www.mtwmag.com
Volume 1 Issue 5
Contents
Vol 1 Issue 5 | October 2015
Publisher
CASE STUDY
Shirish Dongre
CEO
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Shekhar Dongre
Editor
TONiC™ optical encoders support the latest generation of CMMs from COORD-3
Shilpa Dongre
Marketing Team Ladoji Pendurkar, Amol Powle, Bhavin Shah, Bharat Shah, A.Purohit, Vinod Surve, Kavita Chaudhari
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Designer & Layout Arun P. Shinde, Pradeep M. Pillalamarri, Nandan S. Moghe, Dinesh S. Gawade
“Ajikawa & SCI Metal Tech” builds 120m towers using Lantek software
Circulation Executive Satish Kadam, Amol Ranshur Branch Offices (Zonal)
NORTH (Delhi & NCR regions) Sandesh Jain : 09810837877 / 09871602777
SOUTH (Chennai & Coimbatore) Y. V. Raghu : 09566141224 Bangalore Vaman : 09686721340 Kochi Sanjeev Nair : 09846249568
COVER STORY
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26 Metalworking fluids with innate GREEN factor Mr. Chris Sheehan, Managing Director Asia Hangsterfer’s Laboratories, Inc
EAST (Kolkata & Other regions) S. Roy - 09433097806
WEST (Maharashtra & Gujarat) Pune S.Kadam - 09833373371 Gujarat Dinesh Shah - 09327344559 Rajkot (Saurashtra) Swapnil Bhatia: 09227909005
BUSINESS NEWS
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CNC Software, Inc. & Barefoot CNC Showcasing Mastercam X9 & Dynamic Motion at SOUTH-TEC 2015
08 Head Office : Divya Media Publications Pvt. Ltd., 3rd Floor, Harmony Tower, N.S. Road, Thane-400 602. Maharashtra Tel: +91 22-25380574/75, Telefax: +91-22-25418254 E-mail: shekhar@divyamediaonline.com, Website: www.mtwmag.com.
Printed & Published by Shirish Dongre on behalf of DIVYA MEDIA PUBLICATIONS PVT LTD., Printed at Anitha Art Printers 29/30, Oasis, Next to Vakola Market, Santacruz(E), Mumbai-400055, published from 303/304, Harmony Tower, N.S.Road, Court Naka, Thane West, Thane-400601. Editor : Shilpa Dongre
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Horizontal heavy-duty machining now complete and universal machining centres extended
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Grind Master Bags EEPC Star Performer Award
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Metal 3D printing systems for the dental market allow rapid return on investment
COMPANY PROFLE
Lubricants for safe production Klüber Lubrication supports food safety as a member of the EHEDG
TECH UPDATE
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Recent developments in metalworking fluids
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CELOS® with 5 new APPs in 2015
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NuGEN’S forte: Sheet metal working machines
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HE303-CS
44
Grease - Its Components, Consistency & Compatibility
24
46
55
59
‘Bright’ Roller Burnishing Tools The New Generation of Angle Encoders with - Renowned for providing complete burnishing solutions Integral Bearing
PROJECTS
PRODUCTS
Editorial Board
Editorial Index L
B Bosch in India
20
Lantek
33
Bright Burnishing
24
Laser Components
50
M
C
Mitsubishi Heavy
CNC Software, Inc. (Mastercam)
06
Concept Laser
16
Industries
12
N 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
D
NuGEN Machineries
DMG MORI
23
08, 38 P
E
Precihole Machine
Exxon Mobil
44
Tools
60
R
F FARO Technologies
14
Renishaw
10, 12, 30, 62
G Grind Master
09
S Supra Industries
61
H Mr. Arjun Prakash Managing Director Effica Automation Ltd.
Ms.Samina Khalid Marketing Manager
Renishaw Metrology Systems Ltd.
Mr. MIHIR Baxi President – Global Sales Jyoti CNC Automation LTD
Haas Automation
42
U
Hainbuch
13
Unity Controls
Hangsterfer’s
26, 59
Heidenhain
46
61
W Warpp Engineers
62
K Kennametal
22
Z
Klüber Lubrication
22, 34
Zenith Industrial
60
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
Mr. P.K. Balasubbramaniian President VBS Corporate Support
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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.
MTW Overseas Associates USA Nancy TARTAGLIONE, Mepax USA n.tartaglione@mepax.com / usa@mepax.com
GERMANY Sebastian OLLIER Mepax Deutschland, Tel: +49 711 222 54 456, deutschland@mepax.com
FRANCE MEPAX SA, Romain CLASS Tel.: +33 1 39 02 77 78, FRANCE
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
MT
BUSINESS NEWS
CNC Software, Inc. & Barefoot CNC Showcasing Mastercam X9 & Dynamic Motion at SOUTH-TEC 2015 CNC Software, Inc., along with local Mastercam Reseller, Barefoot CNC, will be at the upcoming SOUTH-TEC 2015 show. Attendees will get to see and experience the most powerful Mastercam machining software yet. Stop by booth # 1039 at the Charlotte Convention Center in Charlotte, NC, October 27-29 for a look at Mastercam X9 which introduces Dynamic Motion improvements, Multiaxis enhancements, and many Design and System features to make your job easier.
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 Features Dynamic Xform allows you to switch between gnomon manipulation and geometry manipulation mode at any time without having to reselect geometry. Solid Disassemble is a new Model Prep function that takes an assembly and lays each body out in a single pane. With Mastercam X9, 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.
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.
Multiaxis Improvements 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
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, 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,
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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 211,000 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
Our equipment are approved by major OEMs and exported (up to 2000 KVA) to countries in Europe, Middle East, Africa
Our Allied Products: n
Active Harmonic Filters K-Rated Transformers Light Energy Management Systems
n
KVAR MAX - Real Time Power Factor System
n n
and Asia Pacific. So leave power quality and energy management to the experts – Unity Controls. With our nationwide network we are only a phone call away!
Contact us for Power Quality & Harmonic Audits to Conserve Energy and Save Costs.
405, Sapphire Arcade, 42 M.G. Road, Ghatkopar (E), Mumbai 400 077, India
The power quality & energy experts
+91-22-2501 3832 / 33 sales@unitycontrols.in www.unitycontrols.in
Ahmedabad l Bangalore l Chennai l Delhi l Gurgaon l Hardwar Indore l Jalandhar l Jamshedpur l Kolkata l Kanpur l Mumbai l Pune l Rajkot
l l
vijayshreyaarts@gmail.com
UNITY CONTROLS PVT. LTD
BUSINESS NEWS
Horizontal heavy-duty machining now complete and universal machining centres extended DMG MORI will be presenting three duoBLOCK® - based world premieres at the EMO: the DMC 100 H duoBLOCK® and DMC 125 H duoBLOCK® complete the portfolio for heavy-duty horizontal machining, while the DMC 100 U duoBLOCK® strengthens the line-up in automated 5-axis universal machining. Absolute precision and maximum dynamics in heavyduty machining are the key features of the highly stable duoBLOCK®- machining centres from DMG MORI. In particular, the DMC models with pallet changers are the mark of productivity-driven production. The world market leader in chip removal has extended the 4th generation of the successful platform to include three world premieres with fast pallet changers, which it will showcase at the EMO in Milan. The DMC 100 H duoBLOCK® and DMC 125 H duoBLOCK® complete the portfolio of high-performance horizontal machining centres, while the DMC 100 U duoBLOCK® equipped with a power MASTER®- spindle sets new standards in powerful 5-axis machining. With an increase in precision, performance and efficiency of up to 30 percent
Horizontal heavy duty machining of the extra class the duoBLOCK®- series has continued its success story through to the fourth generation. Since its launch, DMG MORI has successively extended the program of the highly stable machining centre series in order to establish itself as the absolute full-line supplier. DMG MORI once again underscores its exceptional position with the presentation of three world premieres from the DMC portfolio with fast pallet changers at the EMO.
DMC 100 H duoBLOCK® & DMC 125 H duoBLOCK®
EMO world premiere DMC 125 H duoBLOCK®
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– Premium class horizontal heavy-duty machining DMG MORI places great importance on horizontal machining in general. This is reflected in particular in its complete range of taskoptimized series. The NHX series
takes on the role of the allrounder here while the i-series targets equally efficient and space-saving serial production in the automotive sector. Whereby the DMC 60 H linear and DMC 80 H linear as production precision centres excel with rapid traverses of up to 100 m/ min and repeat accuracies of up to 3 µm. So all that remains is the high-performance segment that will be rounded off at the EMO with not just one but two world premieres from the DMC H duoBLOCK® series. DMG MORI will now finally establish itself as a complete full-liner for every demand in horizontal machining, namely with the DMC 100 H duoBLOCK® and the DMC 125 H duoBLOCK®. The special focus of the new DMC H duoBLOCK® models is on highperformance through to heavy-
duty machining. In addition to the standard spindle, DMG MORI also offers a gear spindle with a torque of up to 1,600 Nm, and a 52 kW power rating at 8,000 rpm. Combining this with the heavy-duty machining package enables removal rates of over 450 cm³/min for Ti6AI4V, for example. The DMC 125 H duoBLOCK® boasts a maxim workpiece size of 1,250 x 1,600 mm (ø 1,000 x 1,600 mm. in the case of the DMC 100 H duoBLOCK®). Maximum workpiece weight is rated at 2,000 kg. The large cubic work area offers sufficient space for long tools and multiple clamping devices. The 1,050-mm horizontal clearance allows the use of tools with lengths of up to 900 mm. The two new duoBLOCK® horizontal machining centres owe their high level of precision in part to the extensive cooling concept. Cooling of the motors in all linear and rotary axes ensures maximum long-term precision even in the standard
EMO world premiere DMC 100 duoBLOCK®
BUSINESS NEWS www.mtwmag.com
version. DMG MORI has also optimized the efficiency of the two world premieres by means of a frequency-controlled highpressure pump up to 80 bar (optional).
DMC 100 U duoBLOCK® – universal 5-axis machining with up to 1,300 Nm The enhanced features of the fourth generation are also reflected in the third duoBLOCK®-world premiere. With its fast pallet changer the DMC 100 U duoBLOCK® guarantees the shortest possible idle times in productive 5-axis machining. A 12,000-rpm and 130-Nm spindle ensures outstanding milling performance even in the standard version. Another highlight of the new universal machining centre is the new powerMASTER®- motor spindle that is now available
as an option – one example of the innovative synergy effects arising from the cooperation with the Japanese developers. With a torque of 1,000 Nm and a power rating of 77 kW, the spindle can handle demanding machining tasks with no problem at all. Its Spindle-Growth-Sensor (SGS) compensates spindle growth and guarantees maximum precision. It has a swivel range of -30°/+100°. This makes the powerMASTER® ideally suited for the machining of complex titanium components in the aerospace industry, for example. The DMC 100 U duoBLOCK® can be equipped alternatively with the 5X-torqueMASTER®. The torque of the gear spindle was increased by 80 percent to now stand at up to 1,300 Nm. It has a power rating of 37 kW at 8,000 rpm. Its
structural rigidity has been increased by 50 percent. The 5X-torqueMASTER® has a swivel range of between 0° und +180°. The new B-axis with its 20 higher rigidity and integrated cable track ensures maximum flexibility and reduces machining times to a minimum. The size of the work area offers sufficient space for workpieces of up to ø 1,000 x 1,600 mm and weights of up to 2,000 kg. The intelligent wheel magazine with space for 453 tools and chip-to-chip times from 4.0 seconds boost productivity. As of two wheels, the magazine can be setup parallel to main and secondary production times. A new feature is the automatic changeover of 45-kg angle heads and the changeover of tools in the angle head. In addition, the magazine
5X-torqueMASTER® with 80 % more torque can be setup with sets of tools by means of a dedicated and individually defined access area in the loading wheel. In order to boost efficiency even further DMG MORI also offers a frequency-controlled high-pressure pump with up to 80 bar for the DMC 100 U duoBLOCK®.
For more information, Website: www.dmgmori.com
Grind Master Bags EEPC Star Performer Award Grind Master is proud recipient of EEPC Award “STAR PERFORMER - MACHINE-TOOLS AND PARTS & ACCESSORIES - LARGE ENTERPRISE” for outstanding export performance during the financial year 2013-14. The Award was presented to by SHRI SURESH PRABHU, Hon’ble Union Minister of Railways, New Delhi at an Award Presentation Function held at Mumbai on Tuesday, 29th Sept. 2015. Grind Master is a pioneer and leader in metalfinishing technology. Grind Master “NANOFINISH” range of machines used to generate Engineered Finishes on Automotive Powertrain Components such as Crankshaft, Camshaft, Synchrogears are trusted by leading automotive OEMs around the world,
Milind Kelkar and Mohini Kelkar receiving award at the hands of Honourable Railway Minister Shri. Suresh Prabhu.
Milind Kelkar and Mohini Kelkar with another award winner Mr. Shriram (Endress and Hauser)
including SGM, Great Wall, Tata, Toyota and Renault Nissan. Over the past few years Grind Master has been successful in innovating success in an area dominated by German and Japanese machine builders. Competing with the best in the field, Grind Master offers state of the art technology, and has 5 Patent Pending in the NA-
NOFINISH range of machines. Grind Master exports NANOFINISH range of machines to China, USA, UK and South America. With a Representative Office in China, Grind Master has a very strong presence in the world’s largest Automotive market. In future it is planned to increase reach in the markets in the Americas and Europe.
Notably, Grind Master started exporting machines as long back as 1993, with a small machine sold in South East Asia. Over the years the Exports have grown due to participation in International Exhibitions such as EMO and CIMT, and Collaborations with American, Japanese and European companies. Today Grind Master contributes 18% of all Indian Machine Tool Exports as per data from EEPC for FY 14-15. “We are proud to partake & contribute to PM’s ‘MAKE in INDIA’ campaign,” says Mrs. Mohini Kelkar, Managing Director, Grind Master.
For more information, Website: www.grindmaster.co.in
MTW OCTOBER 2015
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BUSINESS NEWS
Metal 3D printing systems for the dental market allow rapid return on investment Renishaw, the UK’s only manufacturer of metal additive manufacturing (3D printing) machines, is pleased to offer a new product for the dental market. The company is now supplying its AM250 metal 3D printing machine fully optimised for producing dental parts, meaning that it will not require further adjustment to achieve the production of high quality frameworks. To further enhance this offering Renishaw will also supply cobalt chrome powder that can be used in the manufacture of dental frameworks. These exciting new developments have only been made possible due to Renishaw’s extensive experience of 3D printing dental frameworks, which has been gained by supplying hundreds of thousands of high quality dental devices and frameworks to European dental laboratories. Suitable for 3D printing of
a large variety of metal dental devices, the optimised AM250 is a high volume 3D printing machine specifically aimed at the dental market. Fine tuned to the intricacies and challenges of dental devices, it is a popular alternative for those aiming to reduce the costs associated with milling operations and can replace traditional wax casting techniques by building dental frameworks from STL data as part of a digital workflow. Renishaw has conducted its development with an emphasis on accuracy and quality of frameworks, quality and traceability of raw materials, and speed and reliability of manufacture. The key aim is to allow a rapid return on investment for its customers. As with any large scale manufacturing equipment, 3D printing machines would typically require further process development before they meet
a company’s quality criteria. In addition there can be further operational and intellectual property issues that may need to be addressed. Renishaw limits the need to carry out such activities by optimising the AM250 to produce dental devices to the requirements of its customers, meaning that they are able to produce production quality frameworks from the moment their machine is signed over. Renishaw can also offer assistance on all peripheral items such as IP licences, materials and part handling.
Renishaw’s dental CAD system Renishaw supplies the unique Renishaw Dental Studio (RDS) CAD package that combines the speed and flexibility of the company’s DS30 blue light scanners with the accuracy of the Renishaw DS10 contact scanner. Using Exocad, RDS allows a wide range of dental devices to be designed. The ability to add to the software’s capability through additional modules makes the package flexible and scalable for the expanding dental laboratory.
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IDS 2015 Renishaw will be exhibiting its AM250 metal 3D printing systems optimised for producing dental parts and RDS dental CAD software at IDS 2015 in Cologne, Hall 02.2, stand F-021 from 10th until the 14th March.
About Renishaw Renishaw is a FTSE 250 listed global engineering company. The company specialises in measurement, motion control, spectroscopy and precision machining. Renishaw is well known for its industrial metrology products, which are used in applications for machine tool automation, co-ordinate metrology, gauging, machine calibration and position feedback, but in recent years has diversified into areas such as metal 3D printing, CAD/CAM dentistry, additive manufacturing, large scale surveying, stereotactic neurosurgery, and medical diagnostics.
For more information Website: www.renishaw.com
MACHINE TOOLS WORLD | 11 | October 2015
BUSINESS NEWS
Materialise’s - Renishaw build processor magics software functions to additive manufacturing system Renishaw and Materialise are proud to announce the launch of the Renishaw Build Processor. Renishaw has collaborated with Materialise, a leading provider of additive manufacturing software and of sophisticated 3D printing solutions for medical and industrial markets. Renishaw’s extensive process knowledge is combined with Magics’ powerful .stl editor and build preparation software to enhance the capabilities of the AM250 additive manufacturing system. The Build Processor allows users of the Renishaw AM250 system, working in a range of diverse industries to input a
Standard Tesselation Language (.stl) file from any CAD package or to import native CAD formats directly into the Magics software. They can then edit, manipulate and heal models before orientating and adding build supports. Furthermore,
the Renishaw Build Processor allows material files to be freely designed and edited before an output is created, which can be read directly by the AM250 system. The new Renishaw Build Processor offers users a flexible platform. “With this highly flexible platform, the user is able to control up to 170 parameters, fully utilizing Renishaw’s open source parameter ethos. However, it maintains a user-friendly interface, using predetermined parameters so that the build can be prepared in a few simple steps,” says David Ewing, Product Marketing
Engineer at Renishaw. The large suite of functions also gives users greater control of the build, with more support structure generators and powerful build file generation algorithms. With experience, the additional parameters will give the user unprecedented control, which ultimately improves part quality.
For more information Website: www.renishaw.com
MHI Machine Tool Co., Ltd. begins operations On October 1 Mitsubishi Heavy Industries Machine Tool Co., Ltd., a newly created group company of Mitsubishi Heavy Industries, Ltd. (MHI) succeeding to MHI’s machine tools business, will commence operations. The new company will seek enhanced organizational responsiveness through integration of manufacturing and sales functions, and will develop internal structures enabling swift decision-making, in a quest for robust competitiveness in the global machine tools market. The new company’s head office and main plant are located in Ritto City, Shiga Prefecture, at what has until now been the Ritto District Main Plant of MHI’s Machine Tool Division. Operations will launch under a new president: Seiji Shirao, currently General Manager of the Machine Tool Div. in MHI’s Machin-
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ery, Equipment & Infrastructure business domain. The business philosophy being hoisted by the new company aims to “provide optimal solutions to enable the customer to achieve the purposes of, & resolve issues relating to, production activities; & contribute to enhancement of the customer’s value in manufacturing.” In line with this corporate stance the new entity will seek to become a leading global manufacturer in the fields. In the gear cutting machines business, the new company will have a superior position within the global market; going forward it will strengthen its development and combined provision of machines and tools all having superlative product appeal. The new entity will undertake a new form of business to provide optimal solutions to resolve the diverse issues and challenges
confronted on the customer’s manufacturing floor, with its participation to commence from the initial stage of mulling potential problem-solving resolutions. In the advanced production systems business, in addition to offering solutions to improve the customer’s machining technologies and production facilities, the company will also strive to achieve business in factory information processing systems technology making use of ITC (information and communications technology) and MHI’s accumulated expertise as a machine tool manufacturer. In recent years the environment surrounding the machine tools market has changed significantly both in Japan & abroad. In terms of technology, needs are becoming more sophisticated at an accelerating pace, calls are being heard
for advanced automation and energy-saving technologies. Meanwhile attention is focusing on innovations in production making use of information and communications technologies, leading to intensifying competition among the world’s machine tool manufacturers. Against this backdrop, new company, by virtue of its transformation to a dedicated firm, will pursue swifter decision-making & clarification of operational responsibilities. It will advantage of the comprehensive strengths of the MHI Group & organizational responsiveness to be derived from its integration of manufacturing & sales functions, to pursue stronger response capability to changes in the market environment & customer needs, in order to accelerate the strengthening and expansion of its business operations.
BUSINESS NEWS www.mtwmag.com
Hainbuch Workholding Launched New Automation Solutions for Enhancing Productivity Switch to full automatic mode with the automatic clamping head [collet] change station! Small batch sizes, more and more part variants, competition growing bigger and bigger and always less time. A familiar problem! Hainbuch the workholding manufacturer knows all about these issues, they’ve come up with an automation solution that makes you more productive, more independent and more flexible. People who know Hainbuch know that no production process problem is unsolvable. So Hainbuch was looking for a smart, minimalist automation solution that would make work easier. This did not have to be a robot, it should be executed independently by the machine operator.
The solution: A stocking and changing station placed on the workpiece feeder belt of a vertical lathe. To setup, the spindle passes with the chuck over the combination of clamping head and endstop to be changed and it is swapped completely reliably within seconds by a pneumatic pulse. The workpiece to be clamped is then directly grabbed from the next changing station and clamped. Because of this design, there is
example that you would expect from Hainbuch and if you imagine that this is the only one available from think again, this was just one of several of their automation solutions.
Smart solutions: • Optimal set-up changing clamping parts [clamping heads and end-stops] • Ideal for lowering batch sizes or multiple part variants
The clamping head and end-stop can be changed quickly and easily. clutch mechanism
The automation effort is small but the flexibility is enormous.
The automation effort is small but the flexibility is enormous.
no need for extra automation. However, the machine can become amazingly flexible. Using a clamp check with air sensing the efficiency can be increased even further. This simple practical solution is suitable for a variety of machines because the changing station can be installed directly beside an industrial robot or gantry. A genuine high tech
• Operator free production over 3 shifts
• The changing station sets up the clamping head and end-stop together using a pulse trigger • No special alignment, workholding is ready to use
• No expert set-up needed • Low upgrade cost • Low investment compared to conventional automation
How it works: • Clamping head and end-stop use a clever
For more information, Website: www.hainbuch.com
MTW OCTOBER 2015
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BUSINESS NEWS
FARO® releases new handheld 3D laser scanner FARO Technologies, Inc. (NASDAQ: FARO), the world’s most trusted source for 3D measurement technology, announces the release of the new FARO Scanner Freestyle3D X Handheld Laser Scanner, a 3D Laser Scanner designed to transform the way the Architecture, Engineering and Construction (AEC), Law Enforcement, and other industries document 3D data through easy to use, intuitive data acquisition. With the release of the Freestyle3D X, FARO´s portfolio now contains two handheld scanners designed to help customers increase productivity, save time and make effective, data-driven decisions. The new Freestyle3D X incorporates state-of-the-art scanning technology that delivers enhanced scanning accuracy of 1 millimeter at 1-meter range. The Freestyle3D X is available with a U.S. National Institute of Standards and Technology (NIST) traceable calibration accessory to provide
users with verifiable data accuracy – which is critical for forensic scanning and other highly regulated industries. On-site calibration data is exportable to PDF format allowing information to be easily shared with other team members. The Freestyle3D X also incorporates an automatic flash
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mode enabling users to scan objects in a variety of lighting conditions. New software tools deliver an intensely detailed visualization of the created 3D point cloud, and an integrated best-point filter enhances the quality of the scan data by reducing noise up to 35%. Finally, post-processing functions have also been improved, offering up to 5x faster data saving speed to further improve productivity on the job site. The Freestyle3D X can be employed as a standalone device or used in concert with FARO Laser Scanner Focus3D X Series Laser Scanners. Point cloud data from all devices can be integrated seamlessly – even in grey scale. “The Freestyle3D X sets the industry standard for ease-ofuse and verifiable accuracy among professional, portable scanning devices,” stated Joseph Arezone, Senior Vice President and Managing Director - Europe, Middle East and Africa, and Asia Pacific. “The new features such as automatic flash mode, best point filter and new
algorithms decisively enhance the overall scanning experience and en-
able users to carry out more projects with better quality at the same time. Moreover, the new Freestyle3D X will allow the most demanding users to achieve better accuracy in their projects.” With the introduction of the Freestyle3D X to its portfolio, FARO continues its role as a technology innovator for customers – helping them work faster, more effectively and save money in the process. FARO is dedicated to offering a full range of innovative and user-friendly handheld scanners to allow customers to implement and leverage 3D scanning to their business advantage.
About FARO FARO is a global technology company that develops and markets computer-aided coordinate measurement devices and software. Portable equipment from FARO permits highprecision 3D measurement and comparison of parts and compound structures within production and quality assurance processes.
The devices are used for inspecting components and assemblies, production planning, inventory documentation, as well as for investigation and
reconstruction of accident sites or crime scenes. They are also employed to generate digital scans of historic sites. With FARO, 3D measurement and documentation needs can be fulfilled confidently. As a pioneer and market leader in portable computer-aided measurement, FARO consistently applies the latest advances in technology to make its industry-leading product offerings more accurate, reliable, and easy to use. The focus is on simplifying workflow with tools that empower customers, thereby dramatically reducing the on-site measuring time and lowering overall costs. Worldwide, approximately 15,000 customers are operating more than 30,000 installations of FARO’s systems. The company’s global headquarters are located in Lake Mary, Florida, with its European head office in Stuttgart, Germany and its Asia-Pacific head office in Singapore. FARO has
branch locations in Japan, China, India, South Korea, Thailand, Malaysia, Vietnam, Canada, Mexico, United Kingdom, France, Spain, Italy, Poland, and The Netherlands.
For more information, Website: www.faro.com
Design today...
...build tomorrow
Unlock the potential for Additive Manufacturing Renishaw’s laser melting system is a pioneering process capable of producing fully dense metal parts direct from 3D CAD, which has the power to unlock the potential for additive manufacturing. From tooling inserts featuring conformal cooling, to lightweight structures for aerospace and high technology applications, laser melting gives designers more freedom, resulting in structures and shapes that would otherwise be constrained by conventional processes or the tooling requirements of volume production. It is also complementary to conventional machining technologies, and directly contributes to reduced lead times, tooling costs and material waste. • Shorten development timescales - be first to market • Reduce waste product and cost - build only what you need • Enjoy increased design freedom - create complex structures and hidden features
Find out more at www.renishaw.com/additive
Renishaw plc Whitebridge Way, Whitebridge Park, Stone, Staffs ST15 8LQ United Kingdom T +44 (0)1785 815651 F +44 (0)1785 812115 E additive@renishaw.com
www.renishaw.com/additive
BUSINESS NEWS
Concept Laser reports further revenue growth in the first half of 2015 “3D printing that has the potential to revolutionize the way we make almost everything.”
Mr. Frank Herzog, CEO & President of Concept Laser
“
We are very proud that we not only succeeded in maintaining the great growth from last year, but have even managed to build on it. That shows that we remain on the right way. However, anyone who knows Concept Laser knows that our passion for technology and the pronounced innovative drive will not allow us to rest on our laurels.
“
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Concept Laser’s 15th anniversary in 2015 is a brilliant performance – & it has the figures to prove it. After revenue growth of 75% in 2014, Concept Laser consolidated its growth at a high level with a further 35% revenue increase in the first six months of 2015. While 45 systems were sold in the same period of the previous year, the company has already received 68 orders this year, a significant increase of roughly 50%. Concept Laser’s growth continues unabated in 2015. Frank Herzog, CEO & President of Concept Laser: “We are very proud that we not only succeeded in maintaining the great growth from last year, but have even managed to build on it. That shows that we are still moving in the right direction.
However, anyone who knows Concept Laser knows that our passion for technology and the strong drive for innovation will not allow us to rest on our laurels. As a result, I can assure you that our research and development department is already working on new projects which will change future manufacturing processes sustainably.”
30, 2015 was 35% higher than in the same period of the previous year. Once again, the revenue growth was solely due to sales of large-scale systems in the 1000W laser class, and demand from the aerospace industry in the USA. Staff numbers also increased by a further 30% compared with 2014 in the first half of 2015.
2015 semi-annual financial statements indicate growth
Large-scale system segment fills order books and boosts revenue
The continued rising acceptance of additive manufacturing in the markets and the attractiveness of laser melting systems from the Lichtenfels-based manufacturer are reflected once again in Concept Laser’s growth figures. In the first six months of 2015, orders were placed for 68 machines (1st 6 months of 2014: 45 machines). This is equivalent to growth of 51% compared to last year (cut-off date June 30, 2015). In addition to this, the revenue as of June
Demand for the X line 1000R remained high in the 1st half of 2015, driving our revenue. From January 2015 on, the new X line 2000R® supplemented our range in the large-scale system segment. It combines a large build envelope with increased build rates. With a build envelope of 800x400x500 mm3, the X line 2000R® currently offers more space than any other system for laser melting metals. The X line 2000R®’s
X line 2000R® combines the world’s largest build envelope (800x400x500 mm3) for laser melting with metals with faster build rates. The X line 2000R®’s multilaser technology, with 2 x 1,000 Watt lasers, has a direct impact on the exposure time
BUSINESS NEWS www.mtwmag.com
multilaser technology with variable optics has a direct effect on the exposure time. Its heart, the dual laser system in the X line 2000®, is based on two 1,000 watt lasers. The useful build volume is also increased a further 27% from 126 l to 160 l compared with an X line 1000R. The X line 2000R® also 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 the sieving station. The dosing unit is filled completely and fully automatically within one cycle. Compared with competitors’ systems, the X line 2000R® offers almost three to four times the build volume. Key buyers are from the automotive and aerospace sectors.
Expansion of infrastructure progresses The new manufacturing facility in Lichtenfels, with 3,500 m² of floor space, was already running at full capacity in the first half of 2015. It
Manufacturing capacity expanded: The new manufacturing facility is already running at full capacity. It increased Concept Laser’s system production capacity by a factor of 2.5. increases Concept Laser’s system production capacity by a factor of 2.5. The logistics centre, which is also new, pulls the strings for global logistics management in a 1,000 m² facility. It processes incoming goods, outgoing goods, machine dispatch and supplies of spare and wearing parts. A team of external consultants optimised the plant intralogistics for the value stream. To cope with the strong sales of machines, the warehouse handling area was quadrupled in size, while the parts flow and the throughput times were accelerated. Overall, Concept Laser is also structurally ideally prepared for continued growth, and will
make further investments in its infrastructure in future.
Outlook for the second half of 2015 All signs on the global markets indicate that the trend set in the first six months will continue in the second half of the year. Following sales of 110 systems in the previous year, the Lichtenfels-based company expects this figure to reach more than 150 machines by the end of this year. Revenue growth is forecast to remain at 35% for the entire 2015 financial year. Frank Herzog, CEO & President of Concept Laser: “We are pleased to announce that growth will stabilise at a high level.” Accordingly, the plant engineering
provider also plans to introduce new products at the upcoming formnext powered by TCT trade fair in Frankfurt. The company’s R&D activities are running at a high level. This suggests that it will introduce further innovations in laser melting technology in the second half of 2015 and the following financial year. For example, Concept Laser, which has been focusing on quality monitoring since 2004, will supplement QMmeltpool, introduced in 2010, with QMmeltpool 3D. This tool will allow position-related real-time monitoring and three-dimensional visualisation of the part. It identifies and analyses local effects that arise during building of the part clearly. In addition to this, Concept Laser, which is also a pioneer in the field of quality assurance/monitoring for laser melting with metals, is already working simultaneously on other modules, which will take the sector to a whole new level. For more information, Website: www.concept-laser.de
Value stream-optimised logistics centre: The warehouse handling area was quadrupled to 1,000 m², accelerating the parts flow and throughput times.
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BUSINESS NEWS
Ahmedabad Machine Tool Expo harbingers a new era for Machine Tool Industry in Western Region The first ever Ahmedabad Machine Tool Expo at Mahatma Mandir, Gandhinagar from 24 to 27 September 2015, organized by the Indian Machine Tool Manufacturers’ Association (IMTMA) concluded on a positive note. The industry’s overwhelming response in making the regional machine tool show that witnessed a footfall of about 9000 visitors has heightened expectations. The expo displayed state-ofthe-art technologies primarily focusing on manufacturing solutions from the industries located in the western region. Fervent business activities transpired at the expo postinauguration. Trade leads were generated amidst a lot of learningand information sharing in a business environmentand thus culminating into a heightened euphoria for the industry. The show had the presence of industry delegations representing various sectors such as textile machinery, pharmaceutical machinery, petrochemical engineering, agriculture implements, auto engineering,
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mining equipments, and many more. Elaborating on the importance of the show from a regional perspective, IMTMA President Mr. L. Krishnan said, “The show gave an opportunity for visitors to meet the small and medium enterprises who are the original equipment manufacturers and their sub suppliers. The expo opened avenues to penetrate niche industry sectors as well as the untapped regional market.” Concurring with IMTMA President’s opinion, Mr. V. Anbu, Director General, IMTMA said, “There is a sizeable demand emerging in west India as a
result of the foreseen growth in the manufacturing industry. The current expo has shaped up to be an ideal platform to initiate business in the region.” Exhibitors were enthralled by the responses solicited from their customers. Many of them felt that participating in such a show was vital not just for sales but also for services. The show enabled them to meet the different regional customers and thereby better understand the requirements of the regional markets. The understanding generated at the show will serve as the basis for solid industrial development in India and simultaneously strengthen
the companies’ business while expanding their network to a larger scale. Visitors also spoke in glowing terms about the first edition of the expo. They were quite happy to see and interact with the machine tool manufacturers. Many of them felt that the exhibitors had impressive and innovative displays and they were able to come across good innovations at various stalls. The expo was ideal to locate new technologies and quality suppliers.Exhibitors expressed that visitors were ready for investing on high-end technology which is a positive indicator. The first edition of the Ahmedabad Machine Tool Expo has been a runaway success. The strong presence of visitors from the region made it a truly grand event. The expectations will now grow higher from all sides since the responses have been positive. IMTMA will organize many more regional shows and with the support of the industry expects to build on the success achieved in Ahmedabad in the days to come.
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Rotary Encoders
BUSINESS NEWS
Panish will take over the responsibilities as business head, Bosch Power Tools for India & SAARC About Bosch in India
Mr. Panish P K, Regional Sales Director, Bosch Power Tools
Bosch, a leading global supplier of technology and services, announced the appointment of Panish PK as the Regional Sales Director, Bosch Power Tools for India & SAARC. Mr. Panish has taken over on August 3rd, 2015 from Mr. Vijay Pandey, who was the Vice President of Bosch Power Tools India and will now be shifting to Germany to take on a new responsibility within the company. With an Engineering Degree from Bangalore University and a Post Graduate Degree in Management from IIM Calcutta, Mr. Panish will focus on overseeing sales of Power Tool products in India & SAARC. Additionally, his vision for the organization is to get closer to the customers by providing compelling value proposition and customized solutions for both the markets. In his new role, Panish will spearhead the company’s
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growth across multiple channels for the entire portfolio of power tools, accessories and services business. His long term focus will encompass deeper penetration of the brand through channel expansion and focused sub dealer programmes in tier 3 & 4 cities. He will also focus on widening the power tool accessories product portfolio besides strengthening the services network. Commenting on his appointment, Mr. Panish said, “I am honoured to lead Bosch Power Tools, a global reputed company built by many iconic leaders in the industry. I want to continue to focus on strengthening local innovations and ensure that the current opportunities are well tapped thereby contributing to the growth of the company. I look forward to my new role and am excited about working with the entire Bosch team.”
About Bosch Power Tools The Power Tools Division of the Bosch Group is the world market leader for power tools, power tool accessories and measuring tools. In 2014, its roughly 19,000 associates generated sales of 4.2 billion euros, about 85 percent of which outside of Germany. With brands such as Bosch, Skil and Dremel, the division stands for customer focus and great engineering progress. The core success factors are innovative strength and pace of innovation. The division generated about 35 percent of its sales in 2014 with products that have been on the market for less than two years. In 2015, Bosch Power Tools will again launch more than 100 new products on-to the German market in its four business segments power tools, accessories, measuring tools and garden tools.
In India, Bosch is a leading supplier of technology and services in the areas of Mobility Solutions, Industrial Technology, Consumer Goods, and Energy and Building Technology. Additionally, Bosch has in India the largest development center outside Germany, for end to end engineering and technology solutions. The Bosch Group operates in India through nine companies, viz, Bosch Limited, Bosch Chassis Systems India Limited, Bosch Rexroth India Limited, Robert Bosch Engineering and Business Solutions Private Limited, Bosch Automotive Electronics India Private Limited, Bosch Electrical Drives India Private Limited, BSH Home Appliances Private Limited, ETAS Automotive India Private Ltd.and Robert Bosch Automotive Steering India Pvt. Ltd.. In India, Bosch set up its manufacturing operation in 1953, which has grown over the years to include 14 manufacturing sites, and seven development and application centers. Bosch Group in India employs over 29,000 associates and generated consolidated revenue of about `15,250 crores* in 2014 of which `10,800 crores* from third party. The Group in India has close to 12,000 research and development associates and has filed for around 150 patents in 2014. For more information, Website: www.boschindia.com
BUSINESS NEWS
Kennametal Recognized with Bosch Global Supplier Award Kennametal Inc. (NYSE: KMT) announced that it has been awarded the Bosch Global Supplier Award 2015 from Robert Bosch GmbH (“Bosch”), a leading global supplier of technology and services. The biannual award recognizes outstanding performance in the manufacture and supply of products or services – notably in the areas of quality, costs, logistics and innovations. “It is an honor to be recognized by Bosch as the only tooling manufacturer to receive their Global Supplier Award,” said Don Nolan, Kennametal president and CEO. “This award acknowledges Kennametal’s
global team who is working relentlessly to deliver innovative products, superior quality and outstanding performance to the customer every day.” Kennametal was among 58 suppliers out of 35,000 that Bosch presented with this esteemed award. To be eligible, suppliers must deliver bestin-class services, quality and total cost of ownership as well as guarantee global footprint and significant sales in the purchasing category. “The Bosch Global Supplier Award honors our top suppliers, who play such a key role in Bosch’s success,” said Dr. Volkmar Denner,
chairman of the Bosch board of management. “Our suppliers are important partners in helping us shape the connected world. We want to work with them to develop beneficial solutions for our customers.”
Kennametal At the forefront of advanced materials innovation for more than 75 years, Kennametal Inc. 1600 Technology Way | Latrobe, PA 15650 USA | Tel: 724.539.5000 | www. kennametal.com is a global industrial technology leader delivering productivity to customers through materials science, tooling and wear-
resistant solutions. Customers across aerospace, earthworks, energy, general engineering and transportation turn to Kennametal to help them manufacture with precision and efficiency. Every day nearly 13,000 employees are helping customers in more than 60 countries stay competitive. Kennametal generated more than $2.6 billion in revenues in fiscal 2015.
For more information, Website: www.kennametal.com
Competence & experience - added value for customers KlüberEfficiencySupport helps increase food safety and protect valuable resources Next to a lubricant that is optimally suited for the respective application, its proper handling is also essential for food safety. In particular within a sensitive area such as the foodprocessing industry, stringent requirements have to be met. Therefore, Klüber Lubrication offers a wide range of speciality lubricants and services for the food sector. In addition, KlüberEfficiencySupport can help protect valuable resources such as energy and water, thus helping to reduce operating costs. “Klüber Lubrication is more than just a manufacturer of speciality lubricants”, explains Aldemir Oliveira, Global Market Manager Food Industry at
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Klüber Lubrication. “We as the specialist offer our customers a comprehensive lubrication package. Lubricant users benefit from our experience and tribological know-how and do not have to worry about finding the optimum solution for their particular application themselves.” The services and consulting services combined under the keyword KlüberEfficiencySupport
are precisely tailored to the requirements and challenges of the respective customers – far exceeding the actual lubrication issue. In close cooperation with lubricant users, the tribology experts of Klüber work on the systematic optimisation of lubrication processes in the plant. This includes services such as the development of lubrication schedules, cleaning & relubrication, general inspections as well as lubricant and component analyses. All this is aimed at the optimal utilisation of the machines & know-how of the staff. Another important offering from Klüber Lubrication is training tailored to the foodprocessing sector. Besides
tribology basics and the properties of oils and greases, the lubrication of machine elements operating in the sensitive environment of the food-processing sector is at the focus of these KlüberCollege trainings. Participants learn about the optimisation of lubrication processes, inspections and maintenance, correct lubricant application and the prevention of typical errors such as excessive lubrication or lubricant starvation.
For more information, Website: www.klueber.com
COMPANY PROFILE www.mtwmag.com
NuGEN’S forte: Sheet metal working machines
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uGEN Machineries Ltd. specializes in manufacture of ‘Trimans’ Conventional, NC and CNC Hydraulic Press Brakes, Shears and other sheet metal working machines for more than three decades in India. The manufacturing facility is based near Ahmedabad, and has a workforce of 80 people, out of whom 15 are Engineers. The company is run by technocrats and professional directors who work full time in various work areas such as Product Design & Improvements, Marketing, Contracts Execution, After Sales Service, Quality Control, Finance and Customer Support according to their area of specialization and core competence. NuGEN, an ISO 9001 certified
company, who introduced and pioneered the Rear Cylinder Hydraulic Press Brake in India, has also designed and manufactured variable Rake Hydraulic Shear with in-house R & D effort and has installed nearly 2000 Press Brakes and Shears in India and abroad. The company has also successfully designed and manufactured Special Purpose Presses and plants for manufacturing SAW pipes (Press Cap. 1500MT X 6000MM), Hydro. Tube Tester, Extrusion Presses (500MT) and Welding Electrode Plants. NuGEN’s list of customers includes Tata Motors, TAL Manufacturing, Punj Lloyd, Thermax, Mahindra and Mahindra, VIP Industries, LG Electronics, L & T, Alfa Laval, ISRO, PRL, HMT, BHEL, HAL, Sintex, Videocon, Blue Star, Carrier, Powerica, Trumac Engg, Inductotherm, Electrotherm, Haier, Havell’s, Jindal Steel, etc. just to mention a few. NuGEN machines have been exported to Malaysia, Turkmenistan, Kuwait, Tanzania, Bahrain, Dubai, Sharjah, Abu Dhabi, South Africa, Sultanate of Oman, Ethiopia, Jordan, Ghana, Zimbabwe and USA.
For more information, Website: www.nugenindia.com
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COMPANY PROFILE
‘Bright’ Roller Burnishing Tools Renowned for providing complete burnishing solutions
C
oimbatore-based Bright Roller Burnishing Tools Private Limited, incorporated in the year 1994, is an ISO 9001: 2008 certified company. With its sustained efforts, quality products and after-sales service, it is enjoying a reputation in the field of burnishing for more than 27 years.
Clientele
The company has a very wide customer base in India covering MNCs, Corporate, Medium and Small Industries and Public sector undertakings. With a vast experience and an ever-expanding list of satisfied customers in India, the company has set its sight on the overseas market. It is exporting its quality products to countries like, USA, Iran, Australia, Thailand, Indonesia, UK, Singapore, etc. Applications
Bright Burnishing Tools are being used in sectors like automobile components manufacturing, motors and pump industry, textile machinery manufacturing, hydraulic and pneumatic parts, home and office appliances, machine tool manufacturing, earthmoving equipment manufacturing, railway parts, defense, aircraft parts and many more.
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The Process and its Advantage
Burnishing is a cold rolling process on ferrous and non-ferrous machined components. Achieving superior surface finish (0.1 Ra to 0.3 Ra based on pre-burnishing condition) and close tolerance is easier with less cycle time and at negligible cost, thereby eliminating finishing and quality problem, which are encountered in the day-to-day production process.
• Tools with machine feed / self feed design available • Tools available with different shank options Outer Diameter Burnishing Tools • Tools for through and stepped bores • Min. External Dia. 2mm and above • Tools available with different shank options • Highly suitable for diameter less than 30mm & with short burnishing length
Product range
Bright’s product range includes burnishing tools for Internal Diameter, External Diameter, Internal and External Tapers, Flat circular faces, Grooves, etc. Internal Diameter Burnishing Tools • Tools for through and stepped bores • Min. Internal Dia 5mm and above • Designs available for Short bore length, Long bore length, Big internal dia.
Taper Angle Burnishing Tools (Internal & External Angle / Taper) • Tools for Internal tapers and external tapers • Min. Minor Dia 5mm and above. • Highly suitable for mating taper assembly, like hydraulic end fittings • Can be burnished directly after CNC turning. • Tools available with different shank options. Special Roller Burnishing Tools Apart from its standard product ranges, the company also manufactures special purpose burnishing tools as per customer’s requirements. These include: • Single Roller Tool • Multi Surface Single Roller Tool
COMPANY PROFILE www.mtwmag.com
• • • •
OD H Type tool Face Burnishing Tool Flat circular face burnishing tools Groove Burnishing Tools
Burnishing Machine
Apart from Burnishing tools, Bright also manufactures Burnishing machines like Hydraulic OD Burnishing Machine, Pneumatic ID Burnishing Machine, and Portable OD Burnishing Machine. • Portable OD Burnishing Machines can burnish plain shafts of diameter ranging from 2mm to 30mm. These are designed for achieving very close tolerances and high surface finish in plain shafts. This machine is highly suitable for mass production of Mixi Shafts, Motor Shafts, Piston Rods, OD of Bushes, etc. Separate burnishing kits are supplied according to the components size requirement. These machines can be moved anywhere in the production line.
finish. The machine is provided with automatic spindle feed and rapid return control with pneumatic cylinder arrangements. The standard machine can burnish 40mm diameter maximum and has a spindle stroke of 80/100mm. • Hydraulic OD Burnishing Machine is constructed as per machine tool design standards. The standard machine can burnish outer diameter ranging from 6mm to 60mm. The machine is capable of burnishing both plain and stepped shafts. There is no limitation of burnishing length. The machine can be tailor-made according to the customer’s production requirements. Auto part loading attachments can be designed and fixed in the standard machine for plain shafts. Very high surface finish can be obtained (0.05 to 0.2 Ra) in single pass. This machine is ideal for both batch and mass production. New Introduction
• Pneumatic Internal Diameter Burnishing Machine is used to achieve very high production rate, close tolerance and very high surface
Tube expanders are made of special alloy tool steels carefully heat treated to withstand severe operating forces. These tools are produced by a highly skilled
workforce using the latest machinery and state-of-the-art manufacturing technology. Tube expanders are precision made tools. After rolling several tubes, submerge tools in solvent to clean and cool, then dip in light weight oil to lubricate. For best results in rolling tubes, it is suggested to use two or more tube expanders alternately. Representation
The company has been widely represented throughout India by Regional Representatives, who handle both domestic sales and after-sales service. To strengthen the domestic marketing base, the company has participated in numerous engineering trade fairs in India. Customer appreciation
“Customer appreciation is our source of strength and inspiration, and the same will help us to make our products better every time and in all ways. Many of our customers have sent letters appreciating the quality of our products and after-sales service. We always focus on continuous improvement and customer delight,” says the company – P.K. Balasubbramaniian
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COVER STORY
Metalworking fluids with innate GREEN factor Mr. Chris Sheehan Managing Director Asia Hangsterfer’s Laboratories, Inc
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COVER STORY www.mtwmag.com
Q. What is technical importance of “Metalworking Fluids”? Would you please brief us about your products under this category? What is the significance of these products in any specific industries especially in India? Metalworking lubricants are often times overlooked in the entire metalworking process. It is quite an expensive thing to overlook because the cost of the cutting tool, the cause of the machine tool, all these things are in jeopardy if improper lubricant or anything is used in that scenario. Our value proposition for metalworking fluids is predicated on tool life, surface finish, worker health and safety and life of the fluid; how long it is going to last in the system. And then you can truly get a picture for what you are spending in the process for the use of a metalworking fluid. We look at the most difficult materials to machine: nickel alloys, titanium. Some of them really require very specific type of lubricity and those customers are very detail-oriented whereas the automotive industry often times the machinery is cast iron. It is really just about corrosion control and chip removal. Our core competency is to analyses different need of the different market and design application driven products to reduce manufacturing cost. That is where we do our best work. Our value proposition is not based only on price.
Q. What is technical importance of your other type of manufacturing “TSP Equipments”?
The other thing with TSP equipment is what it does is it really controls the amount of consumption because sometimes, the people use laundry detergent or dish detergent or soap. They think some is good and more is better. That is not always the case. There is a specified range in which the lubricant is going to work the best and that is built into the design of the product.
Q. Are the metalworking fluid & TSP equipments correlated to each other? Yes. TSP equipment is designed to handle processing and controlling the metalworking lubricants.
Within our product group, approximately 40 percent of all the metalworking lubricants that we manufacture are either biorenewable or they contain over 50 percent bio-based material. That is truly a sustainable way of doing business.
Q. How your products and services will be a utility and useful to protect support of environment responsibility and sustainability ?
Q. What is the differentiating factor of your products over existing brands available ?
Within our product group, approximately 40 percent of all the metalworking lubricants that we manufacture are either bio-renewable or they contain over 50 percent bio-based material. That is truly a sustainable way of doing business. Some of the ingredients that we use are registered as the highest or most bio or sustainable products in the industry today. Our future design of products is all around that concept because not just in India but all over the world. This initiative is from government is good for the industry and it does drive innovation. This innovation is really not as painful as a lot of regulations typically are. It is turning out some really great products for us.
I can tell you that one advantage that we have now making our product in the United States and shipping into India is the health and safety of our products. Our products are all REACH compliant and we are REACH compliant; GHS and REACH; Global Harmonized System and REACH registry. Our products don’t contain any hazard warnings. As I said, our products don’t contain any hazardous ingredients. There are a lot of metalworking lubricant manufacturing companies that use secondary amines, boron and formaldehyde. These are three toxic ingredients that are very commonly used. We don’t use them and we never have and don’t expect to use them.
TSP equipment is important because most metalwork in lubricants. Once they are started to be used, they have to be maintained properly. If they are maintained properly, then their life is extended. So that reduces the overall operating cost of metalworking lubricant. Water dilutable metalworking lubricants needs to be mixed at proper ratio because of specific additives in the cone that are designed to be depleted over time or concealed. If they are not added back at the right ratios, then you have a problem and then you end up generating much more waste than you need to.
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COVER STORY
Our products are all REACH compliant and we are REACH compliant; GHS and REACH; Global Harmonized System and REACH registry. As I said, our products don’t contain any hazardous ingredients.
The reason people use these ingredients is because it drives down the cost to make a little more profit. Is that a moral ground to stand on for commerce? We don’t believe so. If a product costs more money, it is because its raw materials are more safe. Our advantag might not be seen in the price per gallon or price per litre, it is really in the value we give to our customers, knowing that if you are a manufacturing facility and you have 100 workers that are coming in contact with metalworking lubricant every single day, you know you are doing the right thing for your workers. You are doing the right thing for the environment and you are making the right decisions.
Q. How do you see the trends which are driving the metal cutting industry and how you see the prospects for oils in all the automobiles, aerospace and aviation industry? Technical trends have a lot been driven by environment warning policy. Getting away from short chain chlorinated paraffins, eliminating the chance from formaldehyde are things that are actually driving the industry as a whole. Within that segment, the aerospace industry does not like to use chlorine because of the impregnment. The medical implant industry does not like to use sulphur because of impregnation probably with cleaning. There is a line of chemicals that can come
into contact with the electronics industry because of potential alkali acid and corrosion problems after the electronic device is sealed. So we have been very successful on a global scale in those industries and as those industries move to India, we are just going to transfer that same technology and import here and not just fixed on the technology that we have adopted over the years because of other markets, we believe that the market will be the driver. As long as it operates within our core values, that is the business we are going to go after.
Q. What care should be taken by customers while product selection considering health, safety and environment rating? I did said about the chemicals like secondary amines, boron and formaldehyde is used by 80 percent of the metalworking lubricant manufacturers in the world today and all these ingredients are known as toxic. In Europe, their substance is of very high concern. The health and safety regulation of the worker is moved to the front burner and these chemicals will not be disclosed. That is a very real concern for India because someone can order a product in India and the material safety data sheet does not always make sense about what is in the product and that is unfair to the worker. If it is a trade secret and it is non-toxic, you don’t have to put in on your FDI, in your material safety data sheet. If it has a hazardous ingredient, you need to list it.
Q. Which are the industries you are focusing in India? There is a portion of the industry that really meshes well with our philosophy and our core values and principles. When we connect with those customers, they are customers for many, many years.
Q. Presently you are distributing your products through Sanjay Tools & Adhesives ? How you see the future of this relationship? Our dealer relationships globally is very strong and interdependent .We have been selling in Japan for 50 years. We have
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COVER STORY www.mtwmag.com
been selling in Taiwan for 46 years. We have been selling in China for 40 years. We are looking forward for similar relationship with Sanjay Tools & Adhesives in India.
Q. What is your opinion about Indian market? Emerging markets is nothing new to us but at this point in time, it is really most exciting because the age of the Indian population and how well read they are, how educated they are. We have a prime minister now who really has a great direction.
Q. What are your concluding remarks? Lot of people have in their mind the robot revolution. There is still going to be human interface. Chemicals still has to be there. This is the thing that amazes me. I have gone into manufacturing facilities where they are using a product that has basically hazardous on the shop floor. The
manager’s or the owner’s office is actually above the shop floor or on high ground. He is breathing that all time too. He is inhaling those fumes, interacting with these chemicals. You may think out of self-preservation, you would make the right decision, let alone the person who is standing on the shop floor. I don’t want to sound like I am on a soap box or anything but it is a moral issue. If you know something is hazardous and toxic, why use it? If you have to use it, why wouldn’t you have the proper personal protective
equipment in place? The worker has to use a respirator, has to use a face shield. If you look at the material safety data sheet of some of our competitors, on the last page, it give you the PPE, the Personal Protective Equipment necessary like goggles, smocks, gloves but when you go to the factory, there is no goggles, smocks and gloves. They get coated in lubricants. The skin is interesting; it is the largest organ. You can wash it off. But it is going to get into your skin and it is commonly called the saturation point. Certain chemicals are sensitizers. Morpholine, most common biocide, we don’t use it. But I tell you, if I took ten samples, nine would contain morpholine. What happens the first time you come in contact with it, there is no reaction. The second time, there is a little reaction to your liver maybe. Each time you come into contact with it, it builds up in your system and your body begins to revolt against it but they still make it and it is okay.
ABOUT HANGSTERFER Hangsterfer’s Laboratories, Inc. was founded in New Jersey in 1937 and incorporated in 1942. Hangsterfer’s was built on 90 acres of farmland and is still at the same location today. This setting was selected because of our founder’s fondness for the environment and the belief that both industry and nature can be blended together in harmony. Our products contain additives that help protect the health and safety of mankind and the environment in which we live. Mr. Hangsterfer was dedicated to the research, development and manufacture of high quality, high performance metalworking
lubricants. His principles are still upheld today by both the second and third generation of family operation and ownership. Our experience has shown that an educated consumer is a dedicated consumer. We supply the solution to help lower your manufacturing costs, ultimately keeping you and your company competitive in today’s global marketplace. Customers quickly realize that the lubricant is one of the most important factors in their metalworking processes and that Hangsterfer’s signature green and white drums provide extraordinary results.
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CASE STUDY
Patrizio Vaccaro, marketing manager for COORD-3
TONiC™ optical encoders support the latest generation of CMMs from COORD-3
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continuous product development cycle, horizontal organisational structure and streamlined range of model sizes have made COORD-3 a global CMM brand. Renishaw supplies a wide-range of precision metrology products to COORD-3 and both companies benefit from a long-standing and successful partnership. COORD-3 CMMs make use of the following Renishaw solutions: • Touch trigger motorized probe systems including the 3-axis PH10 PLUS and 5-axis PH20 heads • Universal CMM Controllers (UCC) and software • Laser calibration systems such as the XL-80 laser with XC-80 environmental compensation unit • TONiC high-performance optical encoders with FASTRACK™ mounted RTLC stainless steel scale. Renishaw enhances the COORD-3 customer solution with products that increase CMM throughput, accuracy and automation, resulting in increased
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COORD-3 manufactures its CMM structures from aluminium alloy and silicon-carbide offering maximum metrology performance and productivity sales backed by a strong global support network. Renishaw has also built valuable synergies with COORD-3 to support its demanding product design strategies. Patrizio Vaccaro, marketing manager for COORD-3, says: “Since 2009, we have launched at least two products per year into the market. Our new bridge-type Universal CMM family features a brandnew design and was launched - only one year after the project started.” TONiC and FASTRACK
COORD-3 is one of the few suppliers
CASE STUDY www.mtwmag.com
to manufacture its CMM structures from aluminium alloy and siliconcarbide, offering maximum metrology performance and productivity. Even in a lab with environmental control, traditional granite CMM frames have significant thermal mass and take much longer to absorb and dissipate thermal changes, whereas, aluminium’s high coefficient of thermal conductivity allows the machine structure to respond more rapidly and linearly with temperature fluctuations. This is important as it is necessary to predict CMM thermal behaviour and compensate for it in order to ensure machine accuracy over its operating temperature range. CMMs that expand linearly without induced constraints are easier to compensate for, which improves measurement repeatability. The low structural weight of aluminium also improves the CMM’s acceleration and deceleration - enhancing overall traverse speed and ultimately increasing measurement throughput. This allows the CMM to operate at relatively high speed, which is particularly important for in-line applications where inspection operations need to keep pace with production. Renishaw provides real-time temperature compensation with its 3-axis UCC S3 and 5-axis UCC T5 controllers, allowing temperature monitoring of up to 16 different locations, using sensors which can be fixed to the X, Y, and Z axes of the CMM and to the workpiece being measured. The thermal data is then combined with axis feedback from the TONiC encoder system to produce high fidelity measurements that allow the machine to minimise thermal error and reduce measurement uncertainty. A TONiC readhead, with 0.1 μm resolution, and RTLC FASTRACK scale, is installed on each CMM axis. FASTRACK is a scale carrier system, comprising two miniature guide rails, that securely retains Renishaw’s 8 mm x 0.2 mm lowprofile stainless steel scales and allows them to freely expand at their own CTE (Coefficient of Thermal Expansion) with
almost zero hysteresis (for example, <1 μm on a centre-clamped 2 metre axis over the entire operating temperature range). Another advantage of this system is that damaged scale can be quickly removed and replaced, even when access is limited, thus reducing machine downtime. This feature is also ideal for large machines that need to be sectioned prior to transportation. Fabrizio Tonellato, COORD-3’s principal electronics engineer, explains: “The main challenge with CMMs is
Fabrizio Tonellato, principal electronics engineer for COORD-3
ensuring measurement repeatability. Renishaw’s TONiC encoders with FASTRACK have solved the problems associated with differential thermal expansion between the scale and machine axis on which it is applied. Strong points of the TONiC encoder series include: high measurement precision, linear thermal expansion of scale due to CTE of scale, ease of installation and set-up and easily replaceable FASTRACK scale for straightforward maintenance.” Mr. Vaccaro emphasises: “Scales and readheads are of primary importance for CMMs and TONiC with FASTRACK embodies the COORD-3 design philosophy. Different materials are used to build a CMM and Renishaw’s encoder scales help minimize the CMM measuring error and maximize precision.” Mr Vaccaro adds: “COORD-3 CMMs are built largely from aluminium and Renishaw’s encoders help to compensate for expansion and thermal movement. In creating our CMMs, we are not bound in the choice of the materials because Renishaw’s FASTRACK mounted scale is largely free to expand independently of the machine structure. TONiC with FASTRACK and the UCC S3 / T5 controllers are stable, flexible and well-
TONiC optical encoder and RTLC FASTRACK scale mounted on each CMM axis MTW OCTOBER 2015
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Renishaw’s global network allows COORD-3 to give its customers the best after market service, wherever they are
designed products, which have helped to triple our sales.” The PH20 probe
COORD-3 CMMs can also feature a Renishaw PH20 touch-trigger system, which allows easy access to features at any angle and can deliver a 3-fold increase in measurement throughput over traditional systems. Unlike conventional touch-trigger measurement methods, which rely on speeding up the motion of the CMM to measure quickly,
PH20 utilizes head motion technology developed for the multi-award winning REVO® system to minimize the dynamic errors of the CMM at higher measurement speeds. “For us, Renishaw’s products sell themselves and really drive our business – the PH20 gave us a great competitive advantage and in 2014, thanks to PH20, 5-axis CMM sales were 10 times higher than in 2013.” Global support
A great strength of COORD-3 is its after-market service, since the real value of CMM products is in the customer experience and overall lifetime costs. High-quality and rapid customer support enhances the customers’ perception of value and trust in the COORD-3 brand. Mr. Vaccaro concludes: “If a foreign COORD-3 customer needs some assistance, say a probe installed on one of our machines, we can always count on the quality of Renishaw’s global support. Renishaw’s global network allows us to give our customers the best after market service, wherever they are.”
PH20 probe head mounted on COORD-3 CMMs for 5-axis measurement 32
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About COORD-3
COORD-3 was founded in 1973 and is
headquartered in Bruzolo, Italy – where it manufactures a comprehensive range of CMM equipment including gantry, bridge and horizontal-arm types. Customers typically use CMMs for mechanical part ideation and conception, design and assembly, quality control and certification. COORD-3 also develops software solutions such as TouchDMIS, for touch interface CMM control, to facilitate CMM utilization. In February 2015, in-line metrology specialist Perceptron Inc. announced its acquisition of COORD-3. This became effective from 1st March 2015 leading to the establishment of a new company, COORD-3 Industries s.r.l, fully owned by Perceptron. A winning team
Renishaw’s TONiC encoder system with RTLC scale on FASTRACK, PH20 probe heads and many other leading metrology products give COORD-3 the tools it needs to grow its business with cuttingedge CMM technology. This technical collaboration allows both companies to remain at the forefront of new product development.
For more information, Website: www.renishaw.com/tonic.
CASE STUDY www.mtwmag.com
“Ajikawa & SCI Metal Tech” builds 120m towers using Lantek software
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n Thailand, Lantek is making the manufacture of steel structures considerably easier for Ajikawa& SCI Metal Tech. Based in Bangkok, the company manufactures masts and towers for power transmission lines up to around 500kV and for telecoms applications up to around 120m tall. In addition, Ajikawa& SCI also produce general structures for solar power farms, bridges and wind turbines. Originally, the company purchased Lantek software several years ago to program its PROArc plasma cutting machine, but it did not realise how versatile the software was until Lantek’s local agent KSB3 Machine demonstrated the latest Lantek Expert Cut software and the Lantek Flex3d Steelwork software. SanpetchTiyaekapun, Section Manager at Ajikawa& SCI, says, “Our old software was DOS based and was slow and difficult to use. We are impressed by how fast and simple to operate the new system
is. Furthermore, we can use it to program our other machines too.” Currently the company has marking punching and shearing lines, marking drilling and shearing lines, and plate drilling machines, which can all be programmed with Lantek Flex3d Steelwork. In addition, it has plasma cutters, oxy gas cutters, one plate punching machine and punching and marking machines, which are all programmed with Lantek Expert. With both Lantek systems, parts can be nested to deliver maximum material utilization. Lantek Flex3d Steelwork can then program drilling, tapping, sawing, marking and plasma cutting operations including 5 and 6-axis bevel cutting operations. Simulation avoids the possibility of a collision and tool path modification commands give absolute control for an optimised CNC program. With Lantek Expert, designs can be imported from CAD, nested and then
cut or punched, generating a program that is tailored to the capabilities of each machine tool. SanpetchTiyaekapun says, “After completing the installation and training we were immediately using the new software and, within three months, everything we programmed was 100% Lantek. We have been able to reduce the programming effort from four people down to two for each technology and the processing time is greatly reduced.” He continues, “As well as easier and faster programming, workload allocation to each machine is now more efficient as this can now be done in the office rather than on the shop floor. In addition, we can produce a productivity report. Our aim is to extend this capability to enable us to further monitor our workflow.” Currently, Ajikawa& SCI is developing its programming and productivity monitoring capabilities and it anticipates that this will deliver worthwhile savings. Already it can see that the Lantek software will enable it to minimize scrap rates. However, an immediate benefit is Lantek’s ability to work with numerous different CAD files. SanpetchTiyaekapun says, “We use many different design systems including IUE, BOCAD and TEKLA. We can select whichever one we want to use and exchange files with Lantek without a problem. With Lantek we can control design, engineering and production at the same time and can select other systems in the future, knowing that they will all integrate. Would I recommend Lantek? Absolutely, yes.”
For more information, Website: www.lanteksms.com
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CASE STUDY
Lubricants for safe production Klüber Lubrication supports food safety as a member of the EHEDG
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ood and beverage producers focus on consumer safety. An important part of assuring this is to produce in a safe and hygienic environment using safe lubricants. But how can the manufacturer be sure that the lubricants he uses are safe? Klüber Lubrication production plants are certified according to the ISO 21469 standard for the production of premium quality H1-registered lubricants. Additionally, Klüber Lubrication promotes food safety as a member of the European Hygienic Equipment Design Group – the EHEDG. As a consortium of experts from the machine and component building industries, the EHEDG supports hygienic design in all areas of food production. Lubricants are considered machine components, which motivated an expert group of the EHEDG to create a Guideline -Document 23- specifically for lubricants. Similar to ISO 21469, this EHEDG Guideline describes binding hygiene measures to be used for the manufacture of H1 lubricants. It also contains instructions for the changeover of production machinery or its components to H1 lubricants. The EHEDG lubricants subgroup exclusively recommends the use of H1 lubricants in food production. To quote the EHEDG, “There are many cases where operators knowingly or
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unknowingly use H2 lubricants for production sites in which H1 lubricants are required – either for economic reasons or by simply misunderstanding the use of H1 in comparison to H2”. Despite the classes’ similarity, and whilst it may seem acceptable to use H2 lubricants, the EHEDG opposes this as in some cases they may even turn out to be toxic. Klüber Lubrication advocates that all food and beverage producers use only H1 lubricants and complement them by a service package like KlüberEfficiencySupport consisting of comprehensive training on lubricants and lubrication management including the creation of lubrication charts, optimising lubricants and many more activities supporting safe lubrication. About Klüber Lubrication
Klüber Lubrication is one of the world’s leading manufacturers of speciality lubricants, offering high-end tribological solutions to virtually all industries and markets worldwide. Most products are developed and made to specific customer requirements. During its more than 80 years of existence, Klüber Lubrication has provided high-quality lubricants, thorough consultation and extensive services, which has earned it an excellent reputation in the market. The company holds all common
industrial certifications and operates a test bay hardly rivalled in the lubricants industry. Klüber Lubrication, set up as a retail company for mineral oil products in Munich in 1929, is today part of Freudenberg Chemical Specialities SE & Co. KG, a Business Unit of the Freudenberg Group, Weinheim. Klüber Lubrication has approximately 2000 employees in more than 30 countries. About Freudenberg Chemical Specialities
Freudenberg Chemical Specialities Munich, was founded in 2004 as a new Business Group within the Freudenberg Group, Weinheim, Germany, a familyowned, diversified technology company with a history of more than 160 years. Freudenberg Chemical Specialities has a lean, market-oriented organization with Management Board and Corporate Functions. Its objective is to promote innovation potentials in its field of activities and to expand world-wide market leadership in special lubricants and release agents. The Business Group includes five largely independent divisions which are active in more than 50 countries: Klüber Lubrication, Chem-Trend, SurTec, Capol and OKS. For more information, Website: www.klueber.com
TECH UPDATE
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.
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etalworking 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)
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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
TECH UPDATE www.mtwmag.com
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 analysis 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 bio-lubricants 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 switching from water-based systems to gas-based 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 waterbased 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. For more information editor@divyamediaonline.com
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TECH UPDATE
CELOS with 5 new APPs in 2015 ®
DMG MORI will be presenting CELOS® at the EMO with a total of 16 APPs and as a PC version With CELOS®, DMG MORI has produced a common user interface with a unique multi-touch screen for all new high-tech machines. Structuring by means of APPs makes CELOS® as easy to operate as a smart phone. As a result, users benefit from a 30% saving in setup time and 50% less effort for calculating technical values and searching for important information. The latest CELOS® version will be available from April 2016 and presented for the first time at the EMO trade fair in Milan. Also on display, here will be a PC version of CELOS® for continuous production planning in production engineering with direct connection to the machines. The PC version of CELOS® provides the user with integral options for the optimum planning and control of manufacturing processes and work sequences.
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s an APP-based control and operating software package, CELOS® from DMG MORI enables consistent management, documentation and visualization of order, process and machine data. It also simplifies, standardizes and automates operation of the machine. The version of CELOS® to be presented in Milan now offers 16 APPs. It includes five new APPs. The 5 new CELOS® APPs
Similar to a smart phone, users have direct access to all available applications via the “CELOS® APP MENU”. The CELOS® APPs are divided into five groups for production, utilities, support, configuration and machine views. The five new CELOS® APPs specifically
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TECH UPDATE www.mtwmag.com
target a further improvement in production engineering and company organization, and provide optimized applications and service planning of DMG MORI machines. PALLET CHANGER
Simple handling of 2 or 3 pallets. • Error-free prioritization, setup and monitoring of automated production • Intuitive assignment of a job to a pallet • Reliable transfer of all NC programs to the CNC CELOS® from DMG MORI provides simplified machine operability and effortless connection to higher-level network structures
SERVICE AGENT
Maintenance carried out in house and scheduled maintenance ensure troublefree production • Overview of all maintenance tasks on the machine • Advance notice of scheduled maintenance and service activities • Display of all required spare parts and equipment • Support during implementation TOOL HANDLING
Automated loading and unloading lists reduce tooling times • Intuitive overview of all tools registered on the controller • Display of all tools required for a job including automatic creation of a loading list • Creation of an unloading list through automatic detection of all tools not required for the next jobs JOB SCHEDULER
Machine-related job order planning improves utilization and production flow • Recording, management and scheduling of individual jobs for production • Assignment and transfer of jobs to machine(s) • Overview of complete job order status on all machines
• Clear machine live status of all networked machines • Detail view of each individual machine • Evaluation of machine operating time, downtimes and faults CELOS® as PC version
Along with the 5 new CELOS® APPS, DMG MORI is once again extending the range of applications and services of its revolutionary software with the new PC version. Once users have installed CELOS® on their PC, all CELOS® functions will be instantly available to them. The new CELOS® version is used by customers to optimally plan and control their production process directly during the production engineering phase and to monitor all machines. The CELOS® PC version also provides the option to incorporate any machine or equipment in an integral CELOS® periphery. For this purpose, the CELOS® PC version must simply be made available close to the machine to enable the job order data to be retrieved here for the various machines in the production facility. Planning and production become one with the CELOS® PC version. CELOS® is therefore the key element for networked, intelligent production aimed at Industry 4.0.
MESSENGER
Immediate detection of downtimes increases efficiency in the production
For more information, Website: www.dmgmori.com
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TECH UPDATE
HE303-CS Based in the south of Germany, Metallmanufaktur GmbH has come a long way in a short time. From a standing start in 2013, when the company found early business by simply cold-calling potential customers, Metallmanufaktur now serves a variety of different industries. Investing only in Haas CNC machine tools, including automated five-axis and high-speed models, the firm has thrived, and has recently entered an agreement with local Haas Factory Outlet (HFO) Katzenmeier to be a regional Haas showroom.
The Haas machining centres at Metallmanufaktur are configured identically, with changeover times at just 5 to 10 minutes, with parts fully interchangeable between machines. Photo shows co-founder Roman Zejnic
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n 2013, Jochen Schumacher’s dream of running his own business became reality with the establishment of Metallmanufaktur GmbH in Orsingen-Nenzingen, Germany, 130 kilometers south of Stuttgart, close to the Swiss border. Although not an obvious location for a machine shop, the company has been able to fill a small but lucrative niche for a reliable, fast, costeffective subcontract machine shop that the area was lacking. “We started in 2013 with a Haas
One of the company’s two Haas UMC-750 five-axis universal machining centres is equipped with an automatic parts loader for continuous operation
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VF-2SS Super-Speed CNC vertical machining centre, and a Haas UMC-750 five-axis universal machining centre,” explains Mr. Schumacher, who first heard about Haas in his previous role as head of the mechanical production department at medical technology specialists, Leica Biosystems, near Heidelberg. “Although I never had the opportunity to buy Haas technology during my time at Leica, I always said that if I were to ever start my own
TECH UPDATE www.mtwmag.com
Investing only in Haas CNC machine tools, including automated five-axis and highspeed models, the firm has thrived
business, I was going to do it with Haas machines.” In the very beginning, Mr. Schumacher had to cold-call potential customers to secure business for Metallmanufaktur. He would use the Internet to research trade fair exhibitors whose products and parts might be a good match for his capabilities. Happily, cold-calling is no longer required – new customers now find him, typically through word-of-mouth recommendations. Fresh contacts are added almost every week, which has allowed Metallmanufaktur to expand into a neighbouring building. In early 2015, Metallmanufaktur agreed to become a Haas Factory Outlet (HFO) showroom for regional Haas distributor, Katzenmeier. “There was nowhere south of Stuttgart where it was possible to demonstrate the potential of Haas machines,” says Mr. Schumacher. “So, after discussions with Bernd Katzenmeier, CEO of Haas Factory Outlet Sueddeutschland, and Jens Thing, managing director of Haas Automation Europe, it was decided that here would be a good location. We had around 220 people attend the grand opening of the showroom earlier this year: a mixture of existing
and potential Haas customers. Of course, having all of those engineering companies come and see the Haas machines on our premises is also good for us. It’s great networking!” A short time before the grand opening, a second Haas UMC-750 five-axis universal machining centre was acquired by Metallmanufaktur in March 2015, this time fitted with an automated loading system.
Jochen Schumacher co-founder of subcontract machine shop, Metallmanufaktur GmbH, Orsingen-Nenzingen, Germany
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TECH UPDATE
Parts produced on the UMC-750 include 200-off batches of industrial metrology components, and similar quantities of parts used on garbage collection trucks – all loaded automatically and completed on the five-axis machine in a single setup
Metallmanufaktur has recently entered an agreement with local Haas Factory Outlet (HFO) Katzenmeier to be a regional Haas showroom
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“The idea was to purchase a machine that could run unsupervised the whole day, through the night or at weekends. It’s difficult to find fully trained and qualified personnel in this area,” explains Mr. Schumacher. Parts produced on this machine include 200-off batches of industrial metrology components, and similar quantities of parts used on garbage collection trucks – all loaded automatically and completed on the Haas UMC five-axis machine in a single setup. When a part is finished, the door opens and a robot arm extends inside the working envelope before lifting the part from its fixture. The gripping device then rotates 180° and deposits a fresh blank in its place, before exiting. Chip-to-chip time is around 30 seconds. As an HFO regional showroom, Metallmanufaktur keeps demonstration machines on-site, including a Haas Super Mini Mill and an ST-20Y CNC turning centre with Y-axis capability. Although the company currently out-sources any turning operations, the plan is to bring turning in-house. For now, however, Metallmanufaktur is
focussed on prismatic parts, machined from all types of metals and plastics. For instance, the company produces around 180 different components (from various materials) for special hospital beds designed for overweight patients. The Haas VF-2SS Super-Speed CNC vertical machining centre owned by Metallmanufaktur also plays an important role. The machine’s 12,000rpm spindle and rapid travels ensure Metallmanufaktur can be competitive on all job types. For example, in early 2015, the VF-2SS was used to successfully complete a series of 30,000 relatively simple parts featuring a large number of holes. Anything complex is, of course, assigned to one of the UMC-750 five-axis machines. A case-in-point are batches of 60 aluminium chassis parts for a German manufacturer of workholding and gripping systems. Machined from solid to tight tolerances, each component demands around 3½ hours of machining time. To simplify job scheduling and programming, the Haas machining centres at Metallmanufaktur are configured identically, using zero-point workholding systems, and the same type of cutting tools in corresponding stations in the toolchanger. On average, changeover times at Metallmanufaktur are just 5 to 10 minutes, with parts fully interchangeable between machines. “The moment I differentiate between machines, I lose flexibility,” concludes Mr. Schumacher. “From a process and technical perspective, our operation is nearly perfect now. This is important because, aside from price and delivery, we need to show customers that we have the best offer for all industries; an offer that is based on Haas technology. And just because we are relatively small, doesn’t mean we can’t compete. We’re as lean and competitive as any company.”
For more information, Website: www.HaasCNC.com
TECH UPDATE
Grease - Its Components, Consistency & Compatibility
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reases are most often used instead of fluids where a lubricant is required to maintain its original position in a mechanism, especially where opportunities for frequent relubrication may be limited or economically unjustifiable. This requirement may be due to the physical configuration of the mechanism, type of motion, type of sealing or the need for the lubricant to perform all or part of any sealing function in the prevention of lubricant loss or entrance of contaminants. Because of their solid nature, greases do not perform the cooling and cleaning function associated with the use of a fluid lubricant. With these exceptions, greases are expected to perform all other functions of a fluid lubricant. While fluid lubricants are always preferable, the aforementioned mechanical circumstances will always exist and thus the need for grease will too.
Grease Components
Greases are manufactured by combining three essential components: base oil, thickener, and additives. Base Oils: The liquid portion of any grease is a typical lubricating oil and may be mineral, synthetic, or any fluid that contains lubricating properties. These oils may range in viscosity from as light as mineral seal oil up to heavy cylinder stocks. The base oil comprises the largest component by volume (typically 80 to 97%) of grease and it is this portion of the grease that does the actual lubricating. Thickeners: The thickener may be any material that, in combination with the base oil, will produce the solid to semifluid structure. Simply put, a grease thickener in combination with the base
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oil acts much the same way as a sponge holding water. Principal thickeners used in greases include lithium, aluminum, calcium, clay, and polyurea either alone or in combination. Lithium is perhaps the most common thickener in use today. Additives: As in lubricating oil additives, grease additives and modifiers impart special properties or modify existing ones. Additives and modifiers commonly used in lubricating greases are oxidation or rust inhibitors, pour point depressants, extreme pressure (EP) additives, antiwear agents, lubricity-or friction-reducing agents, molybdenum disulfide, graphite and dyes or pigments. Dyes or pigments impart color ONLY and have nothing to do with a grease’s lubricating capability. Grease Consistency
Consistency is defined as the degree to which a plastic material resists deformation under the application of force. In the case of lubricating greases, it is a measure of the relative hardness or softness and may indicate something of flow and dispensing properties. Consistency is measured in accordance with ASTM D 217, Cone Penetration of Lubricating Grease and reported in terms of National Lubricating Grease Institute (NLGI) grade. Cone Penetration: Consistency is measured at a specific temperature, 77ºF, and (normally) after the sample has been worked 60 strokes in the ASTM grease worker. After the sample has been prepared, a penetrometer cone is released and allowed to sink into the grease under its own weight for 5 seconds. The depth the cone has penetrated is then read, in tenths of a millimeter. NLGI: On the basis of ASTM worked
penetrations, the NLGI has standardized a numerical scale, in order of increasing hardness for classifying the consistency of grease — 000 for semi-fluid greases to 6 for block grease. It should be clearly understood that consistency is due directly to the base oil and thickener ratios, NOT the base oil viscosity. Compatibility
Mixing different types of greases can sometimes lead to incompatibility problems. Grease incompatibility results from chemical interactions between the thickener or additive systems of the dissimilar greases. In some cases, grease incompatibility can lead to equipment failure or damage of the lubricated components. Mixtures of incompatible greases will exhibit excessive hardening or softening relative to the consistency of the individual pure greases. The hardening or softening tendencies of the mixture will generally become more pronounced as the operating temperature increases or as the rate of shearing on the grease mixture increases. Incompatible greases may also exhibit excessive oil separation or “bleeding” tendencies at higher temperatures. The Chart below is a general guide only. When changing from one type of grease to another, it is always prudent to test the compatibility of different greases in a laboratory.
For more information, Mr. Shankar Karnik Mobile: +(91) 9811137268 Email: shankar.karnik@exxonmobil.com Website: www.exxonmobil.com
TECH UPDATE
The New Generation of Angle Encoders with Integral Bearing By A.P. JĂ yanthram, Managing Director Heidenhain Optics & Electronics India Pvt. Ltd.
Figure 1: Aufmacherbild: The new family of angle encoders with integral bearing
H
EIDENHAINâ&#x20AC;&#x2122;s angle encoders with integral bearing have long been the standard for applications where angular measurement in the range of a few angular seconds is necessary. The encoders are characterized by their simple mounting and very high accuracy. Particularly on rotational axes in machine tools, such as rotary tables and tilting axes, they are the best solution for position and speed control. HEIDENHAIN has now developed a new generation of absolute angle encoders with integral bearing based on the field-proven encoders. The goal was to retain the positive properties of the angle encoders while at the same
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time adding numerous new and useful features. So that the new encoders can be used in existing machine designs, it was ensured that their dimensions are compatible to those of their predecessors. Comprehensive analyses and simulations were necessary in order to set another milestone in angular metrology. The knowledge thus gained resulted in a new generation of angle encoders that is completely different from the previous generation: not a single component remained the same. The new, absolute RCN 2000, RCN 5000 and RCN 8000 angle encoders have shafts ranging from 20 mm to 100 mm in diameter, and are characterized by numerous outstanding properties regarding scanning, design and signal interface. Scanning
The new angle encoders of the RCN series operate with two graduation tracks. The absolute position data on the circular scale is encrypted on one track and never recurs within the same revolution. The additional incremental, higher resolution track is scanned according to the single-field scanning principle. The scanning signals of the incremental fine track are interpolated for the position value and are processed together with the information from the serial code track to obtain absolute position values of high resolution. This enables, for example, the RCN 8000 to measure to a resolution of more than 536 million positions per revolution.
TECH UPDATE www.mtwmag.com Design
Figure 2: Single-field scanning principle Thanks to the special optical filtering of the innovative scanning components, the encoder produces scanning signals of very high quality. Test results with the new RCN encoders show that the position accuracy relevant to feedback control, often described as position error within one signal period, is typically superior to the absolute angle encoders of the respective previous series by a factor of three. The optimized scanning now makes it possible to specify the subdivision accuracy values as better than Âą0.5% (the value for the previous RCN encoders was Âą1%). Particularly on direct drives, the high signal quality has positive effects on the control behavior and results in noticeable quality improvements of the finished workpiece surfaces. Although the angle encoders with integral bearing are sealed and feature the IP64 degree of protection, the contamination risk was to be reduced further to the point that this risk could practically be excluded. This goal was met with single-field scanning, which is characterized by its improved signal quality and a significantly reduced sensitivity to contamination. This has been achieved through large scanning windows and the special arrangement of the scanning fields. Even relatively large contaminated areas result only in slightly
weaker scanning signals and somewhat increased signal deviations. In many cases, depending on the contamination, this can even prevent encoder failure where four-field scanning, which up to now was used in the angle encoders with integral bearings, cannot. The results of testing with the angle encoders are also confirmed by positive experience with linear encoders, which have been using this scanning principle for some time now. To be able to meet the growing demands for better performance on machine tools, design engineers are increasingly using rotational axes that distinguish themselves through high accuracy and high rotational speed. They are intended, for example, to make it economical to run milling and turning operations on the same machine. The new, absolute angle encoders fulfill these demands as well. The single-field scanning and the new scanning and evaluation electronics made it possible to dramatically reduce the influence of the rotational speed on the generation of position values. This ensures that, even at high speeds, the scanning signals have a high signal quality and continue to interpolate well. For example, the RCN 2000 with its purely serial interface achieves speeds up to 3000 min-1.
The simple mounting of the new angle encoders is also impressive. Unlike the modular angle encoders, which usually consist only of a scanning unit and a graduation carrier, the hollowshaft angle encoders with integral bearing feature an integrated stator coupling. In this way it is ensured that the components involved in scanning are ideally aligned to each other, even if there are deviations within the defined mating tolerances of the shaft coupling. Radial and axial error in the measured shaft is assimilated in the stator coupling so that the coupling remains free of torsional rotation. The new stator coupling, conceived and developed for the RCN encoders is characterized in its axial and radial deflection and torsional rigidity by excellent behavior and operates virtually without angular error. This permits relatively generous mounting tolerances without limiting the function or accuracy. For example, together with the encoder sealing technique, which is also new, it can tolerate deviations in axial direction of up to Âą0.3 mm. The new angle encoders have an even more impressive set of design details. The encoders feature a plug-in cable assembly. Because the separate adapter cable has a quick disconnect (push-pull design), mounting the plug-in cable assembly to the encoder is very simple. No tools are needed. At the same time, the connecting element has a high leak tightness of IP67, preventing ingress of liquids through this connection. The advantages of the plug-in cable assembly are particularly evident when a cable has to be routed through a tight installation space during mounting. The machine tool manufacturer is also more likely to have the encoder on hand because it can be ordered separately and stocked without regard to a specific cable length or type of connecting element. The RCN 5000 series consists of angle encoders with compact overall dimensions but large hollow shafts. With a hollow shaft diameter of 35 mm, the
MTW OCTOBER 2015
47
TECH UPDATE
Figure 3: RCN 5000 series with plug-in electrical connection cross-section of the RCN 5000 encoders is over three times larger than that of the RCN 2000 encoders, whose hollow shaft only measures 20 mm. This means that there is more room for stiffer machine shafts and hydraulic leads, which are frequently led through hollow shafts.
cycles. This increases machine availability. Cables with M12 connecting elements at the ends can also be used with the purely serial EnDat interface. This enables you to replace the previously common M23 connectors with smaller connecting elements.
Interface
The bidirectional EnDat interface enables the encoder to configure itself during installation without additional transmission lines, since all encoderspecific information such as resolution, ID number, etc. is stored in the encoder and transmitted to the subsequent electronics via EnDat. In addition, it is possible to extensively monitor and diagnose the encoder. For example, the encoder generates warnings when it nears certain tolerance limits before it transmits any incorrect position values. Valuation numbers can be read from the encoder cyclically for diagnostic purposes. The valuation numbers provide the current state of the encoder and ascertain the encoder’s “functional reserves.” The monitoring and diagnostics can be used to signal the need for preventive maintenance, and can prevent unnecessary maintenance
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Safety Technology
The benefits of a purely serial interface can also be used for safety-related applications. Safety-related applications require axes with redundant position information. To obtain independent position values, HEIDENHAIN has decided upon a single-encoder design because two encoders per axis would be both more expensive and unnecessary. HEIDENHAIN is currently the only manufacturer who can offer purely serial single-encoder solutions for safetyrelated applications. For the singleencoder version, two independently generated, absolute position values are provided to the safe control (e.g. the iTNC 530 HSCI from HEIDENHAIN) via the EnDat protocol. This makes it possible to realize a purely digital machine with safe absolute positions.
In addition to the data interface, the mechanical connection of the encoder to the motor is also relevant to safety, since it is not guaranteed that such faults can be detected by the control. Therefore HEIDENHAIN secures the encoders with special methods that fulfill the requirements for excluding the possibility of the mechanical connection coming loose. The new RCN encoders with functional safety will be available soon. They can be operated as single-encoder systems in combination with a safe control in applications with control category SIL-2 (according to EN 61 508) or performance level “d” (of EN ISO 13 849). They form a qualified subsystem within the larger “safe drive” system. It greatly simplifies the evaluation and realization of safety-related processes for the machine tool builder. This makes a simple, purely serial solution possible, especially for axes with direct drive. Summary
The new series of angle encoders with integral bearing distinguish themselves with numerous impressive characteristics. Thanks to the new scanning process, the signal quality is improved once more, the tolerance to contamination is optimized, and higher shaft speeds are permitted. The relatively large mounting tolerances and the plugin cable assembly help make mounting much easier. The EnDat interface with its diagnostic capabilities enables preventive monitoring of the encoder without requiring an additional transmission line. Encoders with purely serial interface can also be installed as qualified subsystems in safety-related applications. There is also the new RCN 5000 series, whose hollow shaft with a diameter of 35 mm is impressive considering its compact outside dimensions. The RCN 5000 will prove to be the proper angle encoder for a multiplicity of applications, and will likely even replace many absolute angle encoders with a hollow-shaft diameter of 20 mm.
TECH UPDATE
Various laser process heads for Fiber Lasers From the Fiber to the Workpiece combinations is possible, optional the use of the patented TLC optics (with a reduced thermal lens). A QBH and other fiber connections are suitable as well as a XY adjustment of the lenses. The PHF-25 series is made for a medium power output of up to 2 kW. For a low power output of approximately 100 W, the new PHFM series is available. This series features a compact design, easy handling through an SMA fiber connection, and last but not least an attractive price. One application in this power range includes, for example, the laser welding of plastic. About LASER COMPONENTS GmbH
T
he G6 series laser process heads were developed for fiber lasers with a high output power between 4 kW and 5 kW and are used for high-speed cutting applications, for example. User friendliness plays a central role in the G6 series. Compartments make it easy to change the optics to quickly adjust the focal distance, for example. They also facilitate the comfortable exchangeability of the protective windows. Standard Ă&#x2DC;1.1â&#x20AC;? optics are used for this purpose. The G6 system is especially variable: The application of several focal length
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LASER COMPONENTS specializes in the development, manufacture, and sale of components and services in the laser and optoelectronics industry. At LASER COMPONENTS, we have been serving customers since 1982 with sales branches in five different countries. We have been producing in house since 1986 with production facilities in Germany, Canada, and the United States. In-house production makes up approximately half of our sales revenue. A family-run business, we have more than 170 employees worldwide.
For more information, Website: www.lasercomponents.com
Seeing is believing ! National Productivity Summit 2015 “Spearheading productivity in metal working”
20 - 21 November 2015 2015
Hotel Crowne Plaza, Gurgaon
To champion the cause of productivity in the metal working industry, Indian Machine Tool Manufacturers' Association (IMTMA) is organizing the National Productivity Summit (9th in the series) on 20 – 21 November 2015 at Gurgaon. The event showcases best productivity practices in metalworking through live case study presentations, Plant visits and Keynote sessions.
Leaders Speak : Renowned industry experts will deliver Keynote addresses on various facets of productivity. Ø Mr. Amit Chatterjee, Managing Director, Sartorius India Group Ø Mr. Pete Baxter, Vice President, Delcam Worldwide, UK * Ø Mr. Rajesh Magoo, Chief Operating Officer, Transmission & Engine Component Business, Hitech Gears Ø Mr. Rajeev Wasan, Senior Vice President - Manufacturing, Honda Cars India
Live case study presentations on best productivity practices from renowned companies
Forgings & 2) Hero Motocorp** Plant visits TOUR A : 1) Sona BLW Precision or 19 November 2015 TOUR B : 1) Honda Motorcycle & Scooters India** & 2) Hitech Gears Key Take Aways Ø Listen to keynote presentations from industry leaders Ø Live case study presentations on best productivity improvement projects Ø Learn innovative approaches to address productivity challenges Ø Cross learning from best productivity practices Ø Exchange new ideas & concepts – Knowledge networking Ø Ideal platform to interact with several manufacturing professionals
Excellent opportunity to witness some of the best productivity improvements on the shop floor * Invited ** Confirmation Awaited
Registration for participation must be made online only. To register online, log on to www.productivity.imtma.in For details or any queries/clarifications during online registration process, please contact IMTMA's Bangalore office: Abhishek, tel no. (080) 66246829 (abhishek@imtma.in) Laxmikant, tel no. (080) 66246665 (laxmikant@imtma.in)
Indian Machine Tool Manufacturers’ Association
Awards Sponsor
PROJECTS www.mtwmag.com
Automobile Mahindra & Mahindra (M&M)
PROJECT
Automobile Chemicals / Fertilisers Aviation Ports & Shipping Transport
UPDATE
Power
The company has signed up an MOU with the Tamil Nadu Government to set up Mahindra Research Valley (MRV) test track and automotive plant. These facilities would come up on 450 acre of land at Cheyyar near Kancheepuram.
Place: Cheyyar Tamil Nadu Contacts: Ravindra Kant, DGM (Advertising & Promotion), Farm Equipment Sector, Farm Division, Sales & Custmer Operations, 5th loor, EPU Building, Gate No-4, Akurli Road, Kandivali (East), Mumbai-400101, Maharashtra. T: 022-28467806, 7805, 66483051, M: 9821123417, E: kant.ravindra@mahindra. com
India Yamaha Pvt Ltd The company has recently inaugu- rated its two-wheeler plant at Vallam Vadagal in Kancheepuram district. The plant will have production capacity of 4.50 lakh units in the initial stage. This will scaled upto 18 lakh units by 2018.
Place: Tamil Nadu Contacts: V K Kaul, Asst. General Manager (Marketing Communication), TVH, Belicia Tower-1, Tower -1, Block No. 94, 8th Floor, MRC Nagar, Raja Annamalai
Puram, Chennai-600028, Tamil Nadu. T: 044-24621304, 05, 06, E: vkaul@yamaha-motorindia.com
ThyssenKrupp Elevator India Pvt Ltd Plans to set up a new plant for manufacturing high-tech elevators in Pune. The work is likely to start in October 2015.
Place: Pune 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
Chemicals / Fertilisers Oil and Natural Gas Corporation Ltd (ONGC) The company has signed MOU with the state government and Chambal Fertilisers and Chemicals in April 2013 to set up the urea plant near Khobal gasield in Tripura. Tripura Govt has recently provided 800 acre of land in this regard. The work is likely to start in 2014.
Place: Tripura Contacts: Sanjeev Sharma, Head (Public Relation and Corp Comm), Jeevan Bharti, Tower-II, 124-Indira Chowk, New Delhi â&#x20AC;&#x201C; 110001 T: 011-23301243, 23320032, F: 23357860, E: ongcdelhicc@ongc.co.in
MTW OCTOBER 2015
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PROJECTS
Aviation Infrastructure Corporation of Andhra Pradesh Ltd Plans to construct a greenield airport at Bhogapuram in Vizianagaram district. The state government has recently issused notiication for land acquisition.
Place: Andhra Pradesh Contacts: R. Srinivasa Rao, Chief Project Consultant, 10-2-1, III Floor, FDC Complex, AC Guards, Hyderabad-500028, Andhra Pradesh. T: 040-23321771/2, F: 23321773, E: incap@incap.co.in, cgmp@incap.co.in
Airports Authority of India Plans to expedite the process of developing integrated airport near Khurda. Around 2,000 acre is identiied by the state government for this project wherein a free runway and air trafic control (ATC) tower can be constructed.
Place: Khurda Odisha Contacts: Bhubaneswar751020, Odisha. T: 0674-2596300, F: 2596302, 2596317, M: 9937384555,
Airbus Group India Pvt Ltd Plans to set up an aircraft mainte- nance and repair
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MTW OCTOBER 2015
overhaul (MRO) facility in India. Airbus is banking on its client Indigo for the success of this MRO.
Contacts: TERI University Campus, Plot no. 10, Vasant Kunj Institutional Area New Delhi â&#x20AC;&#x201C; 110070. T: 011-41627712, F: 41627713
KGS Aranmula International Airport Ltd
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.
Place: Southern India
Directorate of Ports, Valiyathura,Vallakadavu (PO), Thiruvananthapuram-695008, Kerala. T:0471-2509842, 2504483, F: 2504533, M:9847424533, E: director.port@kerala.gov.in
Contacts: Kishore N,
Paradip Port Trust
Sr.Marketing Manager, Begumpeth, Near Old Airport, Hyderabad - 500016. T: 9676999089, E: Kishore.n@turbomegha.com
Plans to undertake the development of a Multi-purpose Berth through Public Private Participation (PPP) on Build, Operate and Transfer basis. United Liner Agencies of India Pvt Ltd (ULA) has been selected as the Operator for this Terminal after a competitive bidding process. The work has not yet started.
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 environ- mental clearance for the airport in May 2014. The company has asked for second environmental impact assessment (EIA). The Centre has approved this request.
Kandla Port Trust (KPT)
Place: Pathanamthitta,
Place: Kandla Gujarat
Ports & Shipping The port plans to develop 1,500 acre into a Smart Industrial Port City (SIPC). The consultants will be invited soon to conduct techno-feasibility studies.
District Kerala
Contacts: Krishna Kumar Contacts: S.Dhinakar, 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 500 crore in the next five years. The company has identified major cities like Visakhapat- nam, Vijayawada, Rajahmundry, Kadapa,
Todermal, Executive Engineer Civil, 06, Ground Floor, New Kandla - 370 210, Gujarat. T: 02836-270149, 233192, F: 02836-220050, M: 08980049099, E: executiveengineercivil@ gmail.com
Kerala Ports Department Plans to develop a cement terminal at Azhikkal port. The project is still in tendering stage. The work is yet to start.
Place: Azhikkal Kerla Hari Varrier, Deputy
Place: Paradip Odisha Contacts: A K Jain, Chief Engineer, Paradip-754142, Odisha. T: 06722-222062, 222242, E: ceppt@paradipport.gov.in
Vizhinjam International Seaport Ltd Plans to set up a deepwater multipur- pose port project near Kovalam with a capacity of 18,000 TEUs (twenty-foot equivalent units). The project will be completed in 3 phases. The work has not yet started.
Place: Kovalam Kerala Contacts: Sunil Kumar, Project Manager, First Floor, Vipanchika Towers, Thycaud, Thiruvananthapuram-695014, Kerala, T: 0471-2328614,
PROJECTS www.mtwmag.com
F: 2328616, M: 8301865723, E: sunilkumar@ vizhinjamport.in
Kandla Port Trust (KPT) The port plans to develop 1,500 acre into a Smart Industrial Port City (SIPC). The consultants will be invited soon to conduct techno-feasibility studies.
Place: Kandla Gujarat Contacts: Krishna Kumar Todermal, Executive Engineer Civil, 06, Ground Floor, New Kandla - 370 210, Gujarat. T: 02836-270149, 233192, F: 02836-220050, M: 08980049099, E: executiveengineercivil@ gmail.com
Kerala Ports Department Plans to develop a cement terminal at Azhikkal port. The project is still in tendering stage. The work is yet to start.
Operate and Transfer basis. United Liner Agencies of India Pvt Ltd (ULA) has been selected as the Operator for this Terminal after a competitive bidding process. The work has not yet started.
Place: Paradip Odisha Contacts: A K Jain, Chief Engineer, Paradip-754142, Odisha. T: 06722-222062, 222242, E: ceppt@paradipport.gov.in
Transport Delhi Metro Rail Corporation (DMRC) The Government of Andhra Pradesh has assigned the Vijayawada Metro Rail Project to DMRC. It is likely that the irst tender for civil works will be announced soon. The project will have two corridors with a distance of 26.03 km and is likely to complete by the year 2018.
Place: Azhikkal Kerala Place: Andhra Pradesh Contacts: Hari Varrier, Deputy Directorate of Ports, Valiyathura, Vallakadavu (PO), Thiruvananthapuram-695008, Kerala. T:0471-2509842, 2504483, F: 2504533, M:9847424533, E: director.port@kerala.gov.in
Paradip Port Trust Plans to undertake the development of a Multi-purpose Berth through Public Private Participation (PPP) on Build,
Contact: Ranga Rao, Deputy Director (Projects), Operational Ofices, Rangpuri New Delhi - 110037, M: 09490717729, E: gampalap@gmail.com
Directorate of Urban Land Transport Plans to implement intelligent transit management system for North Western Karnataka Road Transport Corporation.
Place: Karnataka
M: 9411112167, E: sanatksingh@gmail.com
Contacts: P.Shamanth, Head (TETC), BMTC, TTMC, B Block, 4th Floor, Shantina- gar, KH Road, Bangalore-560027, Karnataka. T: 080-22226627, M: 8105881978, E: dultbangalore@gmail.com
Nagpur Metro Rail Corporation Ltd Consultants are invited for conductiing social impact assessment (SIA) study and prepration of Social Management Implementation plan, Rehabilitation & Resettlement (RR Policy) plan for Nagpur Metro Rail Project.
Place: Nagpur Maharashtra Contact: Anand Kumar, EE, Metro House, 28/2 CK Naidu Marg, Anand Nagar-440010, Civil Lines, Nagpur, Maharashtra. T/F: 0712-2554217, E: md.nmrcl@gmail.com, nag. metrorail@hotmail.com, W: www.metrorailnagpur.com Uttara- khand State Transport Department Plans to design, engineering, procurement and construction of Inter State Bus Terminus (ISBT) at Haldwani, Golapar, Nainital, Uttara- khand. The work has not yet started.
Place: Uttarakhand Contacts: S.K.Singh, Regional Transport Oficer, Haldwani Nainital - 263131,
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: Mumbai Maharashtra 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,
Power Aryan M P Power Generation Plans to set up 1200 MW thermal power in 2 units of 600 MW each. Environment clearance awaited.
Place: Siddhi Madhya Pradesh
Contacts: Manoj Kumar, Manager (Projects), 7th Floor, Corporate Tower, Ambience Mall, N.H.-8, Gurgaon, Haryana, T: 0124-2719000, E: manoj.kumar@acbindia. com
MTW OCTOBER 2015
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PROJECTS
Toshiba JSW Power Systems Pvt Ltd
ired power plant at Kamakhyanagar in Dhekanal district.
Bagged EPC contract for setting up a 660 MW thermal power plant in Aligarh district from Uttar Pradesh Rajya Vidyut Utpadan Nigam Ltd. The completion is targeted in 48 months.
Palce: Dhenkanal District
Place: Uttar Pradesh Contacts: Rajesh Shrivastava, Head- Projects, 9th Floor, Building No-10, Tower B, DLF Cyber City, Phase 2, Gurgaon - 122002, T: 0124-4996600, F: 4996611, E: tjps-contactus@toshiba-tjps. in,
Thermal Powertech Corporation India (TPCIL)
Addl Secretary Odisha Secretariat, Bhubaneshwar - 751001, T: 0674-2392969, E: sangramjitnayak@gmail. com
Aryan M P Power Generation Plans to set up 1200 MW thermal power in 2 units of 600 MW each. Environment clearance awaited.
Place: Siddhi Madhya Pradesh
Contacts: Manoj Kumar,
Place: Krishnapatnam
Toshiba JSW Power Systems Pvt Ltd
Contacts: Nageshwar Rao, Plant Manager, 6-3-1090, Block C, Level 2, T.S.R Towers, Rajbhavan Road, Soma- jiguda, Hyderabad - 500082, Andhra Pradesh. T: 040-49048300, F:040-23398435
Orissa Thermal Power Corpora- tion Ltd (OTPCL) Setting up a 2,400 MW coal-
MTW OCTOBER 2015
Manager (Projects), 7th Floor, Corporate Tower, Ambience Mall, N.H.-8, Gurgaon, Haryana, T: 0124-2719000, manoj.kumar@acbindia.com
Bagged EPC contract for setting up a 660 MW thermal power plant in Aligarh district from Uttar Pradesh Rajya Vidyut Utpadan Nigam Ltd. The completion is targeted in 48 months.
Place: Uttar Pradesh Rajesh Shrivastava, Head- Projects, 9th Floor, Building No-10, Tower B, DLF Cyber City,
Telangana State Generation Corporation (TSGenco)
Plans design, supply and I&C of pre-engineered buildng (PEB) for 50 MW solar project, Qty: 10 rooms.
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
Place: Nalgonda
(Electronics Division), P B No. 2606, Mysore Road, Bengaluru - 560026. T: 080-25146100, W: www.bhel.com
District Telangana
Contacts: Sangramjit Nayak,
TPCIL has completed the 1,320-MW coal-ired power plant at Krishnapat- nam by commencing operations from its second and inal 660-MW unit. The irst unit commenced operation in February 2015.
Andhra Pradesh
58
Odisha
Phase 2, Gurgaon - 122002, Haryana. T: 0124-4996600, F: 4996611, E: tjps-contactus@toshiba-tjps. in
Bharat Heavy Electricals Ltd
Power Grid Corporation of India Ltd. The contract is awarded to Sterlite Technologies Ltd and comprises (I) Package L5cd01 for extension of Biharshaif - 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.
Contacts: P.Balaraju, Chief Engineer (TPC), Vidyut Soudha, Khairathabad, Hyderabad - 844101, T: 040-23499261, E: cetpctgenco@gmail.com,
Telangana State Power Generation Corporation Ltd. The company plans to set up a 4,000 MW ultra mega power project at Damarcharla in Nalgonda district. MOU is signed in this regard with BHEL. The Yadagiri thermal power station is likely to have 5 units with 800 MW capacity each.
Place: Bihar Place: Nalgonda District 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
Telangana
Contacts: Bala Raju Chief Engineer (TPC), Vidhyut Soudha, Kairapabad, Hyderabad - 580082, M: 09440817003, E: cetpctgenco@gmail.com
PRODUCTS
PRODUCTS
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PRODUCT SHOWCASE Grinding Oil 1- Straight Grinding Oil for Gear Grinding Features of Grinding Oil No.1
• • • • • • • •
Translucent and low odor Superior cooling properties Non irritating / Non corrosive Produces excellent surface finishes Excellent filter-ability All grinding wheel compatible Superior lubricity package Excellent oxidation Stability / Long sump life
Grinding Oil 1 is compatible with all types of grinding wheels. It can be used for grinding high-speed steel, cobalt, carbide, ceramics and hardened steel. Grinding Oil 1 can also be used in grinders that require the same oil for both lubricating the machine and the wheel / work-piece interface. Unique advanced synthetic and natural lubricity additives in Grinding Oil 1 help keep the grinding wheels clean and free cutting allowing them to function properly. Conventional oils can allow build-up and packing of the wheel. This can lead to burned parts, smoke and scrap parts. Grinding Oil 1 helps maintain part integrity, surface finish and an overall great working environment.
Grinding Application:
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
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Creep feed Grinding Gear Grinding - Profile & Warm Crush Grinding ID and OD Grinding Center-less Grinding Cylindrical Grinding Diamond & CBN Wheel Grinding Tool & Cutter Grinding
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Multi Axis CNC Gun Drilling / BTA Drilling solutions for Tube Sheet and Die & Mold Industry Precihole Machine Tools has introduced a new series of Multi Axis Column type Gun Drilling / BTA Drilling machines for Tube sheet and Die and Mold Industries. These machines are versatile and can be configured with 3-8 axes CNC for various axial movements. These machines can be tooled up for a wide range of components and cover the whole spectrum of deep hole drilling from Φ 3 mm to Φ 65 mmwith drilling depths of up to 1500 mm. These machines support component weight of up to 13 tons. Pricing on these machines is very attractive in comparison with similarly featured imports. Precihole provides excellent local support with complete product guarantee. Some highlights of these machines include:
For Product Enquiry Contact Precihole Machine Tools Pvt. Ltd. A 180, Wagle Industrial Estate, Road no 16Z, Thane (W), Maharashtra 400604 Tel: +91 22 399 1444 / 45 Fax: + 91 22 25824862 Email: sales@precihole.com Website: www.precihole.com
• Robust Construction that allows high level of precision and accuracy while drilling and machining • Option for 1 spindle or 2 spindle configuration to provide productivity • Machines designed with prime focus on operator safety and ease of operation • Auxiliary spindle for machining allows milling, drilling, tapping, engraving and other machining operations on the same machine which would normally require a separate machine. • No need of any setup changes for switchingbetween drilling & machining operations • CNC Controls for precision positioning of horizontal, vertical, rotary & angular axes • Flexible Fixturing capabilities to accommodate a variety of different size components • Different levels of automation can be incorporated to satisfy custom requirements • Complete enclosure to prevent chips and coolant from contaminating the shop floor 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.
Fasteners for Machine Tools, Light & Heavy Engineering Industries ZIP have developed some Fasteners which are useful in Machine Tools, Light & Heavy Engineering Industries. Components are Hex Socket type Allen Bolt, Hex Socket to Socket type Grub Sc, Plunger Screws, Eye Bolt, Hex Bolt Nut Washers, Machine Bolt, Hex Nut std, Lock, Dome, Nylock, Flanged Castle, Long Nuts. Washers plain, Machine Spring Star, Disk Fan, Bearing Wave, Disk Spring, Tapper Washers, Circlip, Knurled Safety lock washers. BSP, BSPT, NPT Tapper plug, Sq hd, Hex hd, Tapper plug, Hex hd Collar plug, Allen plug. BSP Copper washers. Philips Star Punch and Slotted Machine Sc, Self Tapping Sc, Rivet, Stud, Carriage Bolt, NIB Bolt, Sq hd Bolt, T-Bolt, Set Sc, Solid Dowel pin, Tapper pin, Spring Dowel pin, etc. Components as per sample or drawing. For Product Enquiry Contact Zenith Industrial Products E-122, Ansa Industrial Estate, Sakivihar Road, Sakinaka, Andheri East, Mumbai - 400 072. Tel.: 022-2847 0806 / 6692 3987, Fax.: 022-2847 0705, E-mail : zenith@zip-india.com Website:- www.zip-india.com
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Standard Reference: It can be supply as per IS, BS, JIS, DIN, ISO, ASTM & GOST Standard Threads: MM Size Coarse & Fine Pitch, BSW, BSF, UNC, UNF, BSP, BSPT, NPT/NPTF,
6BA to 0BA, 4 to 12No. Size NC/NF. Material’s Grades: M.S. 4.6gr, En - 8gr, 8.8gr, En - 19, 10.9gr, En - 24, 12.9gr, Brass,
Copper, Nylon, SS 202, 303, 304, 316 & 410, HTS RST & V grade.
PRODUCTS www.mtwmag.com
Mounted points – especially for the machining of steel and cast steel Properties of workpiece material:
Mounted points in various qualities are needed to cover the wide spectrum of the numerous steel types and their resulting workpieces. Industries
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Machine tools Automotive Equipment manufacturers Vessel manufacturers Shipyards and much more
Examples of application:
• • • • For Product Enquiry Contact Supra Industries SP-106,MIDC Bhosari,’S’ Block, Near Century Enka Ltd., Off Telco Road, Pune - 411 026 (India). Cell: +91 8888893791, Tel.: + 91 20 30685648, Email: info@supraindustries.com Website: www.supraindustries.com
General rough grinding Fettling Rough grinding of weld seams Finish grinding of weld seams
LUKAS grinding tools:
The wide selection of LUKAS grinding tools incorporates numerous shapes, sizes and qualities. You will find the correct tool from our standard range to solve most grinding problems irrespective of material to be ground, type of machine or any other influencing factors. These mounted points are designed for high stock removal and long tool life.
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
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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.
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New system for simple length setting of tools on CNC machining centres
For Product Enquiry Contact Renishaw Metrology Systems Ltd. G.K. Arcade, 3rd Floor #125/1-18, Mariappa Road, Jayanagar 1st Block, Bangalore 560 011, India, T.: +91 80 6623 6000 F.: +91 80 6623 6060 E-mail: india@renishaw.com Website: www.renishaw.co.in
Global engineering technologies company Renishaw has launched the Primo™ LTS (length tool setter) at CIMT, Beijing, China. The Primo LTS is a single-axis tool setter which allows users to set tool length, check for breakage, and compensate for thermal growth on a CNC machining centre. The Primo LTS eliminates the need for time-consuming, error-prone manual tool length setting which can lead to scrap, rework, and reduced productivity and profit levels. Automated on-machine tool length setting with Primo LTS is up to ten times faster than manual methods, resulting in immediate and significant cost savings. It is suitable for use on small to large CNC machining centres and helps guarantee “right first time” parts, reducing waste and increasing profits. During a machining process, dimensional accuracy is dependent on a number of variables, including tool length and tool breakage. The Primo LTS monitors these variables automatically, enabling users to compensate for variations which may occur and benefitting the overall machining process. The Primo LTS is a hard-wired product featuring a fully integrated interface for straightforward electrical connection: the hardware can be bolted onto the machine table and is immediately operational, with no additional set-up required. The Primo LTS is designed to operate in the harshest of machining environments, so it is resistant to swarf or coolant ingress and prevents false triggers caused by shocks or vibration. An integrated air blast provides effective swarf removal when necessary. Easy to install and use, Primo LTS provides an accessible solution for increasing the productivity and profitability of a machine tool.
Orbital welding set up
For Product Enquiry Contact WARPP ENGINEERS PVT LTD B-1005, Western edge-II, Near Metro Cash & Carry, Western Express Highway, Borvali (E), Mumbai-400066 Tel : 8080808737, 28542272/73/74, E-mail: sales@warpp.co.in, salessupport@warpp.co.in, Website- www.warpp.co.in
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Warpp Engineers Pvt. Ltd., leading solution provider for welding and cutting industry jas wide range of orbital pipe cutting, beveling and welding solution to suit different industry needs. These equipments are used in application where in high precision with consistent results are required. Orbital cutting set up provides perfect 90o cuts on pipes which can be used directly for automatic welding without any post cutting operations. Orbital welding set up is fully automatic welding system to weld tube to tube, tube to elbow, tube to flange and tube to tube sheet joints. These machines has easy to use software interface, making it very simple to use. Advanced technology along with good data base guarantees precise welding every time. The equipment has a built in printer to print the set parameter and it has provision to store the real time data on a memory card which can be read on any windows based computer there by making full proof.
ADVERTISERS INDEX COMPANY NAME
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BACK PAGE
D DOWEL ENGINEERING WORKS
HAAS AUTOMATION INDIA PVT. LTD. HEIDENHAIN OPTICS & ELECTRONICS INDIA PRAIVATE LIMITED
JYOTI CNC AUTOMATION LTD.
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LAKSHMI MACHINE WORKS LIMITED
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ERWIN JUNKER MASCHINENFABRIK GMBH
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NATIONAL PRODUCTIVITY SUMMIT 2015
RENISHAW INDIA (PUNE)
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SANJAY TOOLS & ADHESIVES
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SPRAYMET SURFACE TECHNOLOGIES PVT. LTD.
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SUPRA INDUSTRIES
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U UNITY CONTROLS PVT. LTD.
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METACUT TECHNOLOGIES
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ZAVENIR DAUBERT
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Mr.
Chris
Inside Story
Sheehan
Managing Director Asia Hangsterfer’s Laboratories, Inc
My Life’s Goals
Aim & Ambition: Growing up in a school for disadvantaged children called Milton Hershey School, from the age of eight to sixteen years old has giving me a unique perspective of success. In 1915 Milton Hershey gave his entire personal fortune - thousands of acres of land, and controlling interest in the Hershey Chocolate Company, worth $7.5 billion to the school. Today theMilton Hershey School is the Americas biggest and wealthiest boarding school for needy children. Vision: I believe with hard work, smart work and the ability to adapt to dynamic situations will allow me to continue my path of professional and spiritual growth. Social Goal: My goal is to give back to society as much as I received as a needy child from The Milton Hershey School Business Goal: Goals in business are to hold true to my principals of producing the world’s safest most effective metalworking lubricants with out compromise. As a multi-national company operating in all of the emerging markets we use the health, safety and environmental standards of United States. This insures our customers in India receive the same respect and protection as we give our customers in any of the developed world.
My Leisure Choices
Favourite Tourist Spot: I will have to admit, because I spend over 50% of my year traveling in Asia, my vacation time is spent in a little town in Delaware called Rehoboth Beach. This is a small family oriented beach town where I can recharge my batteries and really connect with my 15 year old twin daughters. Music I Like: I am a old fashion Rock & Roll fan, bands like Pink Floyd, Led Zeppelin, the Beatles , Rolling Stones this is my play list .. Sports I Love: I love to go to baseball games when in the USA but anywhere else in the world I will have to say football and Rugby are the most entertaining to watch.
Ask my Taste Buds
Favourite Food: I have become an Indian food lover for sure; I really enjoy the many spices and exotic flavors. Recently on a trip to Pune I had the best Vegetarian meal I am hooked! Favourite Drink: I don’t even need to think about this Macallan 18 Year Old Sherry Oak Single Malt Scotch Whisky, with a splash of water or a few ice cubes.
In Awe of
I Admire: Abraham Lincoln is truly my most admired person. He was able to over come great personal loss to sacrifice his entire life to bring about social change to a country that was divided in a brutal civil war.
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BE DYNAMIC!
THE FUTURE OF EFFICIENCY & SPEED IS HERE – MASTERCAM’S DYNAMIC MOTION TECHNOLOGY Since 2008, Mastercam has been building Dynamic Motion into our software. That means it has been shop-tested and proven in real-world environments. Dynamic Motion toolpaths carve out massive amounts of material quickly, reducing cycle times by up to 75% – while doubling and even tripling the tool life – immediately putting more money in your pocket. Sounds unbelievable, right? But as the market leader, we’ve had our Dynamic Motion toolpaths tested in most every conceivable work environment around the world. It works.
For more information, visit www.Mastercam.com 800-228-2877