machinery Specialists, with NUM’s support, have created a CNC retrofit that adds significant value to the customer’s existing manufacturing facilities.” For more information, Website: www.num.com

TECH UPDATE

Achieve “better than new” machine accuracy & extend machine life by advanced ballbar training Semiconductor industry supplier now understands its machine tool’s performance better than OEM service technicians. Ballbar data supports TPM and emerging SPC and OEE programs.

allbar testing is nothing new to those who use fleets of machine tools, including people like Wayne Ross and Jacob Hebbeler of Silfex Inc based at Eaton, Ohio, USA. Both have used ballbar analysis to maintain and enhance the accuracy of the plant’s 50+ machines for more than a decade. But, it turns out that experienced ballbar users can still learn a few new tricks that can be transformational to a business. After upgrading to a QC20-W wireless ballbar and taking Renishaw Advanced Ballbar course, TPM manager Ross and machine operator Hebbeler now use captured ballbar data to

evaluate machines, “super tune” them to better-than-factory accuracy and get longer life out of machine components. They have also changed the way the company proves out machines, schedules maintenance and evaluates the need for new machines. “We’ve done ballbar testing for years, but until we took the advanced ballbar course we weren’t making full use of the results,” said Ross. “Now we’re using the ballbar to qualify metrology, time our maintenance decisions, implement TPM and SPC, and even forecast machine life. It’s helping us make operational and capital equipment decisions in ways we never thought possible.” Unconventional processing with conventional equipment

Silfex’s machining application is like a military proving ground for machine tools, so machine diagnostics are a way of life. Its lathes and VMCs – primarily Haas and Mazak – use diamond tooling to grind and polish silicon and quartz for the semiconductor industry, resulting in glass-like debris and diamond particles forming an abrasive compound that wears out components in months. The 290 employee company is a rapidly growing division of Lam Research Corporation and has built a reputation as a premier single-source supplier of electrodes and silicon fixturing for Lam plasma etching chambers. These consumable parts support the etching

MTW SEPTEMBER 2015

TECH UPDATE www.mtwmag.com

hitting accuracies comparable to much higher-end machines. And, while highend machines are faster, we can only grind so fast. So, we don’t need ‘faster,’ just accurate.” Advanced ballbar training raises the bar for company’s machining capability

process in the manufacture of computer chips, and part values can be as high as $30,000. “We are one of the few companies in the world that can grow defect-free, single-crystal silicon to a diameter of 460 mm,” Ross explained. “We do start to finish manufacturing under one roof, which is important because the semi conductor industry requires 100 percent traceability on everything from the material source to the machined parts, and we have all of that under direct control,” added Ross. “For our customers’ requirements, this is a purchasing manager’s dream.” The plant is environmentally controlled and equipped with multiple clean rooms from class 10,000 to 100. “One speck of contamination can wipe out a lot of computer chips,” Ross stressed. Processing the silicon includes wire sawing, waterjet cutting, milling, drilling, grinding and lap polishing before inspection in metrology rooms with CMM and VCMM equipment. Parts then go to an on-site clean room for packaging. Production runs range from five to

100 pieces per setup and the required tolerances are typically ±0.001”, with some requiring ±0.0005”. Grinding silicon creates an extremely harsh machining environment. “We’re using conventional machines to do unconventional processing, and using ballbar diagnostics to stay on top of our machine capability in a high-wear application,” said Ross. “We use the ballbar to diagnose ballscrew wear every six months, but usually get called to test machines before that. The advanced ballbar training showed us how to determine if we can make machine adjustments or if it’s time to replace the ballscrews. This allows us to control downtime scheduling and maintain our accuracy as machine components wear out, rather than judging machine capability from the quality of finished parts. We run these machines hard, three shifts, five days a week, with quite a few long runs, and the grinding environment is tough on the equipment. I’m amazed at how accurate we can make these machines considering how rapidly the machining environment changes. Our VMCs are

Ross and Hebbeler came away from Renishaw advanced training with a much better understanding of their ballbar data and how to use it. Conducted at Renishaw in Hoffman Estates, Illinois, USA, the hands-on course lets participants practice setting up and running ballbar analysis on a variety of different machine tools in a learning lab. “I’ve been working with ballbars for 13 years and thought I knew my stuff,” said Hebbeler. “But after 10 minutes, I was learning new tricks. Among other things, we learned how to troubleshoot scale mismatch, which has helped us super tune our circular interpolation and extend the useful life of the mechanical parts of our machines. We also look at lateral play to gauge the condition of our linear guides.” “After the advanced class we concentrated on interpreting our numbers to see if there were more details we could control,” Ross explained. “Jacob has gotten really good at adjusting the backlash and reversal spikes, so we can get more life out of the ballscrews, which is our edge until we can get a service technician in. Sometimes we can do two or three adjustments and that buys us a lot of productive time to schedule when to take the machine offline for repair.” Accuracy now starts at ground level

Silfex uses ballbar diagnostics to determine a machine’s squareness, which is the prerequisite for analyzing backlash and reversal spikes. “Many machine shops overlook the effects of the floor, as we were, on machine level,” said Ross. “We are lucky our concrete is substantial enough to support all the weight we put on it, and we check and adjust the machine level upon installation. Once we set the level we can diagnose reversal

MTW SEPTEMBER 2015

TECH UPDATE spikes, backlash and scaling mismatch, which we didn’t know how to do before the class.” Ross & Hebbeler now handle machine levelling, largely because they can hit specs that some technicians have trouble achieving. “The two-tenths bubble servicemen can meet our requirements, but the five-tenths bubble guys can’t,” said Hebbeler. “Our levelling is so precise today that we often wish the levelling screws had a finer pitch on them.” After the training Ross and Hebbeler used their new knowledge to push the boundaries of machine accuracy. “Our goal on squareness was 0.000050”/ inch, and I decided we would try for 0.000025”/inch,” said Ross. “When I told Jacob he expressed doubt, but I showed him data that proved he had already achieved it three times prior.” Based on their success with the ballbar, Ross and Hebbeler are expanding their machine diagnostics. “The ballbar tells us about the foundation: the linear guides, the ballscrews and the truss bearings – the bottom end of the machine – that’s where mechanical tolerances are established and it also confirms

our metrology,” said Ross. “We’ve also started using some vibration analysis, and that tells us about the top-end of the machine which dictates finish. So, between the two, we are analyzing all the factors that affect our size and finish. We’d like to get into volumetric compensation testing with the ballbar. We currently test X and Y on VMCs, and X and Z on the lathes and have done full Y-Z testing in the past on a few machines but with volumetric testing we’ll also hit X-Z and I think we’ll be able to get what we need in the 220-degree sweep the ballbar is capable of performing.” No wire, no worry

Upgrading to the wireless ballbar simplified data collection, and made it safer, Hebbeler explained. “With the wired ballbar, I spent a lot of time babysitting a machine under test,” said Hebbeler. “I had to feed wire in through the back of the machine, and if I walked away for a few minutes I often came back to a twisted wire. I always had a nagging thought that any little tug on a wire during a test might skew the results. We don’t have those issues with wire-

less operation. I can set it up and go do something else until the test is complete. It’s also safer now that we’ve eliminated open-door testing.” Ballbar data opens doors for new programs

Silfex is now using ballbar data to establish thresholds in relation to its various processes and determine process capability. “We now have diagnostics to back up what we think is happening with our machines,” said Ross. “This data is being used for our TPM program, implementation of SPC and our future OEE (Overall Equipment Effectiveness) monitoring. Full SPC will allow us to move away from 100 percent inspection. We are also working to determine what will be the useful life of a machine based on capability, maintenance costs and consistent quality.” Even machine tool technicians are impressed with the expertise demonstrated at Silfex. “Some of them will say, ‘well, this machine is now as good as new,’ and we tell them we need it better,” said Hebbeler. “Their response is, ‘well then tell us what to do,’ and when we show them they ask how we did it. The advanced training provided us with knowledge that is tech-level and, in some cases beyond, so we have data to backup our thinking.” The data generated through ballbar analysis has even found its way to the company’s C-suite. “The executives at corporate now want to see a ballbar report every time a machine is qualified,” said Hebbeler. “This is filed with the machine documentation as part of our regular procedures between here and headquarters. Manufacturing keeps raising the bar and ballbar analysis helps us reach higher.” Ross added, “The world revolves around numbers and ballbar analysis is our magnifying glass to help make good business decisions.”

For more information, Web: www.renishaw.com/calibration

MTW SEPTEMBER 2015

TECH UPDATE

Additive manufacturing with a digital process chain in the Blok Group Investment in two laser melting systems from Concept Laser for a wide range of 3D printing components Lichtenfels (D) / Velsen-Noord (NL), 03/08/2015: Blok Group, from the Netherlands, a top level technical partner in Engineering, Prototyping, Production, Assembly, Industrial services, Project & Supply Chain Management and 3D-printing, is investing in two new laser melting systems from Concept Laser. They include an X line 2000R system, which combines the largest build envelope currently available with the latest multilaser technology for reactive materials. A new M2 cusing supplements the manufacturing range in the medium-sized system segment. Oliver Edelmann, Head of Sales & Marketing at Concept Laser: “We are delighted to have found an important strategic partner in the Netherlands in the Blok Group. A partnership of this kind offers the processing company an opportunity to combine materials expertise and new design approaches for 3D geometries with optimal system parameters. That allowed us to combine application requirements ideally with system and process engineering options.”

he Blok Group views itself as a trend-setter and innovator with a comprehensive range of services for developing and producing high-quality components and solutions for demanding industries, including the aviation industry with its high quality and safety requirements. The Blok Group’s development and manufacturing processes therefore comply with the AS 9100 C Aviation Standards, developed by the International Aerospace Quality Group (IAQG). Concept Laser’s systems come with the tools, which the Blok Group needs for QS and documentation, and provide valid data during the build process.

dual laser system in the X line 2000R, is based on two 1,000 watt lasers. The useful build volume also increased nearly 27% from 126 l to 160 l compared with the X line 1000R. In addition, the X line 2000R features a new sieving station that uses a quiet vibrating sieve instead of the tumbler sieve. The concept is incredibly compact, as the oversized particle container is now smaller, and has been integrated into

Big build envelope for big jobs

The new X line 2000R at Blok will be the first system of this scale in the Netherlands. With a build envelope of 800x400x500 mm3, the X line 2000R currently offers the largest build envelope for laser melting metals. Its heart, the

MTW SEPTEMBER 2015

The X line 2000R, with a 800x400x500 mm3 build envelope, uses a dual laser system in which each laser has an output of 1,000 watts.

TECH UPDATE www.mtwmag.com

Signing the deal: Jan Floor van Egmond, Director of Landré and Erik Blok, CEO of the Blok Group (from left to right) in the Landré showroom. Erik Blok: “Overall, the additive solutions offer diverse potential which cannot be achieved, or cannot be achieved satisfactorily with conventional machining strategies.”

the sieving station. The new sieving unit reduces the unit’s footprint – and its fully enclosed design keeps the surrounding area clean and tidy. The dose unit has also been redesigned. The dose chamber is now filled completely and fully automatically within one cycle. Erik Blok, CEO of the Blok Group: “Speed and volume are important requirements for high-quality, economical production. The benefits offered by the X line 2000R can also be seen clearly when compared with competing systems: It offers almost three to four times the build volume. Overall, the 2nd build module gives us high availability, 24 hours a day, 7 days a week for additive manufacturing.” The design of the X line 2000R system is also suitable for processing reactive materials. A new M2 cusing system by Concept Laser completes the range at Blok Group in the medium-sized machine segment. It has been redesigned compared with the previous model. The laser and the filter are also fully integrated into the system. The surface area of the filter has also been increased fivefold. Moreover the M2 cusing is fitted as standard with a water-submersible filter in order to guarantee safety when changing the filter. This system will be used in future to build medium-sized 3D

the local sales partner and Concept Laser is the system provider. Oliver Edelmann, Head of Sales & Marketing at Concept Laser, describes the partnership as follows: “We are delighted to have found an important strategic partner in the Netherlands in the Blok Group. A partnership of this kind offers the processing company an opportunity to combine materials expertise and new design approaches for 3D geometries with optimal system parameters. This allows us to blend application requirements perfectly with system and process engineering options.” Erik Blok adds: “This network allows us to operate in two directions: Redesigning existing products which until now have been built conventionally via machining, and manufacturing new products which are developed specifically for the opportunities that additive manufacturing offers as early as the design phase. Overall, the additive solutions offer diverse potential which cannot be achieved, or cannot be achieved satisfactorily with conventional machining strategies. Blok Group as a 3D printing center

M2 cusing as a compact solution in the medium-sized machine segment: The M2 cusing comes fitted as standard with a 20 m² filter that can be immersed in water, in order to guarantee safety when changing the filter. The filter surface area was increased fivefold compared with the previous model.

geometries, positioning Blok as a comprehensive service provider for laser melting metals in the Netherlands. Installation of the new capacity will start in August 2015 with the M2 cusing, followed by the X line 2000R in Q1 of 2016. Strategic partnership between Blok Group, Landré and Concept Laser

The investment in 3D printing is testimony to a strategic, long-term partnership between the Blok Group, Landré and Concept Laser. In the partnership, the Blok Group serves as the technical manufacturing service provider, Landré is

The Blok Group is head and shoulders above its competitors with its years of experience and expertise in manufacturing high-quality metal components. As a progressive and innovative company, the investment in additive manufacturing is an inevitable step towards the future. Erik Blok: “As a leading manufacturer in the Netherlands metal industry, we intend this strategic investment to drive our future-proofing forward. The Blok Group is known for investments in the latest manufacturing technologies. In the early 1990s, we were the first company here to invest in state-of-the-art lathes and milling machines. And now we are the first to purchase the most advanced system technology for additive metal manufacturing. Our goal is to maximize the value added for us and our customers and to make the most of the options offered by the process.” For more information, Website: www.concept-laser.de

MTW SEPTEMBER 2015

TECH UPDATE

High Insulation Gate-Drive Transformer to Control MOSFETs in Automotive DC/DC Power CVs The new GDAU series offers high insulation >3kV and supports double-transistors control in a reduced SMD package.

mbedded AC/DC and DC/DC converters are a growing technology in the automotive marketplace. For EV and HEV cars that become to be produced at huge volumes, both onboard battery chargers and 14V power supplies are required to ensure the transfer of energy from the 50/60Hz mains when charging to the final equipments used during a drive (ECUs, radio-GPS systems, lightning…). The related power electronics involves not only transformers and filtering chokes built in half- or fullbridge topologies but also semiconductors like IGBTs or MOSFETs that have to be accurately commanded to deliver the expected output voltage while perturbations at the input or load can affect the global performances. The control-loop often requires a good insulation between the primary side connected to the HV DC-bus (typically 350-800V) and the gate of the transistors (10-15V). PREMO has developed a new high isolated gate-drive transformer for such applications. The GDAU series is highly recommended whenever a low-size insulated SMD transformer is required to control the MOS transistors. This less than 8mm height device guarantees an insulation level of 3kV and a creepage distance greater than 5mm. The use of special insulated wire and special construction lower the parasitic elements to values (the leakage inductance is 2µH max whereas the prim-sec stray capacitance is less than 12pF) fully optimized for a switching

MTW SEPTEMBER 2015

frequency in the 90-125kHz range. The GDAU-001 reference provides a 1:1+1 turn-ratio that can command 2 transistors of the same polarity at once. It can withstand 150Vus without any noticeable saturation (15V control at 100kHz for example). GDAU series shows a magnetizing inductance value of no less than 400µH to prevent the output control voltage from any noticeable droop. The low DC resistance values of the windings ensure its capability to drive currents up to 0.5Arms continuous without overheating. GDAU series is a SMD technology delivered in Tape&Reel packaging for easy Pick&Place assembling process. Moreover it is fully compliant with most of the RoHS lead-free reflow soldering techniques. This technology is 100% compatible with AOI (Automatic Optical Inspection) system for final assembled PCB control. GDAU series is a design fully compliant with the automotive AEC-Q200 standard. It has been validated in operation from -40 to +155°C. With only UL94V-0 listed

insulating materials and a total weight of less than 5g, this component shows no thermal aging effect on this wide operating temperature range. PREMO offers samples to test this high reliability solution. Documentation of this product can be downloaded on PREMO website wwww.grupopremo.com PREMO is a Spain-based company engaged in the development, manufacture and sale of electronic components with special focus on the growing market of H&EV, Smart Metering and market segments including automotive, telecommunications and industrial electronics. Our product portfolio includes NFC & RFID antennas (worldwide leader), power transformers, inductors & chokes, current sensors, EMC filters, PLC components and accessories. In addition to our broad range of standard components, off-theshelf products, PREMO designs custom solutions to fit customer requirements.

For more information, Website: wwww.grupopremo.com

MACHINE TOOLS WORLD | 53 | September 2015

PROJECTS www.mtwmag.com

Automobile

elevators in Pune. The work is likely to start in October 2015. Place: Pune Maharashtra

DSK Motowheels Pvt Ltd Plans to set up a two-wheeler plant in Maharashtra. This unit will be ready in 18 months.

Place: Maharashtra

Contacts: Narendra Devendra Bedare, Head (Projects), 1007, Windfall, Sahar Plaza, J.B. Nagar, Andheri (E), Mumbai - 400059. T: 022-40429429, 020-26139610 E: narendra.bedare@tkeap.com

Contacts: Shivapada Ray,

PROJECT

Automobile Chemicals /Fertilisers Airports/ Aviation Transport

UPDATE

Power

COO, Gandharva Heights, Bhamburda, Near Rahul Talkies, Pune - 411016 T: 020-66271111, E: shiva.ray@dskhyosung.com

Honda Cars India Ltd Japanese automobile manufacturer is currently implementing expansion of its manufacturing plant in Rajasthan. After expansion the capacity would be enhanced from 2.4 lakh units per annum to 3,00,000 units per annum. The expansion project would complete by mid 2016.

Place: Tapukara Rajasthan Contacts: Anita Sharma, AVP (Marketing Communication), Plot No. A-1, Sector 40/ 41, Surajpur-Kasna Road, Greater Noida Industrial Development Area, Distt. Gautam Budh Nagar, U.P - 201306. T: 0120-2341313, E: anita@hondacarindia.com

ThyssenKrupp Elevator India Pvt Ltd Plans to set up a new plant for manufacturing high-tech

Chemicals /Fertilisers Thermax Ltd Plans to set up a chemical manufacturing unit at Dahej for ion exchange resins. The unit will be set up in two phases. Land acquisition is in place. The completion is targeted in 2017.

Place: Dahej Gujarat Contacts: A. M. Roshan, Head (Corp Comm), Evnironent House, Plot No. 19/92, B.G Block MIDC Bosari, Pune - 411026, T: 020-67156000-6304, M: 9823116417, E: a.roshan@thermaxglobal.com

Airports/ Aviation Kannur International Airport Ltd Kannur International Airport is coming up at Mattanur in Kannur District. The work is progressing well and expected to complete by 2016. So far around 40 per cent of the terminal building and 60 per cent of the runway construction is completed.

MTW SEPTEMBER 2015

PROJECTS

The completion is targeted by May 2016.

Place: Kannur Kerala Contacts: K.P Jose, Chief Project Engineer, New Municipal Building, 2nd Floor Maruthai Road, Mattannur Kannur - 670702. T: 0490-2474463, 2474464, F: 0490-2474464, E: kpjose@kannurairport.in

KGS Aranmula International Airport Ltd Chennai based group plans to build a greenfield airport at Aranmula in partnership with the State Govern- ment. The airport would require around 700 acre of land. The Green Tribunal had cancelled the environmental clearance for the airport in May 2014. The company has asked for second environmental impact assessment (EIA). The Centre has approved this request.

Metrino Global Projects Ltd

Contacts: Sapna Lalwani,

The ropeway transport system project called Metrino is launched as a pilot project between Dhaula Kuan in Delhi and Mansesar via Gurgaon in Haryana. Metrino covers distance of 70-km and aims to decongest Delhi. The per km cost of this project is Rs 50 crore.

Communications Director, IHDP Building, Plot # 7, Sector 127, Noida-201301, Uttar Pradesh. T: 0120-4731676, M: 9811908403, E: sapna.lalwani@power. alstom.com, shreyosi.sen@ alstom.com

Place: Southern India

Place: Delhi

Bharat Heavy Electricals Ltd

Contacts: Kishore N,

Contacts: PO Box 65-322,

Sr.Marketing Manager, Begumpeth, Near Old Airport, Hyderabad - 500016. T: 9676999089, E: Kishore.n@turbomegha.com

Mairangi Bay, Auckland 0754 New Zealand, T: 021 323219, 64 21 323219, E: info@metrino-prt.com (Ollie Mikosza, Managing Director)

Transport

District Kerala

Contacts: S.Dhinakar,

Place: Mumbai Maharashtra

General ManagerKGS Corporate House, No.43, Besant Avenue Road, Adyar, Chennai - 600020. T: 044-24426662 / 24426663 / 24426664, F: 24426665, E: dhinakar.iob@gmail.com

TruJet Trujet plans to invest Rs

MTW SEPTEMBER 2015

Plans to assign the design, engineering, manufacturing, testing, supply and E&C support services for coal bunker level monitoring system for various projects. i.e. Gadarwara 2x800 MW, Nabinagar 3x660 MW, North Karanpura 3x660 MW & Unchahar 1x500 MW.

Place: Bihar Mumbai Metropolitan Region Development Authority The development authority is working on the second phase of the monorail corridor in Mumbai. This corridor will connect Wadala to Sant Gagde Maharaj Chowk.

Place: Pathanamthitta,

500 crore in the next five years. The company has identified major cities like Visakhapat- nam, Vijayawada, Rajahmundry, Kadapa, Coimbatore,Tirupathi, Salem, Hubli and Tuticorin for its operations in Southern India. As of now, the company plans to add two more aircrafts to its fleet.

Contacts: M R Kharat, Executive Engineer, Office, 1st floor, B-wing, Bandra- Kurla Complex, Bandra (East), Mumbai-400051. T: 022-24062174, 24062159, 26594183, M: 9819951975, E: kharatmr@gmail.com, (Vishnu Kumar, Director Mono Rail)

Power Alstom India Ltd The proposed JV with Alstom Transport S.A has got a letter of acceptance from Dedicated Freight Corridor Corporation of India Ltd (DFCCIL) for the design, construction, supply, testing and commissioning of 2x25 kv AC 50 Hz electrification, signalling, and telecommunication and associated works of double track railways lines under construction on a design, build lump sum basis for lump sum basis for Bhaupur-Khurja section of Eastern Dedicated Freight Corridor (System Works Contract Pack-age-104).

Place: Khurja Uttar Pradesh

Contacts: S.Savithri, DGM (Electronics Division), P B No. 2606, Mysore Road, Bengaluru - 560026. T: 080-25146100, W: www.bhel.com

Bharat Heavy Electricals Ltd Expression of interest is invited for the transfer of technology / business sharing agreement for in-house manufacturing of Smart Electronic Transmitters (PT & DPT Type) required for power plants & other process industries.

Contacts: S.Savithri, DGM (Electronics Division), P B No. 2606,

PROJECTS www.mtwmag.com

Mysore Road, Bengaluru - 560026. T: 080-25146100, W: www.bhel.com

Bharat Heavy Electricals Ltd Plans design, supply and I&C of pre-engineered buildng (PEB) for 50 MW solar project, Qty: 10 rooms.

Telangana State Generation Corporation (TSGenco) Plans to setup 4,400-MW super critical thermal power station based on imported coal at Damaracherla in Nalgonda district. The project got environment clearance recently. The contract is awarded to Bhel and the work is likely to start soon.

Contacts: S.Savithri, DGM (Electronics Division), P B No. 2606, Mysore Road, Bengaluru - 560026. T: 080-25146100, W: www.bhel.com

Power Grid Corporation of India Ltd The contract is awarded to Sterlite Technologies Ltd and comprises (I) Package L5cd01 for extension of Biharsharif - Sasaram to Varanasi (Part Qty) Transmission Line Under Conductor Package for (Lot V) and (II) Package L5cd02 for a Extension of Biharsharif - Sasaram to Varanasi, etc.

Place: Bihar Contacts: Chetan, General Manager (Corporate Communication), Saudamini, Plot No.2, Sector 29, Near IFFCO Chowk, Gurgaon-122001, Haryana. T: 0124-2571845, F: 2571912, E: chetan@powergridindia. com

Place: Nalgonda

Plot No.2, Sector 29, Near IFFCO Chowk, Gurgaon-122001, Haryana. T: 0124-2571845, F: 2571912, E: chetan@powergridindia.com

Plans to assign operation and maintenance of 1200 MW (2x600 MW) Kalisindh Thermal Power Plant, Kalisindh, Jhalawar.

manufacture, supply, erection, testing and commissioning of Boiler, Turbine, Generator (BTG) package & its auxiliaries and allied civil works related to BTG on Engineering, Procurement and Construction (EPC) basis for the establishment of 1x800 MW supercritical coal based North Chennai Thermal Power Project, Stage-ill at Thlruvallur District, Tamil Nadu.

Place: Kalisindh Rajasthan

Place: Thlruvallur District

Rajasthan Rajya Vidyut Utpadan Nigam Ltd

District Telangana

Contacts: P.Balaraju, Chief Engineer (TPC), Vidyut Soudha, Khairathabad, Hyderabad - 844101, T: 040-23499261, E: cetpctgenco@gmail.com, (D. Prabhakar Rao, CMD)

Power Grid Corporation of India Ltd The contract is awarded to Sturdy Industries Ltd and comprises (I) Package-L5cd03 for a 400 KV D/C LaraRaigarh and B400 KV D/C (Quad) Lara-Champa (Part Qty.) Transmission Lines Under Conductor Package for (Lot-V) and (II) Package-L5CD04 for 400 KV D/C (Quad) Lara-Champa (Part Qty) Transmission Line Under Conductor Package for (Lot-V).

Tamil Nadu

Contacts: S.S.Meena , C.E (Kalisindh Thermal Power Plant), Kalisindh, Jhalawar, Rajasthan, T: 07432-243002, E: ce.katpp@rrvun.com

Rashtriya Chemicals and Fertilisers (RCF) Plans investments for reducing consumption of energy at its two urea-ammonia units in Thal in Maharashtra. As part of this plan, the company would change the existing steam turbine driven machinery to the motor driven mode in the two units.

Manager (Corporate Communication), Saudamini,

Engineer Projects, NPKRR Maaligai, 144, Anna Salai, Chennai - 600002. T: 044-28520131, 28520878, 28521915, E: cepr@tnebnet. org (N.Sankar, Director / Generation)

Tata Power Delhi Distribution Ltd (TPDDL)

Place: Maharashtra

The company has recently commissioned its 66 kV gas insulated switchgear (GIS) sub-station at Prashant Vihar, Rohini. The sub- station has come up on an area measuring 540 sq mtr.

Contacts: R G Rajan,

Place: Delhi

Chairman and Managing Director

Contacts: Ajey Maharaj,

Place: Chhattisgarh Contacts: Chetan, General

Contacts: Y Balan, Chief

Tamil Nadu Generation and Distribution Corporation Ltd Plans to assign the design,

Head (Corp Comm), Hudson Lines Kingsway Camp, Delhi-110009. T: 011-66112489, E: ajey.maharaj@tatapowerddl.com

MTW SEPTEMBER 2015

PRODUCTS

PRODUCT SHOWCASE Hangsterfer’s CC 10 - 22 Straight Cutting Oils For Deep Hole Drilling • • • • • • • • • •

CC 10 & CC22 oils are Chlorine-Free Non-Staining Can be used safely on all materials Non-Toxic Non-Irritating Non-Corrosive Easy to recycle and waste treat Lower misting Fewer residues

Hangsterfer’s neat cutting oil CC10 is recommended for Deep Hole Drilling /Gun Drilling application. CC10 (Viscosity 10) has all the capability to outperform. Hangsterfer’s neat cutting oils are recognized by various machine manufacturers around the world. These oil improves tool life and surface qualities to the large extent. In addition to the lubricity provided at the cutting zone, Hangsterfer’s cutting oils provide excellent lubrication for the machine’s slides, guide bushings, bearings, and spindles. 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

CC 10 - This is the lowest viscosity in the series. CC 10 is ideal for Gun Drilling application which allows for more heat removal with high pressure. CC 22 - This oil is ideal for use in BTA application. It has enough lubricity for the more demanding operations and materials, including lubrication of the guide-bushings.

BTA Drilling Machines Precihole Machine Tools has introduced a new range of extremely precise, efficient and affordable BTA Drilling machines for drilling of central holes in screw barrels used in Injection molding industry.These machines are reliable, versatile and can be configured for ID drilling of these screw barrelsfor holes from Φ 30 mm to Φ100 mm solid and Φ 165 mm counter boring in diameter. The length of these barrels can be up to 3,000 mm deep. BTA drilling is a form of deep hole drilling where the coolant oil is pumped in from a pressure chamber to the cutter at the end of a long boring bar and the swarf from the

MTW SEPTEMBER 2015

PRODUCTS www.mtwmag.com

cutting process is flushed from behind. Carbide inserts and pads are attached on specially designed cutters that fit on very long boring bars. BTA Drilling produces holes at faster speeds, offers better straightness and surface finish compared to conventional gun drilling. Faster feeds result in higher productivity and this offers maximum value for customers looking into increasing their outputof screw barrels by incorporating this process in-house.

Some highlights of these BTA Drilling 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

• Excellent design and Robust Construction that allows customer to accommodate a wide range of drilling sizes on same machine. • Tool and component rotation configurations appropriately selected as per needs of the application and L/D of the holes • Use of linear motion guide ways, three point work steadies, quick change pressure heads and rotating vibration dampeners • Machines designed with prime focus on operator safety and ease of operation • PLC Controls for precision positioning and control of various machine parameters • High pressure coolant filtration system to allow required quantities of cutting oil at appropriate pressure • 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.

Steady volt servo voltage stabilizers Frequent voltage variations are a menace that can damage electronic components like power supplies, drives, PLCs, controllers, etc. Their effects are widely felt in CNC, printing and textile machines as well as laboratory, data processing, medical & telecommunication equipment. Frequent breakdowns of such machines are costly to repair. This apart, the downtime and frequent interruptions in operation brings substantial loss of revenue. Steady Volt from Unity Controls is a state-of-the-art Voltage Stabilizer designed to protect such equipment from voltage variations and its ill-effects.

Following are some of its unique features:

For Product Enquiry Contact Unity Controls Pvt. Ltd 405, Sapphire Arcade, 42 M.G. Road, Ghatkopar (E), Mumbai 400 077 Phone: 022- 2501 3832 / 33 E-mail: sales@unitycontrols.in Web: www.unitycontrols.in

• • • • • • •

Intelligent microprocessor-based system(available in new digital models) Digital interface with large LCD display and keypad Auto re-start, adjustable output voltage, trip bypass, fault list No hunting, oscillation and noise generation Innovative transformer design to minimize power loss Constant output voltage across a wide input voltage range Single phasing prevention, surge suppressor and EMI / RFI filter

With the best-in-class response time and correction rates, Steady Volt offers improved power quality and greater energy efficiency, thereby saving the cost of breakdowns and energy utilization. Apart from protecting your equipment from damage, Steady Volt also saves energy during continuous operations.

MTW SEPTEMBER 2015

PRODUCTS

iQ Series SLTT – for highest chip removal! Feel the efficiency compared to grinding wheels or conventional lamellar flap discs. A patented new design and configuration of flaps (more grains in action) Ideal for • removing weld seams • deburring • fettling • fine finishing • rust removal

Characteristics • • • •

exceptional stock-removal capability enourmous tool life strong steel backing plate quite less vibration

The four qualities in the iQ Series – for all materials and for every application!

For Product Enquiry Contact Supra Industries SP-106,MIDC Bhosari,’S’ Block, Near Century Enka Ltd., Off Telco Road, Pune - 411 026 (India). Cell: +91 8888893791, Tel.: + 91 20 30685648, Email: info@supraindustries.com Website: www.supraindustries.com

INOX - Z-Power coated abrasive • recently developed for the machining of stainless steel • no glazing or heat generation • equally efficient for both edge and surface applications • iron-sulphur-chlorine free Heavy Duty- Ceramic coated abrasive • recently developed for the most demanding and severe applications • particularly robust for edge grinding, on heat treated steels, surface scale or coated surfaces • iron-sulphur-chlorine free Steel - ZK coated abrasive • optimized for universal application on a wide variety of steels and aluminium • tough grain with a high degree of resistance to pressure • quicker, more aggressive and longer tool life when compared with our current ZKS quality ALU - SIC – coated abrasive • specially suited for weld preparation and finishing of aluminium • also ideal for fibre reinforced materials such as CRP and GRP • machining of glass and ceramic

Precision Cutting Tools The KOMET GROUP, one of the leading single-source providers of precision tools, will be appearing at EMO Milano 2015 (Hall 10 – A16/B07), where it will exhibit an extensive range of tools. This press release will provide details

New tools for success

For Product Enquiry Contact Komet Group Email : info@kk-pr.de, Fax : +49 821 22 93 96 92

MTW SEPTEMBER 2015

The KOMET GROUP, a single-source supplier of precision tools, will be showcasing a wide range of innovations under the slogan “THE CUTTING EDGE – Solutions for the best performance”. The highlight will be the extended range of indexable insert milling cutters, accompanied by new tools from the fields of drilling, reaming and threading. Highlights from the field of the KOMET SERVICE® and KOMET® BRINKHAUS service brands will complete our trade-fair appearance.

PRODUCTS www.mtwmag.com

CNC Profile cutting systems

Warpp Engineers Pvt Ltd, leading solution provider for welding and cutting industry has wide range of cutting solution to suit different industry needs. We understand that cutting is the first step to move towards automatic welding and to help industry take their first step towards the automation. WARPP has come out with Portable, Shape Cut Easy & Shape Cut fine series CNC cutting systems which can be configured for either flame, plasma or for both. These cutting systems can be built with different controller and different plasma power source as per customer requirement. Our 20 years of experience in welding & cutting industry backed by good pre & post sales service will ensure that your first step towards automizationwill go a long way in increasing your product quality , consistency and productivity.

New Seco MS2050 milling grades optimised for titanium machining

For Product Enquiry Contact Seco Tools India (P) Ltd. Tel: 02137-667300 Email: seco.india@secotools.com Website: www.secotools.com/in

Seco has increased the versatility of its MS2050 milling grade with new variations that bring optimised cutting performance to shops processing parts from titanium and high chromium content steels. The latest additions span a wide scope of insert sizes, radii and geometries along with special coating technology. The grade’s new silver-colored PVD uni-coating provides enhanced heat-resistant capabilities as well as virtually eliminates the occurrence of built-up edge when cutting sticky materials such as titanium. And with the absence of built-up edge, the inserts last approximately 50 percent longer than existing products, which provides users with reduced tool costs. Applicable for use with the company’s Turbo 10, Helical T4-08 and Highfeed cutters, the new MS2050 insert grades are available in a radii selection from 0.4 mm to 6.3 mm as well as positive geometries that can perform productive shoulder, face, copy and high-feed milling operations.

Tools for Notching Pipe Ends Fabricators of pipe work frequently come across the need to prepare a pipe end, for joining (by welding) with another pipe.

For Product Enquiry Contact Unipunch Toolings Pvt. Ltd. Chennai. India, Mobile : 99419 05061 Email : unipunch@gmail.com Website:www.fabmachinesindia.com

Pipe ends can be prepared for joining at right angles to each other or any desired angles to each other. Tools offered by Unipunch make this work a press operation (instead of slow milling, coarse cutting, bent grinding). Reproducibility and quality of the joints are enhanced. Tools can be used in your own press.

MTW SEPTEMBER 2015

ADVERTISERS INDEX COMPANY NAME

PG. NO.

COMPANY NAME

PG. NO.

COMPANY NAME MACHINE TOOL EXPO 2015

53 5

ADOR WELDING LIMITED

GLEASON WORKS (INDIA) PRIVATE LIMITED

METACUT TECHNOLOGIES

ACMEE 2016

GRIND MASTER MACHINES PVT. LTD.

C CNC SOFTWARE, INC.

H BACK PAGE

D DMG MORI INDIA DOWEL ENGINEERING WORKS

HAAS AUTOMATION INDIA PVT. LTD.

HEIDENHAIN OPTICS & ELECTRONICS INDIA PRAIVATE LIMITED

INSIDE FRONT COVER

J 45

JYOTI CNC AUTOMATION LTD.

INSIDE BACK COVER

EFFICA AUTOMATION LIMITED

ENGITECH EXPO - 2016

ERWIN JUNKER MASCHINENFABRIK GMBH

SANJAY TOOLS & ADHESIVES

SBS PRECISION SYSTEMS (INDIA) PVT. LTD.

SUMI CYCLO DRIVE INDIA PVT. LTD.

SUPRA INDUSTRIES

U UNITY CONTROLS PVT. LTD.

LAPP INDIA PVT. LTD.

PG. NO.

30-31

For advertising contact:

shekhar@divyamediaonline.com

MACHAUTO EXPO - 2016

or call: 09820551279

2015 - 2016

MACHINE TOOLS WORLD |

64 | September 2015

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