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

How large is a critical difference? Those like HEIDENHAIN who manufacture micrometer-precise measurement technology know: it’s the details that make the vital difference. This applies to our products—and to our company. HEIDENHAIN has been engaged in metrology since 1889. We find this unparalleled performance to be worth investment: more than 10 percent of our revenue is allocated to research and development. The human side is also an important distinguishing feature. Mutual respect, fairness and trust are important to us—particularly when dealing with our customers. These “inherited traits” make our products that decisive tad better, and make HEIDENHAIN the world’s preferred partner in measurement technology. HEIDENHAIN OPTICS & ELECTRONICS INDIA PRIVATE LIMITED, Citilights Corporate Centre, #1, Vivekananda Road, Off Spurtank Road, Chetpet, Chennai 600031, India Phone: +91 44 3023 4000, Web: www.heidenhain.in, Email: sales@heidenhain.in; service@heidenhain.in angle encoders

linear encoders

contouring controls

digital readouts

length gauges

rotary encoders

Come see Haas Machines Cutting Parts @

HAASTEC HAASTEC PUNE 2015

Come see Haas Machines Cutting Parts @

9th - 12th, December PUNE 2015 10:00 am to 6:00 pm 9th - 12th, December

10:00 am toCLUSTER 6:00 pm AUTO EXHIBITION CENTER Hall B, C-181 • Pimpri - Chinchwad, Pune 411019

AUTO CLUSTER EXHIBITION CENTER Hall B, C-181 • Pimpri - Chinchwad, Pune 411019

Haas Automation, Inc. • www.HaasCNC.com • Proudly Made in USA Haas Automation, Inc. • www.HaasCNC.com • Proudly Made in USA

www.mtwmag.com

Volume 1 Issue 7

Contents

Vol 1 Issue 7 | DECEMBER 2015

Publisher

COMPANY PROFILE

Shirish D.

CEO Shekhar D.

Editor Shilpa Dongre

HEIDENHAIN stays closer to the customer

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

Designer & Layout

Gurutzpe CNC Lathe Machine : Excellence with technology innovation

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

Circulation Executive Satish Kadam, Amol Ranshur Branch Offices (Zonal)

NORTH (Delhi & NCR regions) Sandesh Jain : 09810837877 / 09871602777

SOUTH (Chennai & Coimbatore) Y. V. Raghu : 09566141224 Bangalore Vaman : 09686721340 Kochi Sanjeev Nair : 09846249568

COVER STORY

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

Effica unleashes robotic automation in India Mr. Arjun Prakash, Director, Effica Automation Ltd.

BUSINESS NEWS

Printed & Published by Shirish Dongre on behalf of DIVYA MEDIA PUBLICATIONS PVT LTD., Printed at Anitha Art Printers 29/30, Oasis, Next to Vakola Market, Santacruz(E), Mumbai-400055, published from 303/304, Harmony Tower, N.S.Road, Court Naka, Thane West, Thane-400601. Editor : Shilpa Dongre

MTW DECEMBER 2015

BFW – Ganesh Technologies Tech-center Launch

Renishaw unveild Inspection Plus with Supa Touchoptimisation delivering intelligent speed

Grind Master bags SME business excellence award

11 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.

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

TECH UPDATE

DMG MORI confirms annual forecast 2015

CASE STUDY

Haas Automation experiences new highs at EMO 2015

CNC Software, Inc. launches global “Dynamic Motion Challenge”

ExxonMobil showcased its lubricant portfolio at EXCON 2015

HAAS : Super Mini Mill Renishaw brings 3D printing expertise to Land Rover BAR Technical Innovation Group

Axle supplier approaching zero scrap

The specialist for tube machining

Top cut 4 indexable holemaking platform from WIDIA: One highperformance tool series for many applications

Ceramic Coatings in Machine Tool Industry

Automation in sheet metal cutting and welding

MAX-PAC Advanced CAM Software for Manufacturing Turbo-machinery Components

PROJECTS

PRODUCTS

Our Lean Selection speed reflects our own core values. Speed, high performance, efficiency.

JUNKER Lean Selection speed High-speed cylindrical grinding.

The Lean Selection speed grinds shaft-type components and cutting tool blanks at impressive speeds. One or two high-performance grinding spindles mounted at the swivel-action wheelhead (B axis) work using both the plunge-cut and QUICKPOINT grinding methods. This facility makes the grinding machine extremely flexible and capable of implementing several grinding operations in a single clamping. The Lean Selection speed cylindrical grinding machine is ideally suited for the grinding of small and medium-sized series: It not only operates with outstanding cost efficiency, but also benefits from operating simplicity and fast retooling.

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

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

www.junker.in

Editorial Board

Editorial Index A

Heidenhain

Ador Welding

46, 60 K KASTO

B Bharat Fritz Werner

22, 40

8 L Lantek

C CNC Software, Inc. Mr. A.P. Jayanthram Managing Director Heidenhain Optics & Electronics India Pvt. Ltd

Mr. GK Pillai Managing Director & CEO

Walchandnagar Industries Ltd.

Mrs. Mohini Kelkar Managing Director Grind Master Machines Pvt. Ltd

(Mastercam)

Concepts NREC

DMG MORI Dormer Pramet

16 23, 64

E Effica Automation

28, 66

ExxonMobil Corporation

Effica Automation Ltd.

Ms.Samina Khalid Marketing Manager

Renishaw Metrology Systems Ltd.

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

O Oriental Machine Tools

Precihole Machine Tools

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

MTW DECEMBER 2015

Mr. B.P. Poddar Vice President - Sales & Marketing FEMCO Fatty Tuna India Pvt. Ltd.

Mr. Jayant Vaidyanathan VP - Sales & Application Tsugami Precision Engineering India Pvt. Ltd.

R Renishaw

15,34, 36, 62

S Spraymet Surface Technologies

Grind Master

Unity Controls

Haas Automation 10, 11, 32

Warpp Engineers

Hangsterfer’s

WIDIA

HARTING

Winkelmann

For editorial contribution contact editor@divyamediaonline.com

Mr. Dinesh Khambhayta President MTMA-RAJKOT

D DesignTech Systems

Mr. Arjun Prakash Managing Director

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

MACHINE TOOLS WORLD |

7 | December 2015

BUSINESS NEWS

BFW – Ganesh Technologies Tech-center Launch Bharat Fritz Werner Limited, popularly known as BFW, is India’s major machine tool builder. One of the flagship companies of the Kothari Group, BFW was incorporated in 1961 in collaboration with Fritz Werner Werkzeugmaschinen GmbH of West Germany. We have a wide product range of solutions for metal cutting applications – Vertical machining Centers, Horizontal Machining Centers, Turning Machines, Special Customized Machines, high-end 5 Axis machines etc. There are more than 30,000 BFW products across the globe. Catering customers like Ashok Leyland, Bosch, Force Motors, Greaves, Honda, Kirloskar Toyota Textile Machinery, L&T MHI Turbine Generators, Mahindra & Mahindra, Maruti Suzuki, Renault, Sound Castings, Tata Motors, TVS Motors and many more.. Our products find applications in a wide range of industries – Aerospace, Automotive, Defence, Die & Mould, General Engineering, Medical Implants, Pums & Motor, Railways etc… We are an ISO 9001:2008 and ISO 14001:2004 manufacturer, with our main manufacturing facility at Bengaluru, Chennai and Stuttgart Germany. Our products are available through a vast sales & service network, both domestic and international. We are the recipient of several awards and recognitions – Including ‘Star Performer for Large Enterprise’ by Government of India, awarded for exports for 3 years

MTW DECEMBER 2015

ket knowledge, sales expertise and customer relationships developed over two decades, this association will further strengthen the Kolhapur region and our support.

Initiatives:

by EEPC (Engineering Export Promotion Council) and many more…

German Subsidiary Matec Matec Machinenbau GMBH is the German subsidiary of BFW located in Stuttgart, Germany and is premier manufacturer of Travelling column 5 axis VMCs having more than 1500 installations globally. Matec supplies to OEMs and large organizations like Airbus, ABB, Trumpf, John Deere and Thyssen-krupp and caters to a diverse clientele across international market, boasting of its own overseas office located at Shangai, China.

Entry in Turning Business: BFW is known for milling technology. Responding to customer requests we entered into Turning Solutions in 2015. We acquired Turning Business from Chennai based company Proteck Machiniery in April 2015. With this acquisition BFW is in a position to cater end-to-end Turning range, standard products & Solutions Turning etc.

Why Kolhapur: Kolhapur is major casting hub for automotive and farm

equipment, and has seen several foundry based industries operating here synchronously with the “Make in India” programe. This region is growing consistently over few years, and has become a vibrant hub for Manufacturing. To meet needs of customers in Kolhapur region like Sound castings, Mahabal metals, Mourya Industries, caspro metals, General Machine Tools etc, we have decided to strengthen our presence here by way of establishing a Tech Centre.

BFW association with Ganesh Technologies (Channel Partner): M/s Ganesh Technologies is our channel partner for Kolhapur region; with the mar-

1) Products display: We will showcase cutting edge new products at Tech-Centre for customer’s next-Gen requirements. 2) Service & Spare-parts supply: We will position dedicated service engineers and stocking of the spares in techcentre to closer to customers and providing effective aftersales and service. 3) Applications: Applications engineers stationed at Tech Centre providing solutions to challenging problems faced by customers. 4) Trainings: We will conduct customized and comprehensive training programs for production processes, engineering applications, maintenance etc. For more information, Website: www.bfwindia.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

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UNITY CONTROLS PVT. LTD

BUSINESS NEWS

HaasTec Pune 2015 event set for December The popular HaasTec showis returning to India this year. Managed by the Haas Factory Outlet (HFO) in India (Phillipscorp, CNCSSIPL division), the HaasTec will take place on 09th – 12th December at Auto Cluster, PCMC,Pune. In line with previous HaasTec events, a number of innovative, affordable Haas CNC machine tools will be on view. Machineslike UMC-750 five-axis universal machining centre and the ST-35 big bore CNC lathe will be on display. All of the Haas CNC machine tools on display will be powered and performing demonstrations,

cutting metal.Haas specialists from the HFO will be available to guide visitors through the demonstrations and answer any questions about the machines. The UMC-750 five-axis vertical machining centre offers a capacity of 762 x 508 x 508 mm in the X, Y and Z-axis respectively. It features a two-axis inbuilt trunnion rotary table and a 40-taper, 22.4 kW, 12000 rpm direct drive spindle. Other features of this advanced machine include a 40+1 side mount tool changer, 25.4 m/ min rapids, co-ordinate rotation and scaling, rigid tapping, a wireless intuitive probing system

and a 284 litre flood coolant system. The Haas ST-35 big bore CNC lathe can accommodate bars up to 102 mm in diameter and offers a capacity of 533 (dia) x 660 mm (length) with 806 mm of swing. The 29.8 kW, 2400 rpm spindle is served by a twospeed gearbox, while additional features include a 381 mm chuck, 12-station bolt-on turret and rigid tapping capability. Other Haas CNC machine tool models scheduled to appear at both HaasTecevents include the ST-10Y turning center with Y-axis, the ever popular DT-1 Drill Tap machine

with new 30 taper 15,000 rpm spindle, a VF-2 VMC, a VF-2SS, Mini Milland the VF-7/50 VMC. Visitors are invited to bring along components or drawings for a full evaluation of optimized machining solutions. Indeed, the HaasTec events will also feature a number of the company’s industrial partners, all able to offer complementary technologies and advice.

For more information, Website: www.haascnc.com

Grind Master bags SME business excellence award Karur Vysya Bank and Dun & Bradstreet (D&B) launched an awards initiative to recognize and felicitate SMEs who have demonstrated exemplary performance in their respective fields. A rigorous Filtering and Selection narrowed to 26 Awardees from amongst 100,000 Plus nominations. Grind Master is the proud recipient of this prestigious SME Business Excellence Award in the Mid Corporate segment under Engineering & Machinery sector. The award was presented at a grand ceremony on Monday, 23rd November 2015 at New Delhi by Shri Jayant Sinha, Minister of State for Finance, Government of India. The event , attended by eminent business leaders and senior government officials, also included the release of the publication “Leading SMEs of India 2015”.

MTW DECEMBER 2015

Sameer Kelkar, Executive Director at Grind Master represented Grind Master at the award program. The award selection was based on all round performance and track record of the nominees. Grind Master has been growing at a phenomenal rate in the past few years, closing FY14-15 with a Turnover of more than Rs.120 Crores. As one of the large machine tool builders in India it qualified in the “Mid-Corporate” Category, thus also reflecting the trans-

formation into a Professionally Managed Business. With a track record of developing breakthrough technologies including Microfinishing, Dynamic Balancing and Robotic Automation in the last few years, Grind Master represents India on the global stage with a very strong Export record. Recently completing the 50th machine in China, Grind Master has created a brand known for expertise, innovation in metal finishing internationally.

“I have personally witnessed the journey of Grind Master for the past 32 years, earlier as a child watching his parents and in the last few years as a Team member. It has been a really exciting journey, and gives me great satisfaction and pleasure that we emerging on a national and international stage as a trustworthy and passionate machine builder as I celebrate 5 years in Grind Master. As we work towards becoming an international professional company I would like to personally thank all our customers, suppliers, well wishers, associates for their enthusiasm and support in this journey. Looking forward to an exciting future …”

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

BUSINESS NEWS www.mtwmag.com

Haas Automation experiences new highs at EMO 2015 At EMO 2015 in Milan, Haas Automation chose to highlight the many, productivityenhancing innovations that go towards making Haas CNC machine tools the best value, most reliable machines in the world, with the lowest cost of ownership and, therefore, the lowest cost per part produced. Visitors to the Haas Automation booth were able to join a multi-stop tour of the company’s CNC vertical machining centres, turning centres and 5-axis machines, to see and learn first-hand the difference made by Haas innovations in software and control, automation, part and tool cooling, probing and setting-up, live tooling and highspeed machining. “This was a fantastic event for Haas,” says Mr. Jens Thing, managing director of Haas Automation Europe. “It was our biggest trade show investment to date and it yielded far greater than expected returns.” Mr. Thing points out that this dramatic result is a clear indication that the company’s collaboration with Milan-based machine tool group Celada, operating the official Haas Factory Outlet (HFO) for Italy, also has the potential to exceed expectations. “We joined forces with Celada a little over two years ago,” he says. “In that short

time, the company and its people have invested significant capital and enormous energy in creating what will undoubtedly prove to be one of the best HFOs in the world. “It’s still relatively early days, so the results at Milan just go to show how committed the Haas and Celada teams both are, and how well we work together. I’d like to thank everyone who contributed on our booth at EMO – we had operators and sales engineers from all over Europe, but my biggest thanks go to the Haas Automation team and the Celada team. ” During the show, journalists and Haas customers had the opportunity to meet Mr. Bob Murray, general manager of Haas Automation Inc., who was visiting from the company’s factory in Southern California. As always, Mr. Murray shared plans for future Haas products, and his thoughts about opportunities and challenges in Europe & the rest of the world.

“We never stop innovating and designing new machines,” he said. “That’s really one of the keys to our continued success. We have a new CNC currently in development – a next-generation, more powerful control that will build on the current system and still be very familiar to Haas customers around the world.” There are also new versions of the UMC750 currently in development. “This machine has proved to be very popular in Europe,” says Mr. Murray, “so we plan to build it in different configurations. Also, we have CNC gantry machines nearing launch and, of course, we already have available the ST-15 and ST-35 CNC tuning centres, which offer robust, big-bore capability and more powerful spindles, in machines with smaller footprints. We find more and more that our customers need capable machines with generous travels but small physical dimensions.” As for challenges in the European and global economies,

Mr. Murray openly discusses Haas’ strategies for maintaining growth. “We have great potential for increasing our market share,” he says, “especially amongst the small to medium, privately owned machine shops. We have a large range of CNC machine tools, all of which are built in volume, which means we can supply existing and new customers with exactly the capabilities they need at the right price and with excellent back up and support from the HFO network.” All Haas prices – machines and spares, are available on-line, so customers know exactly what they can expect to pay. “As our customers grow, we can continue to supply the reliable, productive machines they need. It doesn’t matter where a customer is based, we can support them, help them do business and, of course, make money.” It’s a strategy that has worked very well in the USA, where in some market niches, Haas enjoys 50% market share. “These are great results at EMO 2015 in Italy,” concludes Mr. Murray. “It goes to show, customers around the world all want the same things, wherever they are: high levels of service and support, and reliable products. Italian companies are very demanding and I’m happy to say, our machines and our service make sense to them.”

MTW DECEMBER 2015

BUSINESS NEWS

CNC Software, Inc. launches global “Dynamic Motion Challenge”

CNC Software, Inc. has launched a worldwide Dynamic Motion Seminar Program where manufacturing managers, CNC programmers, machinists and operators can learn about achieving higher material removal rates, cycle time reductions of up to 70%, and greater tool life using Dynamic Motion. With support from our tooling and machine partners we are bringing live cutting demonstrations, featuring difficult to machine materials, to local venues so attendees can experience the benefits of Mastercam’s Dynamic Motion for themselves. In the coming months, Mastercam Resellers from around the world will be conducting these seminars which include educational presentations by cutting tool and machine tool experts, followed by live milling and turning demonstrations using Dynamic Motion.

MTW DECEMBER 2015

About Mastercam Developed by CNC Software, Inc., Mastercam is Windows®based CAD/CAM software for 2- through 5-axis routing, milling and turning, 2- and 4-axis wire EDM, 2D and 3D design, surface and solid modeling, artistic relief cutting, and Swiss machining. CNC Software is a privately owned corporation founded in 1983. The U.S.-based company provides Mastercam CAD/CAM solutions to more than 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, Website: www.mastercam.com

Free online Mastercam university course for maintenance customers

CNC Software announced that Mastercam University, their online learning tool that gives both students and experienced users alike 24/7 access to Mastercam training materials, is providing free copies of their Mastercam X9 Update course to Maintenance customers. This course is designed to help you understand the new features in the Mastercam X9 release. Some topics that are covered in the Maintenance course are: • Geometry – 2D bounding box, level & WCS modeless dialog, selecting geometry by level • Design – Dynamic transform, Gnomon manipulation, translate/rotate, select all entities • Solids – Solid positioning, mating faces, inserting clamps, rotate & translate fixture components • Offset – Xform offset, offset contour, analyze distance, create arc polar • Mill – Contour, lead in/out, solid chains, Backplot verify options, Verify / Mastercam

Simulation • Toolpath – Peel Mill, Dynamic Motion, 2D HST Blend, center start cut direction, extend entry/exit • Tool – New tool shape/ types, Barrel, Threadmill, Slot Mill with new upper corner radius control • And much more. Mastercam University is online video training that lets you learn at your own pace, your own time, and from experienced Mastercam trainers. Use these new online classes to get upto-speed quickly, keep your skills sharp, or even prepare for official Mastercam Certification. Mastercam University is open to anyone with internet access, and can be purchased through Authorized Mastercam Resellers.

For more information, Website: www.mastercamu.com

Renishaw fixtures Your single source for metrology fixturing

Renishaw modular fixtures for CMM, Equator™ and vision applications: • Improved throughput, reproducibility and accuracy of your inspection • Quick and repeatable fixturing set-ups for your components • Complete solution for any part regardless of its size, shape or material

For more information call 01453 524111 or visit www.renishaw.com/fixtures

Renishaw plc New Mills, Wotton-under-Edge, Gloucestershire, GL12 8JR United Kingdom T +44 (0)1453 524524 F +44 (0)1453 524901 E uk@renishaw.com

www.renishaw.com

Renishaw fixtures single source A4 1114.indd 1

19/01/2015 08:57:45

BUSINESS NEWS

ExxonMobil showcased its lubricant portfolio at EXCON 2015 ExxonMobil Lubricants Private Limited, a wholly-owned affiliate of Exxon Mobil Corporation, showcased its outstanding lubrication products and solutions for the construction equipment and mining industryat the 8th edition of EXCON held in Bengaluru from 25th–29th November, 2015.ExxonMobil comprehensively elaborated on its safety, environmental care and productivity concept of sustainable development and practical experiences, attracting wide attention from participating companies & representatives. The mining industry is one of the most fundamental components of the industrial landscape and also one of the most challenging from a lubrication standpoint. With industry-leading technology and engineering resources, Mobil Industrial Lubricants offers innovative products and services that help deliver tangible performance and “Advancing Productivity”- related benefits. “Advancing Productivity” focuses on how ExxonMobil’s innovative products and services help deliver tangible performance benefits in the areas of safety, environmental care and productivity. • Safety: Enhance mining equipment performance and reduce equipment failures and unscheduled downtime, thus lower maintenance requirements and the potential risks in safety of maintenance personnel • Environmental Care: Improve energy efficiency of

MTW DECEMBER 2015

lubricant, reduce oil waste and environmental impact; improve mining equipment performance to strengthen the comprehensive utilization of mineral resources • Productivity: Improve mining equipment reliability, extend equipment life and ensure sustainable and efficient production The overall productivity and profitability of a mine site is directly linked to the reliability of equipment and as a result, it is vital that mining operators have equipment’s that function at maximum efficiency, even in extreme conditions. Mining equipment such as excavators, dump trucks, conveyer belts and loaders to name a few, are reliant on a number of lubricants to help them function. Whether it’s an engine oil, gear lubricant, hydraulic fluid or grease, one failure can bring the entire machine operation to a halt. The availability and output of these machines have a direct link to the overall productivity and profitability of a mining site, and operators can gain a competitive advantage by selecting high-performance lubricants.

While the primary function of a lubricant is to protect equipment, reduce unscheduled downtime and extend oil drain intervals, advancements in lubricant technology now mean mining companies can select oils and greases which provide outstanding levels of protection as well as other potential benefits such as improved fuel economy. Heavy-duty diesel engine oils, hydraulic oils and greases work hand-in-hand to enable mobile machinery on mining sites to operate effectively. “The mining industry is beginning to recognize that in order to improve productivity, strategies need to be implemented with an operations-wide approach. Building a comprehensive, solutions-oriented maintenance plan, which takes into consideration the highquality lubricant technologies and monitoring services that will best help to deliver operationwide benefits, while reducing overall cost of maintenance, is one major way that mine operators can advance overall productivity of their operations,” said Mr. Shankar Karnik, General Manager Industrial, ExxonMobil Lubricants Pri-

vate Limited. He further added, “By combining the use of high quality lubricants and an effective oil and equipment analysis programme from ExxonMobil, mining operators can look to achieve a competitive advantage in their operations in challenging environments, helping to maximise productivityand reduce the fuel consumption potential of their mining machinery and equipment.Additionally, by reducing scheduled and unscheduled maintenance, the associated safety risks that engineers face when undertaking work can also be eliminated.” The company’s advanced technology offerings for the construction equipment and mining sector which was displayed at EXCON 2015 included: • Mobil SHC™ Gear Series: A family of superb performance fully-synthetic, industrial gear oil qualified by major gear original equipment manufacturers. In statistically validated laboratory tests and field trials, Mobil SHC Gear fluids exhibited energy savings of up to 3.6 percent compared with conventional gear oils.

BUSINESS NEWS www.mtwmag.com

• Mobil SHC™ 600 Series: High-performance synthetic circulating and gear lubricants that can be used in a wide range of stationary equipment commonly found in construction and mining applications. In a gearbox and circulating oil system, the low traction and high viscosity index in Mobil SHC 600 Series oils combine to significantly reduce energy consumption by 3.6%* • Mobil SHC™ Rarus Series: A family of supreme performance air compressor lubricants primarily intended for the lubrication of severe duty rotary screw and vane air compressors. These breakthrough oils have demonstrated the capability to last up to 24,000 hours in a compressor field trial† and are backed by a three year warranty. Mobil SHC Rarus

Series formulation provides the potential to deliver up to 3 times oil drain interval versus a leading synthetic compressor lubricant • Mobil DTE 10 Excel™ Series: The Mobil DTE 10 Excel Series of hydraulic oils provide outstanding hydraulic system efficiency; ultra keep clean performance, and a high degree of fluid durability. It also helps minimize maintenance costs and downtime by keeping systems clean upto 3 times longer than other competitive oils. Designed with the latest in hydraulic fluid technology, Mobil DTE 10 Excel™ Series provides hydraulic pump efficiency benefits up to 6 percentwhen compared with a typical reference hydraulic fluid in controlled bench testing.Their excellent oxidation and thermal stability can help in extending oil and

filter change intervals. • Mobilgrease XHPTM Mine Series: A range of premium lithium complex grease specifically designed to meet the needs of off-highway and mining equipment that requires exceptional extreme pressure/antiwear performance and will remain in place even in tough conditions of water spray, high sliding and high temperatures • Mobilgrease XHPTM 220 Series: A range of premium quality greases that are designed to help optimize equipment reliability in a wide variety of heavy-duty applications and operating conditions. Mobilgrease XHPTM222 is part of the Mobilgrease XHP™ 220 Series of extended service lithium complex greases intended for a wide variety

of applications and severe operating conditions • Mobil DynagearTM Series: A family of high-performance open-gear lubricants that have been designed to provide outstanding protection of heavily loaded open-gear sets exposed to a wide range of operating conditions, especially those common in the mining industry • Mobil Delvac 1™ Series:A full range of synthetic heavy-duty diesel engine oil that helps extend engine life while providing long oil drain intervals, extreme high- and low-temperature performance and fuel economy potential

For more information, Web: www.mobilindustrial.com

Renishaw unveild Inspection Plus with Supa Touchoptimisation delivering intelligent speed

Renishaw, a market-leading engineering technologies company, introduced Inspection Plus with SupaTouchoptimisationat EMO 2015, Milan, Italy (5th10th October, hall 5 stand D15). This enhanced software package automatically optimises on-machine measurement cycles to minimise cycle time and maximise productivity. The software features an easy-to-use optimisation process

to automatically determine and select the highest feedrates a machine tool can achieve whilst maintaining measurement accuracy. It also uses intelligent in-cycle decision making to implement either a one or twotouch probing strategy for each measurement routine. Inspection Plus with

SupaTouch optimisation eliminates the need for manual optimisation of onmachine positioning feedrates, measurement feedrates and strategies. When compared with traditional software cycles, it provides a significant cycle time reduction of up to 60% on CNC machine tools. To ensure maximum accuracy, the software detects any measurements taken during machine acceleration or deceleration phases and compensates for errors by taking corrective action and remeasuring. It also introduces a calibration process that improves measurement

repeatability in all directions and improves the accuracy of probe positioning during multi-axis vector moves. Inspection Plus with SupaTouch optimisation enhances the many proven benefits of Renishaw’s established Inspection Plus software. With this new software, users can significantly improve cycle times and onmachine measurement results, maximising the productivity & profitability of their machine tools.

For more information, Website: www.renishaw.com

MTW DECEMBER 2015

BUSINESS NEWS

DMG MORI confirms annual forecast 2015 DMG MORI AKTIENGESELLSCHAFT completed the first nine months of the financial year 2015 according to plan. As at 30 September, we were able to increase sales revenues by 6% to € 1,648.8 million (previous year: € 1,562.4 million). We made good on more ground in the third quarter; order intake was slightly higher than in the previous year at € 1,742.0 million (previous year: € 1,740.8 million). EBITDA amounted to € 151.9 million (+4%; previous year: € 145.9 million), EBIT reached € 111.5 million (previous year: € 111.7 million) and EBT climbed to € 108.8 million (+2%; previous year: € 106.7 million). As at 30 September 2015, the group recorded earnings after taxes of € 75.1 million (+2%; previous year: € 73.7 million). Positive impulses were largely received from the Asian markets China and Korea. In Europe, we recorded a rise in the demand for machine tools foremost in Italy and France. Sales revenues in the third quarter rose to € 558.6 million (+6%; previous year: € 528.0 million). In the first nine months, sales revenues rose to € 1,648.8 million and were thereby 6% above the previous year’s value (previous year: € 1,562.4 million). International sales of the group rose by 9% to € 1,098.7 million. Domestic sales amounted to € 550.1 million. The export quota amounted to 67% (previous year: 65%). As to order intake we made good on more ground in the third quarter; it amounted to

MTW DECEMBER 2015

€ 538.7 million and was thus above the value of the previous year (€ 530.7 million). As at 30 September, order intake reached € 1,742.0 million (previous year: € 1,740.8 million). Orders from the domestic market amounted to € 600.5 million (previous year: € 628.6 million). International orders amounted to € 1,141.5 million (previous year: € 1,112.2 million). The quota of international orders was 66% (previous year: 64%). Key income figures of the DMG MORI group developed as follows in the third quarter: EBITDA rose to € 57.0 million (previous year: € 55.7 million), EBIT amounted to € 43.1 million (previous year: € 43.9 million) and EBT reached € 43.1 million (previous year: € 42.1 million). As at 30 September, EBITDA amounted to € 151.9 million (previous year: € 145.9 million), EBIT amounting to € 111.5 million was at the same level as in the previous year (previous year: € 111.7 million) and EBT rose to € 108.8 million (previous year: € 106.7 million). As at 30 September 2015, the group reported earnings after taxes of € 75.1 million (previous year: € 73.7 million). Investments in plant, property and equipment as well as intangible assets amounted to € 80.1 million in the first nine months (previous year’s value: € 78.6 million). The focus of investments is on the construction projects started in the previous years. Upon completion of our construction projects in 2016 in Russia and South Korea, we will significantly reduce the

investment level. The expenses for research and development in the first nine months amounted to € 34.4 million (previous year: € 32.7 million). At international and national trade fairs in the first nine months, we presented jointly with our Japanese partner 10 world premieres, which are equipped with the CELOS control and operating software, and in the new Corporate Design. The changeover of our product portfolio to the Corporate Design was completed successfully at the EMO autumn fair in Milan. On 30 September 2015, the group had 7,361 employees, of whom 312 were trainees (31 Dec. 2014: 7,166). The number of employees rose by 195. At our domestic companies, 4,056 employees are on staff (55%) and 3,305 employees (45%) at the foreign companies. Cost of personnel amounted to € 404.7 million (previous year’s period: € 371.4 million). The personnel ratio was 23.6% (previous year’s period: 22.8%). The share of DMG MORI AKTIENGESELLSCHAFT proves stable in the course of the year in comparison to the volatility in the capital markets. The security

showed a positive performance with a plus of 45% within the first nine months. The MDAX recorded a plus of 14% in the same period. In the third quarter, too, the share showed a stable development: The price in the beginning of the reporting period was € 32.79 (01 July 2015) and closed at the end of the third quarter with € 34.29 (+4.6%). The market capitalisation currently amounts € 2,824.0 million (reporting date: 23 Oct. 2015).

DMG MORI annual forecast: Sales revenues should amount to around € 2.25 billion. In the fourth quarter, we still expect rising sales and earnings contributions. On the assumption that the market development will continue according to our expectations, we plan to achieve EBIT of around € 165 million and EBT of around € 160 million for the complete year. Furthermore, we continue to assume a positive free cash flow between € 10 million and € 20 million. Provided that these figures are achieved, we plan to pay a dividend for the financial year 2015.

Key figures on business Development of the DMG MORI group

2015 30.09.2015

2014 30.09.2015

€ million

Sales revenues

1,648.8

1.562.4

86.4

changes 2015 against 2014

Order intake

1,742.0

1,740.8

1.2

EBITDA

151.9

145.9

6.0

EBIT

111.5

111.7

-0.2

EBT

108.8

106.7

2.1

Earnings after taxes

75.1

73.7

1.4

BUSINESS NEWS

“Leverage technology for product excellence” DesignTech Systems Ltd., a leading CAD/CAM/CAE, PLM and Additive Manufacturing solutions and technologies provider in India, organized a one day Technology seminar in Pune to showcase to the engineering and product development industry the latest technologies in Product design, development and manufacturing. Being Strategic Business Partners with world leaders such as Siemens PLM for their product design and PLM software solutions, Altair Engineering for their CAE suite of solutions, Stratasys for their Additive Manufacturing Machines, and SLM for their Metal 3D Printers, DesignTech showcased technologies at every stage of product lifecycle starting from Concept development, 3D Modeling and Validation, Product Design analysis and simulation, Rapid prototyping, Alternative Production technologies, through to PLM for managing and optimizing the entire product design and development data and processes. Organized at Le Meridien in Pune, this full day event saw a congregation of some of the big names in the engineering industry along with an encouraging participation from the SMEs which make for the backbone of Engineering and manufacturing industry in Pune. On this occasion, Vikas Khanvelkar, Managing Director, DesignTech Systems Ltd. expressed his views stating, “I am extremely overwhelmed to see such a fantastic response to this event. It makes me happy to see the enthusiasm among the engineering industry to learn about, understand

MTW DECEMBER 2015

Mr Vikas Khanvelkar - MD- DesignTech Systems speaking at DesignTech Technology Day event the advantages, and consider adopting new and advanced technologies to add more value to their engineering initiatives. With Government of India strongly emphasizing on and heavily promoting ‘Make in India’ in the foreign countries, Brand India had never had such a huge thrust. This is going to significantly boost manufacturing and product development initiatives in India. Pune has always been at the center of engineering industry in India. Being an engineering hub, industry here should be among the first to adopt new technologies that will enhance their quality of productivity, augment efficiency of processes and improve the overall performance of product making them more competitive and bringing them at par with the global standards of engineering and manufacturing excellence. With more Hybrid R&D centers being set-up, and more and more indigenous companies investing heavily in R&D, India has the potential to outweigh competition from foreign markets

and Pune will definitely gain prominence as being a strategic and preferred destination for engineering industry. Through events like today, we attempt to make industry aware of the latest trends and technologies in the product design, development and manufacturing arena. These technologies together can make for a robust R&D set-up and will help companies achieve their desired goals of product quality, time and cost efficiency, optimization of resources and funds, and of overall productivity of their department.” DesignTech systems Ltd. through their education and training wing, DesignTech CAD Academy is an Authorized Training Partner of Siemens PLM and Altair Engineering for their CAD and CAE suites of solutions. Besides that, DesignTech Systems is also a renowned name in engineering services as they cater to companies from cross vertical domains assisting them in their most complex and challenging engineering initiatives. The client base of DesignTech’s Product

development and engineering services spans across North America, Europe and Asia. Sanjay Daga, President – Operations, at DesignTech Systems exclaimed, ‘‘Through this event we got a chance to showcase our entire product, services and training portfolio and offerings to the industry. With the huge impetus of policies and schemes being promoted by the Government of India, the Indian engineering and manufacturing industry is anticipated to grow leaps and bounds. The only way, the Indian industry can compete with their foreign counter parts, is if they adapt as per the changing times and adopt the technologies that will help them build better products, faster and cheaper than others. This is where we will surpass the competition. For this it is critical for the industry to understand the application of these technologies and the benefits that they will bring to their engineering initiatives. DesignTech has been a pioneer in popularizing and promoting the use of latest technologies in the field of product design and development amongst the engineering Industry in India right from late 90s during when the industry and particularly the SMEs were most apprehensive about investing in such perceived expensive technologies. But today there is a greater awareness about these technologies and competition has necessitated the companies to invest in such tools that will add value to their design and manufacturing processes. Besides promoting cutting-edge technologies, we have always

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been a customer oriented company, determined to provide seamless customer service, training and support thereby making every dealing with the customer a delightful experience for them. The customer case studies being presented at this forum are a testimony to our service to them. We are thrilled and extremely grateful to all the customers who very readily and willingly agreed to present their technology usage and DesignTech support experience on this big platform” Mr. Hemant Jere, Head Design & Development, Supreme Industries Ltd, a recognized name in Plastic product manufacturing, and a customer of Stratasys 3D printer shared their experience of how Stratasys 3D Printer helped them develop better products. Mr. Prakash Khot, Manager Product Design and Mr. Suraj Kolte, Engineer Product Design, from Kalyani Maxion Wheels, a leading player in Wheels manufacturing and a supplier to many big OEMs and CAR companies presented a Case Study on Altair CAE suites of solutions and how it enabled them to analyze and evaluate their product designs thus helping them develop more robust products. While, Mr. Sajith Chenat, Director ,Matrix Tools and Solutions, an ardent user of Siemens NX solutions, spoke at length about the benefits of NX as an Advanced CAD and 3D Modeling software which helped them develop even the most complex geometries and shapes effectively. These case study presentations added more insight into the use, applications and benefits of these technologies

and the value they add to the company’s engineering and product development initiatives. They also illustrated the customer support being extended by DesignTech which helped them implement and use these technologies to the very best thus enabling them derive highest return on their investments. More than 200 guests from engineering industry being present for the seminar made this event significant and note worthy of recognition.

About DesignTech Systems DesignTech Systems Ltd. is a leading CAD / CAM / CAE / PLM Solutions, Additive Manufacturing technologies, and Engineering Services provider from India. With more than 16 years of experience we have been working with companies from cross vertical domains from India and overseas to support them in their most complex and challenging engineering initiatives while helping them derive best returns on their investments. DesignTech Systems is strategic business partners in India for Stratasys, Siemens Industry Software, Altair Engineering, ESI, SLM and MathWorks. DesignTech Systems is Recipient of some of the prestigious awards like Maharashtra Government IT award in 2010, being adjudged among the top 50 emerging companies of India by NASCCOM in 2010 etc, also operates training centres, “DesignTech CAD Academy” is an authorized training partner of Altair for their CAE and Siemens PLM for their CAD and PLM suite of solutions.

For more information, Web: www.designtechsys.com

MTW DECEMBER 2015

BUSINESS NEWS

IMTMA presents South & South East Asia’s leading Metal Forming Machine Tool Exhibition ‘IMTEX FORMING 2016’ Key Highlights • Display of high power fibre laser cutting machines. • More than 450 exhibitors from 22 countries. • Group participation from 4 nations: Germany, China, Japan and Taiwan. • Exhibition net space covering about 30,000 sq.mts. in 3 halls. • Visitor footfall of about 50,000.

About IMTMA

Indian Machine Tool Manufacturers’ Association (IMTMA) is happy to invite you to its flagship IMTEX FORMING 2016 exhibition at the Bangalore International Exhibition Centre (BIEC) from 21 to 26 January 2016 in Bangalore. Tooltech 2016, a concurrent event of dies & moulds, forming tools, machine tool accessories, metrology and CAD/CAM will be held simultaneously. IMTEX FORMING 2016 & Tooltech 2016 will be a significant exhibition for South East Asia with the presence of leading national and international manufacturing firms from the metal forming sector. IMTEX FORMING is expected to be a greatly expanded fair which would feature all aspects of forming technologies, predominantly sheet metal forming. This exclusive business-to-business event will attract Indian and foreign exhibitors who would offer a range of technologically

MTW DECEMBER 2015

innovative manufacturing and engineering products and applications. Sharing his views on the technology display at IMTEX FORMING 2016, Mr. L. Krishnan, President, IMTMAsaid, “High power fibre laser cutting machines is definitely one of the new technologies that would be on display at this IMTEX. Companies will also display servo presses, hydroforming, plasma cutting, profile bending machines, robotic welding and service, and welding technologies.The event will benefit the entire manufacturing sector.” Concurring with the President’s statement, Mr. V. Anbu, Director General, IMTMA said, “World class technology and knowledge sharing will be on display at IMTEX FORMING 2016. By participating in the show,exhibitors will gain an insight on the latest techno-

logical requirements and get an opportunity to cement business relationships. This will be made possible by the high level delegations that are expected to visit from key private and public sector undertakings. The event will help policymakers to prepare a roadmap for the industry and enable them to take informed decisions.” As in earlier years added attractions will form part of IMTEX FORMING 2016. These include: International Seminar on Forming Technology (a seminar on the latest research and trends in forming technology) on 20 January 2016, i2 Pavilion (Industry – Institution Pavilion, a forum for academic and research and development institutions to showcase their activities in manufacturing and engineering fields), and Connect (imparting knowledge on the machine tool industry for young engineers).

IMTMA was formed in 1946 the year before India got its independence when 20 machine tool manufacturers joined hands to form an Association.Over a period of nearly seven decades it has grown in size to have around 500 members representing around 90% of the organized machine tool and allied equipment manufacturers as on date. Today, IMTMA is the apex body and single point of contact for the entire machine tool industry of India and plays a critical role in the development of the metalworking industry.A not-for-profit association, IMTMA’s initiatives range from government advocacy to industry and export promotion, trade fairs and events, training and seminars, technology missions, publication of various industry and technical writings, structuring of regional councils, and development of clusters.

BUSINESS NEWS

KASTO, expert provider of sawing and storage equipment, opens subsidiary in Singapore in the German Centre Singapore, an office and business centre for German companies. The opening ceremony, which took place on 26 October, featured an honorary guest from the German state of Baden-Wuerttemberg, where KASTO has its headquarters: Dr. Nils Schmid, Minister of Finance and Economics, had the special task of cutting the red ribbon to officially open the subsidiary.

Mr. Armin Stolzer, General Manager of KASTO KASTO is strengthening its position in Asia. The German company, which specialises in the development and manufacturing of metal sawing and storage equipment, opened a subsidiary in Singapore on 26 October. From here it plans to expand its presence in the Southeast Asian market. Customers in the region can look forward to clear advantages: more comprehensive and personal service, short response times and expert local advice. In the course of its more than 170-year history, KASTO Maschinenbau GmbH & Co. KG has grown to become a leading manufacturer of systems for sawing and storing of bar stock. The German company, which has some 700 employees worldwide, already has subsidiaries in England, France and the USA. Singapore is the latest addition. “We’ve been active in Southeast Asia since 1991 and have had many loyal customers here for years, from Singapore to Malaysia and Thailand,” explains Armin Stolzer, managing partner of the family-owned company which is now being run by the fifth generation. “In addition,

MTW DECEMBER 2015

About KASTO: KASTO, expert provider of sawing and storage equipment, opens a subsidiary in Singapore. the region has become increasingly important as a growth market. For us, it made good sense to establish a subsidiary here in order to strengthen our position.” “Our location has an excellent infrastructure and we’re very close to all the other countries in Southeast Asia,” Area Sales Director David Van Loo emphasises. “Here we have excellent access to the market.” Another reason for

KASTO is also a global leader in the manufacture and sale of semi-automatic and automatic storage systems for bar stock & sheet metal.

establishing the subsidiary was to provide better service: “The operators of our sawing and storage systems expect quick, comprehensive and personal service from the manufacturer. We’re now going to expand this network.” KASTO wants to offer its customers in the region faster and more personal service. “We support users in every phase of a project: from planning and development of a plant through construction and commissioning all the way up to maintenance and servicing. It will be a big advantage for us to be able to get to our customers more quickly.” The new subsidiary is located

KASTO specializes in innovative sawing technology – like the automatic bandsaw series KASTO win.

KASTO Maschinenbau GmbH & Co. KG, based in Achern-Gamshurst, Germany, specialises in sawing and storage technology for bar stock. The company is a global leader in the manufacture and sale of metal-cutting saws and semi-automatic and automatic storage systems for bar stock and sheet metal. It is also a leading manufacturer of automatic handling systems for metal bars, sheet metal and pre-cut parts. One of Europe’s oldest family-owned companies, KASTO celebrated its 170th anniversary in 2014. In the course of its successful history it has registered 160 patents, delivered more than 140,000 sawing machines to all parts of the world and installed more than 1,700 automatic storage facilities. In addition to a branch in Schalkau, Thuringia, KASTO has subsidiaries in England, France, Singapore and the USA. In 2014 the company’s roughly 700 employees achieved revenues of about 120 million euros. For more information, Website: www.kasto.com

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Lantek reaches global agreement with Vanad 2000 Lantek, a global leader in CAD/ CAM for sheet metal applications is further pursuing its policy of increasing its export market by signing a worldwide agreement with Vanad 2000, which manufactures fiber laser, oxy-fuel and plasma cutting machines at its headquarters in the Czech Republic. Vanad has delivered well over 1000 machines through its distribution network which extends across Eastern Europe, Russia, Germany, Austria and as far as South Africa. It has a programme of continuous development and has recently added four new machines to its portfolio, the VanadKompakt Light plasma cutter which can cut material up to 30mm thick with plasma or 50mm with oxy-cut; the VanadBluester with

automatic plasma 3D head; the Vanad Suprema which can cut sheets up to 12m x 3.1m and the Vanad Laser Kompaktfiber laser which offers travel speeds of over 45m/minute. The Lantek Expert CAD/CAM software is already distributed in more than 100 countries worldwide and Lantek has its own offices in 15 including the USA, Germany, Chile, Japan and China enabling it to deliver high quality global support to its customers. Francisco Perez, Director of OEM Channel at Lantek says, “By agreeing a worldwide strategic partnership with Vanad 2000, we will be

able to increase our penetration of the Eastern European market. Vanad has been particularly successful there. We already have partnership arrangements with some of its distributors.With our office in Poland and our existing dealers in Hungary and Croatia, we will be able to deliver high quality support and training to new customers in the region.” For Vanad 2000, offering Lantek Expert CAD/CAM nesting software as a turnkey solution with its machines will bring access to premium CAD/CAM solutions to Vanad’s customers, enhancing the return on investment they achieve from investing in Vanad equipment. In addition, Lantek’s global network will open up opportunities for Vanad in new export markets, allowing it to extend

its dealer network and grow the reputation of the company. Since its formation in 1986, Lantek Expert has been the flagship product for Lantek and is used by over 16,000 customers globally. The continuous development of the software has enabled Lantek Expert to maintain its market leading position. In 2015 alone, new features include highly accurate time calculation algorithms and enhancements to ease of use and CAD interoperability. By building a long term relationship both Vanad 2000 and Lantek will be able to build mutually profitable business at an international level, based on service and performance for customers.

Website: www.lanteksms.com

Pramet expands shoulder milling range Pramet’s popular shoulder milling range has been expanded with a new program of cutters, geometries & inserts. This includes a program of helical cutters for roughing applications. Offering a depth of cut up to 108mm, the cutters are suitable for use with Pramet’s versatile ADMX 16 inserts and support medium machining of most engineering materials including cast iron, stainless steel & aluminium alloys. The large clearance between the cutting teeth, combined with internal coolant delivery, promotes efficient chip evacuation. The axial clamping of inserts on the end teeth increases milling stability. This creates less noise and vibration which, in turn, also reduces tool wear. Karel Tiefen-

bach, indexable milling product manager at Dormer Pramet, said: “The new range of helical cutters offers additional performance and reliability for a variety of operations including shoulder milling, grooving and contouring. “Our ADMX 16 range is one of our most popular inserts. The creation of a new milling cutter further expands this versatile program. Customers can now use the same insert type for several milling cutters and applications, offering a more efficient and reliable service.” As part of the launch, two new positive geometries – MF and MM – have been added for

milling stainless steel, super alloys, low carbon steel and non-ferrous materials. MF is a sharp and highly positive geometry, ideal for light machining and finishing operations. MM is a universal sharp and highly positive geometry with stabilised cutting edge for finishing and semi-roughing operations. For use with shoulder milling inserts ADMX11 and ADMX16, as well as the LNGX12 range, the new geometries’ positive rake angle provides low cutting resistance, reduced cutting forces and less power consumption. Meanwhile, Pramet has also expanded its range of inserts for eco-

nomical shoulder milling. New radii and geometries have been added to the LNGU/LNMU16 assortment to provide greater choice. A further four radii options are now available offering a range of sizes from 0.8mm to 4.0mm. New geometries include F, M and R for machining stainless steel, steel and cast iron. A highly positive geometry FA is for copper and aluminium. An overview of all the new indexable ranges launched by Dormer Pramet in November 2015 is available in its latest product brochure. To order a printed copy or for more information contact your local Dormer Pramet sales office. Web: www.dormerpramet.com

MTW DECEMBER 2015

BUSINESS NEWS

Deburring and Polishing Technology Now at Home with a Trade Fair in Karlsruhe DeburringEXPO delivered a custom-tailored trade fair premiere from the 13th through the 15th of October, 2015. With 108 exhibitors from eleven countries (22% from outside of Germany), event promoters fairXperts GmbH & Co. KG succeeded in putting together comprehensive, representative offerings in the areas of deburring, rounding and polishing. The unique platform drew 2038 visitors to the Karlsruhe Exhibition Centre. 14.8% of the visitors came from 31 countries outside of Germany. “Due to the fact that this was a premiere event, we came to Karlsruhe with minimal expectations and were pleasantly surprised. Feedback from the visitors was tremendous and practically every visitor had a concrete task in hand, for which a solution is required. Many brought components and drawings along with them, making in-depth discussions possible which resulted in tangible projects. We’ll exhibit again at DeburringEXPO in 2017”, reports Jürgen Mang from sales at Kennametal Extrude Hone GmbH. Rösler Oberflächentechnik GmbH is also very satisfied with the way things went at the debut event: “As a globally leading company in the field of barrel finishing, there was no question for us that we mustn’t miss out on DeburringEXPO, and participation has paid off. We had visitors from a great variety of industries, for example automotive, medical technology and casting, and each and every lead was good because they all

MTW DECEMBER 2015

involved definite tasks. At times it would have been good to have a bigger booth and more personnel”, says Lucca Schlichting, barrel finishing machine sales, regarding her experience. And it wasn’t just the number of visitors that resulted in satisfaction amongst the exhibitors, but rather their high levels of technical qualification and decision making authority as well. 94.6% of the expert visitors are involved in company procurement processes. For Costa Levigatrici S.p.A., an Italian manufacturer of deburring and polishing machines, this led to definite orders: “All of the visitors came here in search of solutions for their own specific deburring tasks, some of which have to be implemented on short notice. Consequently, we were able to sell two machines directly at the event and establish lots of very valuable contacts. It was a very successful trade fair for us and I think we’ll exhibit again at DeburringEXPO 2017”, explains sales manager Roberto Martini. Günter Gölz, managing director of Benseler Entgratungen GmbH, was every bit as enthusiastic: “We’re very happy that fairXperts has initiated this platform. Our expectations have been more than exceeded. For us, it’s been

our most successful trade fair presentation ever so far, and thus there’s no question that we’ll be back again in 2017.” For strategic business director Sitanshu Gupta as well, the decision has already been made that Imexsu Europe GmbH will be on hand at the upcoming trade fair for deburring and polishing: “We manufacture deburring products, which makes it extremely important for us to be represented at DeburringEXPO. The promoter has succeeded in making the right audience aware of the event – beyond Germany’s boundaries as well. As a result, we not only had significantly more high quality leads than we expected, they were very international as well, for example from Poland, Portugal, Austria, Great Britain & even India.” The fact that the concept developed for DeburringEXPO, which is consistently aligned to the fields of deburring, rounding and polishing, was also wellaccepted by the visitors, is not only illustrated by the exhibitors’ positive reactions. 80% of the visitors are satisfied to very satisfied with the offerings presented at the first trade fair for deburring and polishing technology, and roughly 69% would recommend the event to their business

partners and colleagues. With regard to visitor distribution, main focal points included vehicle manufacturing, machinery and equipment manufacturing, medical technology, as well as tool and mould making.

Expert Forum in Demand The expert forum was one of the highlights at DeburringEXPO. 1473 visitors took advantage of it during the three-day trade fair in order to expand their knowledge of various issues regarding all aspects of deburring, rounding and polishing, & to exchange experience. Roughly one third of the expert visitors chose the day on which they attended the trade fair on the basis of the agenda for the expert forum. The all-in-all highly positive feedback indicates that the suppliers as well as the users of products and services covering all aspects of deburring, rounding and polishing are now at home with their trade fair in Karlsruhe. This is also confirmed by the fact that numerous exhibitors have already entered the next DeburringEXPO to their trade fair calendars, which will take place at the Karlsruhe Exhibition Centre from the 10th through the 12th of October, 2017. Web: www.deburring-expo.com

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National Productivity Summit 2015 concluded in Gurgaon Indian Machine Tool Manufacturers’ Association (IMTMA) has been in the forefront of championing a productivity movement in Indian metalworking industries by organizing the National Productivity Summit. This event showcases the best productivity improvement projects in metal working industries which have excelled in achieving superior performance through sustained productivity improvements. IMTMA had organized a series of successful National Productivity Summitsfrom 2006 to 2014. The ninth summit in the series was organized at Hotel Crowne Plaza, Gurgaon, on 20 and 21 November 2015. The key highlights of the National Productivity Summit 2015 were the 4 inspiring keynote presentations, 4 interesting plant visits and 12 live case study presentations.

Plant visits Plant visits to 4 companies were arranged on 19 November, one day prior to the summit. Hero Motocorp and Sona BLW Forging in Gurgaon, Hitech Gears and Honda Motorcycles &

Scooters India in Bhiwadi were the 4 companies visited. Eighty delegates attended the plant visits where various productivity improvement measures being practised on the shop floor were demonstrated.

Inaugural and Keynote Addresses Mr. L. Krishnan, President, IMTMA gave the welcome address. Dr. V. K. Saraswat, Hon’ble Member, National Institution of Transforming India (NITI) Aayog, was the Chief Guest for the event. Speaking at the event, Dr.Saraswat briefed on the current Indian economic scenario, the challenges and opportunities lying ahead. He then impressed upon the importance

of productivity and manufacturing to the growth of the nation, in conjunction with the drive of the government on the‘Make in India’ campaign, to equip the Indian manufacturing fraternity and scale them to greater heights in the global arena. About 300 participants from 102 companies listened to the keynote presentations on innovative approaches to address productivity challenges, new ideas and concepts. The presentations were made by teams from Maruti Suzuki, Honda Cars, Hitech Gears and Sartorius India Group. Case Study presentations Leading firms such as Ashok Leyland, Bajaj Auto, Bosch, Keihinfie, Lucas TVS, Mahindra & Mahindra, Maruti Suzuki,

Tata Motors, TVS Motor and Wabco India presented their case studies on productivity practices, all of which contested for IMTMA – Ace Micromatic Productivity Championship Awards 2015 that gave away cash awards of Rs.10 Lakhs.

Award Winners Towards the close of the event, Wabco India, TVS Motors, Bajaj Auto, Keihinfie, Lucas TVS and SKF India were adjudged the winners of the IMTMAACE Micromatic Productivity Championship 2015 Awards. Further, a VoxPopuli Award was given to TVS Motors. This award was voted by the delegates at the summit as the most popular case study presentation.

National Productivity Summit 2016 The next edition of the National Productivity Summit will be held in November 2016, scheduled in Bangalore, for which entries on the latest productivity practices will be called for and evaluated to compete for the Productivity Championship Awards 2016.

MTW DECEMBER 2015

BUSINESS NEWS

Winkelmann develops vibration dampers for Jaguar Some car components really do keep a low profile. You’d only notice how they function if they weren’t there. Vibration dampers are a good example, reducing unwanted vibrations produced by engines and drivetrains. Winkelmann Automotive in Ahlen in Westphalia, Germany is a development partner and system specialist when it comes to vibrations and how best to dampen them. High-quality vibration dampers are further enhanced by the use of elastomers. In the case of a decoupled pulley which has recently been developed for Jaguar, two elastomer components help boost vibration damping performance. We found out more by talking to Michael Metzinger, from the development department for elastomer technology (materials, processes and tooling) at Winkelmann. High-quality vibration dampers are not just made of steel but also oils, thermosetting plastics and elastomers with enhancing damping qualities. Winkelmann develops each vibration damper specifically for a vehicle’s vibrations. Manufacturing volumes for customer-specific designs range from between 2,000 and 3 million units for construction site, commercial and passenger vehicles.

Torsional vibration dampers with integrated decoupled belt pulleys for Jaguar Winkelmann has developed a vibration damper with two elastomer components for

MTW DECEMBER 2015

Manufacture of “doublewidth” EPDM rings

the drivetrain of Jaguar cars. To be technically precise, this component is a torsional vibration damper with an integrated, decoupled belt pulley. This assembly, comprising 10 metal parts, is supplemented with a pressed EPDM rubber ring and a hybrid, bonded EPDM-Metal part. The assembly weighs a total of 2.99 kg. The elastomer components weigh 180 g. Vibration dampers with rubber-metal composite parts mean less limitations on geometries and are suitable for high-frequency and complex vibration loads which have to be dampened both radially and axially. The EPDM rubber ring completes the whole part and is responsible for further positive

characteristics of the finished component. Torsional vibration dampers with integrated decoupled belt pulleys are highly effective at absorbing vibrations as well as decoupling low frequencies. Such vibration dampers are tested to approx. 10 million load changes, for both axial and radial acoustic frequency absorption and exposed to temperatures as high as 140 °C. Michael Metzinger: “The vibration damper with an integrated, decoupled belt pulley for Jaguar is a very highquality component; in manufacturing terms we are talking here of a medium-volume, premium quality part with a maximum capacity of 660,000 units per annum.“

Horizontal machines from Maplan are deployed for rubber ring manufacture. High-precision EPDM rings are vulcanised to very tight tolerances in a fully automatic process on the horizontal MHF 2600/460 machine using multi-cavity moulds by tooling specialist Peta Formenbau. Very precise wall thicknesses are essential to ensure true running pulleys. These wall thicknesses are automated inline and continuously checked offline by means of reference samples. EPDM material combines an excellent performance bandwidth with reasonable costs. Winkelmann has also focussed on increasing production output. The trick here has been to vulcanise the rings in double width and then radially cut them inline, creating two rings which are then transported to the tempering oven for further treatment. The cutter for this process is from KAMtec. Michael Metzinger: “The automation and double-width rings have proven themselves as an economical and reliable manufacturing solution. This way we could avoid stack mould technology and thus achieve highest quality with low tooling costs.” The horizontal Maplan MHF 2600/460 machines possess full-size heating platens to maintain temperatures of both halves of the mould.

COVER STORY

Mr. Arjun Prakash, Director, Effica Automation Ltd.

Effica unleashes robotic automation in India Coimbatore-based Effica Automation, incorporated in 2005, is today in the focal business of materials handling automation encompassing machine tending, palletizing and conveying, making the most of robots. Under the stewardship of Mr. Arjun Prakash, Director, who is the grandson of late Dr. G.R. Damodaran â&#x20AC;&#x201C; a statesman, educationist, humanitarian and founder of the legendary PSG Tech, Effica is eminently poised to take industrial automation in India to subliminal heights. A mechanical engineer from PSG, Mr. Arjun pursued an internship and intensive training and experience in the field of mechatronics. The education and insights he received in mechanical engineering, electronics, robotics, computers and software applications helped him build a strong foundation for Effica Automation which is today in the forefront of integrating robotic systems to enhance operational efficiency, productivity and profitability in Indian industry which is poised to join the big league using robots for automation and manufacturing excellence. Mr. P.K. Balasubbramaniian converses with Mr. Arjun Prakash to get a clear perspective of Effica Automation and its capabilities, commitments & path-breaking initiatives in the high-tech field of robotics. Excerpts:

MTW DECEMBER 2015

COVER STORY www.mtwmag.com

Efficaâ&#x20AC;&#x2122;s state-of-the-art production facility in Coimbatore Q. Effica is a name to reckon with in automation. What precisely is your niche? We started off in 2005 designing and manufacturing special purpose machines (SPMs) for a plethora of applications. We even developed robotized special plasma cutting systems for marking and precision cutting power transmission poles of 60 ft long. Way back in 2009 we executed a project worth Rs. 2 crores in Houston. This was a complex job involving different disciplines â&#x20AC;&#x201C; mechanical, electrical, electronics, robotics, and industrial PCs. It involved handling, rotating, marking and cutting of poles where cost of error was very high. Over the years, we have changed our focus. Since 2011, to be precise, our focus is on material handling automation using robots which includes machine tending, palletizing and conveying.

Q. What are the automation solutions you offer for the manufacturing sector? We offer robot based component loading and unloading systems. The solutions are available for multiple CNCs, forging presses, sheet metal presses, plastic injection moulding and similar processes. Along with this we offer all the accessories required to complete the

With dedicated robots one can achieve increased machine utilization and enormous savings

solution like conveyors â&#x20AC;&#x201C; roller, belt, and slat, the end effectors for gripping various types of components, the safety systems, infeed and outfeed component stacking magazines. We also offer gantry machine tending to replace articulated machine tending projects for payloads from 2 kg to 100 kg. This is an economical solution, and with this the existing plant layout need not be disturbed. We also do bag conveying & palletizing automation. This is a robot-based high speed palletizing system with a speed of 20 tonnes per hour. For the FMCG segments we offer pick and place solutions for the packing requirements. These are very high speed solutions for light weight products with a special emphasis on hygiene. We have made our systems modular and user-friendly so that in the event of a failure, the end-user can fix it themselves. This way we have removed the fear of breakdown and consequent downtime from the mind of the end-user.

Q. Could you throw some light on your infrastructural facilities? Well, we have a sprawling manufacturing facility housed in a land of 10,000 sq. mtrs. We have an in-house machine shop, assembly shop, design department, quality control section and so on. Our main strength is in our software and

programming capabilities required for our solutions. We have a dedicated trained workforce of 35 people. Marketing has traditionally been done directly. However, we now have channel partners in strategic locations like Coimbatore, Chennai and Bangalore to extend our reach to the customer.

Q. Productivity enhancement is understandable. How do you increase efficiency and flexibility? Robots help enhance flexibility. Special purpose machines need retooling but robots need only reprogramming. The changeover is minimal and not timeconsuming. Practically we observe that our customers have seen an increase in machine utilization by up to 35% while using our solutions. This is because people are prone to fatigue and night shift efficiencies are very low. This is not there when robots are at work. Naturally efficiency levels are high.

Q. Could you elaborate on the cost saving aspects? To begin with there is a form of instant savings from the increased machine utilization. In the case of CNC machines, if we are able to tend to 3 machines and increase their machine utilization by a factor of 35% then it is the equivalent of having the fourth machine which may

MTW DECEMBER 2015

COVER STORY

be priced similar to our robotic solutions. This is even more pronounced in the case of forging presses where the cost of a single press can run up to multiple crores and the savings are massive in terms of capital investments when robotic machine tending is used. Added to this the unavailability of skilled labour and the attrition turnover of trained people is a bugbear. This disrupts production and uptime of machines. When you switchover to robotic automation, the breakeven is achieved in less than 18 months in most cases and in some cases even instantly as mentioned above. The risk factor is less and no recurring costs. All these bring enormous savings to be accrued to the bottomline. Today we see even very small scale machine shops and businesses breaking even with robotic automation. As the prices of robots keep dropping in the future we are only likely to see more and more of this trend.

Q. Who are your major customers and markets? Our customers vary from small machine shops to automotive ancillary manufacturers like Pricol, Amara Raja, Rane, Mothersons, Tubes India (TI) and

With robots attrition turnover of trained people will not be a bugbear

Arkkays. In the engineering sector we have customers like LMW and in the FMCG sector we have customers like ITC. Even large companies like Ford, Nissan and Saint-Gobain have been our customers in the past.

Q. Why do customers come to you again and again? We are highly customer-centric in our operations. Since the time we have increased our focus to materials handling robots, we have been able to standardize a lot of our internal processes and respond to our customer very fast at a much lower cost. This results in much higher customer satisfaction and quicker ROI. This must be the reason why customers come to us again and again. Recently we supplied one robot to Rane EVL. They were so happy with its performance that they immediately ordered more Robotic systems!

Q. What are the challenges ahead for a company like you in todayâ&#x20AC;&#x2122;s context?

A customized robot engaged in machine tending

MTW DECEMBER 2015

The field of Robotics is in a massive growth phase similar to what IT was in the late 90s. When this happens, we have to be ready to scale up our production to ride the growth wave. Side by side, we must educate the customer on the benefits of automation. They must be induced to adapt the manufacturing processes to make room for robots to take charge. We have to remove the fear from the minds of the customer that there wonâ&#x20AC;&#x2122;t be any issues of breakdown and idle

time since they themselves can address the snags if any and keep the machines humming.

Q. Whatâ&#x20AC;&#x2122;s the shape of things to come in factory automation and how do you envisage making a dent in this exciting field? Some 20 years ago a robotic solution cost Rs.30 lacs. Today it is in the vicinity of minimum Rs.15 lacs. The inflation adjusted prices are dropping down massively and will drop down further in the days to come. This will help manufacturers to go in for more and more robotic automation. There has not been any change in technology in Robotics for the past four decades. However, we are seeing significant changes in technology in the last 2-3 years. The next wave of robotic technology like collaborative robots which work side by side with humans and super easy programming and operation methods which are similar to your mobile devices and apps are already rolling out. The worldwide robotic sales for the year 2013 is said to be 179,000. This is nowhere near the potential demand for robots in the world. In the year 2014 China is the largest consumer of robots. Indian SMEs should think progressively and take path-breaking decisions to reap the benefits of productivity and flexibility offered by robots. We in India are on a growth trajectory. And robots will play a pivotal role in enhancing our quality, productivity and operational efficiency in the days to come.

CASE STUDY

Super Mini Mill Based near Udine in the northeast of Italy, Haas customer Modeltek is a successful international motorsport business supplying teams and privateers all over the world. The fact that the cars and parts it produces are one-fifth scale doesn’t make the company’s achievements any less impressive.

ven when his wife is present, Modeltek founder, Mr. Zeno Noacco, happily admits to being “married” to his four Haas CNC machine tools. To her credit, company director Paola doesn’t appear to be the least bit put out, even though Zeno frequently uses words like love and passion to describe his feelings for the machines. “I was at a trade show when I first saw her,” he says, reminiscing not about how he met Mrs. Noacco, but about how he came across the company’s first Haas, a Super Mini Mill. “I immediately liked the simplicity of the machine; the control was very easy to use, and as someone with no experience of CNC machining, I was worried that I might buy a machine and then not know how to use it.” Turns out, he worried unnecessarily. “I told myself I’d give it a go, and if I’d made a mistake, I’d sell the machine and go back to using subcontractors to make our parts. I’m glad I kept it. I think it’s a great product. After a few weeks, I was completely confident, and I knew all the machine’s functions and capabilities.” Modeltek’s 1:5 scale model “‘professional” racing cars, sold under the name Genius RC, cost around €2000. Each is a painstaking replica of a full-scale counterpart, with custom designed and

MTW DECEMBER 2015

made differentials, gearboxes, hydraulic disc-brake systems, drive shafts, and suspension. All of the parts are created to tight and specific criteria – size, weight, materials, etc. – laid down by the sport’s governing body, the European Federation of Radio Operated Automobiles (EFRA). In the years before he started his company, Zeno was a hobbyist who lived for the weekends, when he and his friends would race the scale models they made at home in their spare time. Of course, as history now shows, the models

Zeno made were exceptional. So much so that his fellow racers – his competitors – would often ask him to make parts for their cars. “Little by little, I began modifying and making a few of the more simple parts on my cars. Eventually, I made almost all parts, not only for my cars, but also for anyone else who wanted them.” Thanks to the Internet, and the closeknit community of fellow scale-racers, Zeno’s customers were able to easily track him down. The orders began to

CASE STUDY www.mtwmag.com

roll in. “It’s a niche market,” he says, “so production volumes are not huge, even though we sell worldwide. However, we now make around four hundred full cars a year: the ‘Touring’ model – designed to resemble a BMW, Mercedes, or Alfa Romeo – as well as the ‘F1’ model.” Given such a positive early experience with the Haas Super Mini Mill, Zeno didn’t need to look far for his next CNC machines. “We bought a Haas VF-2SS, a

VF-3SS, and a standard VF-2,” he says. “So, now we have four Haas machines, a dedicated, fully trained operator, Mr. Clemente Pocovaz, and no need to use subcontractors or buy-in parts except for the motor – from Japan – and the fiberglass body shell.” On a bench in an assembly area adjacent to the machine shop, there are several chassis in various states of build, at different stages on the production line. The parts – even a beautifully miniaturized centrifugal clutch – look just like those used on full-sized race cars, and they behave very similarly. “Like when engineers are designing a full-scale vehicle, we begin a project by doing the maths,” says Zeno. “For example, with a new, self-locking differential, we work out the forces generated by the motor, and the desired power and torque output of the car, and we use these figures to create parts with the correct weight, dimensions, etc.” The final prototype parts are designed on a CAD system, then cut on the Haas machines. It’s a thorough process, and the end results, if the numbers are good, are steel, titanium, and aluminium creations, many of which look like jewelry and are as precise as wristwatch components. “We have lots of small parts, which we usually machine on the Super Mini Mill,” says Zeno. “But, we also have parts such as the chassis floor, the plate on which everything else is mounted. It’s almost 700 mm long, which is why we need the VF-3. In fact, the best size Haas machines

for us now are the VF-2SS and the VF-3SS, as they give us plenty of table space, and the flexibility to make large or small parts. Production batches are typically around two hundred off, which we can machine in less than eight hours.” Once all the prototype parts are assembled into a complete vehicle, the testing phase begins. “We build five working models for the race team,” says Zeno. “Over the course of a year, we will refine the new car and fine tune it until we have something we’re happy with, and that is as close as possible to the minimum weight of ten kilos.” In many ways, the world of large-scale model racing is very similar to the real racing world. “As well as providing cars and parts for customers, we have a race team,” says Zeno: “Genius Racing! We’ve also built next door a two million Euro racetrack equipped with telemetry. We travel all over Europe and the rest of the world; there’s a large following amongst the automotive companies. I have many friends at Ferrari, for example, and everyone takes it very seriously. Although, we have a lot of fun, too.” After all, for most people, it is a pastime. Except, that is, for Modeltek and its four employees. “We may be a small company, but we see some great opportunities, now that we’ve developed some good design and machining skills, including work with the Italian Air Force. That would be exciting, but at the moment, we have little time for anything except the model cars. It sometimes feels like we work twenty four hours a day!” If you spend most of your waking hours in a business running CNC machine tools, life is sweeter if the machines are easy to use and you like them – a lot. “I’m a little in love with the Haas brand and the Haas machines,” confides Zeno Noacco. “They’re affordable, easy to use, and reliable. In fact, I don’t think we’d be running this business now if we hadn’t discovered Haas.” For more information, Website: www.HaasCNC.com

MTW DECEMBER 2015

CASE STUDY

Renishaw brings 3D printing expertise to Land Rover BAR Technical Innovation Group

enishaw is proud to announce that the company has joined Land Rover BAR’s Technical Innovation Group (TIG) as an official supplier – joining the quest to bring the America’s Cup home to Britain. The company will contribute its expertise in metal 3D printing and position feedback encoding. The America’s Cup is the oldest international trophy in world sport, pre-dating the modern Olympics, the Ryder Cup and the World Cup – and Britain has never won it. It’s the world’s

MTW DECEMBER 2015

premier sailboat racing contest, and the 35th edition will be held in Bermuda in 2017, in foiling multi-hulls. Land Rover BAR is the British challenger, and Ben Ainslie, winner of four Olympic gold sailing medals, is the Team Principal and skipper. The Land Rover BAR Technical Innovation Group was formed to bring together the best of British talent and industry. The goal is to find advanced technologies and develop them to give the team a competitive edge. The TIG

CASE STUDY www.mtwmag.com

complements the existing Land Rover BAR design team and allows it to rapidly develop, test and prove these technologies. The TIG has already engaged a number of key partners and suppliers from British industry, including Land Rover, BT and BAE Systems. The TIG is governed by a steering group, chaired by PA Consulting’s Dr. Phil White with the BAR team represented by Andy Claughton, Land Rover BAR’s Chief Technology

Officer. Renishaw is one of the world’s leading engineering and scientific technology companies, with expertise in precision measurement and healthcare. The company supplies products and services used in applications as diverse as jet engine and wind turbine manufacture, through to metal 3D printing, dentistry and brain surgery. The Renishaw Group currently has over 4,000 employees, of which 2,700 people are employed within the UK. “As a British engineering company with core skills in precision and performance, combined with expertise in position encoding and metal 3D printing, we are delighted to have the opportunity to make a valuable contribution to the TIG and help Land Rover BAR bring the America’s Cup back to Britain”, explained Robin Weston, Marketing Manager of Renishaw. Renishaw’s contribution will be through its expert metal additive manufacturing knowledge, helping to optimize the design and construction of critical, 3D printed metal parts of the team’s race boat. It is also contributing by providing ongoing expert advice on position encoder technology. Ben Ainslie commented, “We don’t underestimate the challenge ahead of us. We are a first time challenger for the America’s Cup, and only one challenger has ever won it at the first attempt. We want to leave no stone unturned in our search for new technologies that will help us to bring the Cup home. That’s why we have developed the Technical Innovation Group and are pleased to have the support of Renishaw with its heritage of over 40 years of breakthrough innovation.” For more information, Website: www.renishaw.com

MTW DECEMBER 2015

CASE STUDY

Axle supplier approaching zero scrap In-process probing reduces downtime and sees scrap rates approach zero at Albion Automotive

lbion Automotive’s axle design and manufacturing comes from an established track record of reliability and engineering quality. Albion products have been specified by truck users for most of this century, and the Glasgow plant now embraces a just-in-time philosophy to develop a product range that will carry its customers into the next century. A programme exists at Albion Automotive that sees the company continually upgrading its production capabilities with the latest CNC machine tool technology, part of a process of continual improvement. The company took delivery earlier this year of a turnkey Univer 6 flexible machining centre fitted with Renishaw probing. Manufacturing Engineer, Robert Kirkwood explained, “The Univer 6 is a customised vertical machining system, the first of its kind, with a fixed 6-metre bed, fitted with two Sempuco rotary tables, giving us a fourth axis and allowing pendulum machining. The machine is fitted with a 52-tool magazine that allows us to machine ten different axle components”. Whilst he spoke, the machine was producing a front axle beam for a 7.5 tonne truck. Held in a ‘yoke fixture’ on the left-hand side of the 6-metre table, the beam would be delivered as a fully machined component, whilst on the right-hand side a 100cwt component for an 18-tonne truck was being loaded by hoist into its fixture. The cell operates in three shifts in a 24-hour day, the pendulum machining

MTW DECEMBER 2015

having eliminated downtime. However, a key component enabling continual machining is a Renishaw MP3 probe with radio transmission, integrated into the machining centre for measuring of the exact position of the forged front axle within the fixture. Mr Kirkwood explained, “We load the machining programmes into the Univer 6 manually or from a laptop computer. The probe enables the length of each axle beam to be measured, setting the offsets. We also have limits set into the control whereby if the part is too long it will rejected. This has allowed us to machine 100% accurately forged components and gain an unexpected

area of cost control as each rejected part is now returned to the supplier. The Renishaw probing system is detecting inferior supplied forged components, something that was not possible before.” The Univer 6 machines the complete axle to a tolerance of 3 microns, drilling and reaming the mounting holes for the chassis and the bore hole for the king pin, together with a host of other operations. Mr Kirkwood continued, “Using Renishaw’s probe tells us where to machine the king pin hole and boss, which is critical, especially when we put a cross hole through the king pin bore, because each of those holes have to be in relation to one another”. The Renishaw MP3 radio transmission system, stipulated by Albion, does not require line of sight between the probe signal transmitter and the receiver, which can be mounted anywhere within 10 metres of the probe. So far, the results of Albion’s continual improvement policy look good machining of axles on the Univer 6 with Renishaw in-cycle probing has seen scrap rates approach zero, with greatly improved throughput times.

For more information, Website: www.renishaw.com

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COMPANY PROFILE

HEIDENHAIN stays closer to the customer With fascinating product lines and efficient technical support

TEAM HEIDENHAIN INDIA

r. JOHANNES HEIDENHAIN GmbH, with a history starting from 1889, has its presence in India for several decades, though indirectly. With a wide range of products comprising Linear Encoders (Exposed and Sealed), Length Measuring Gauges, Angle and Rotary Encoders, Touch Probes, Digital Displays and Computer Numerical Controls, HEIDENHAIN has always been a preferred quality supplier to the Indian Engineering Industry. The customer segments in India are spread across a variety of areas like Machine Tool Building, Automation, Steel, Automotive, Packaging, Elevators, Solar Energy, etc. to name just a few. A fully owned Subsidiary in the name of HEIDENHAIN OPTICS & ELECTRONICS INDIA PVT. LTD. has been functioning successfully since 2008

MTW DECEMBER 2015

at Chennai. “We have a 17-member core team, six of whom are Service Engineers. We have presence in Pune as well and so we are closer to our customer base. We have created a support hub for techno-commercial back-up manned by highly experienced Managers and Engineers with several years of exposure to Precision Metrology and Control Electronics,” explains A.P. Jayanthram, Managing Director. The company has installed state-ofthe-art programming systems, testing and diagnostic equipment of the highest class to undertaking training, trouble shooting and repair of HEIDENHAIN PRODUCTS. It has also created a high level IT infrastructure which will ultimately mean faster communication, resulting in more efficient order executions and problem solving for its clients who look like a Who’s Who of

India’s machine tool fraternity. “Our customers now have many more reasons to opt for HEIDENHAIN products known for unequalled precision, reliability and longevity,” pinpoints Jayanthram. Whether it is for getting trained on the efficient application of HEIDENHAIN control features, servicing of scales / scanners / encoders / CNC controls / inverters, or for ideas on proper mounting and maintenance of its products, application or sales support, HEIDENHAIN INDIA could help them out. They can talk to the SERVICE HOTLINE +91 44 30234030 for discussing / registering their service needs. Or send a mail to service@ heidenhain.in For feedback on response to enquiries, status of order execution, one can call Sales Support Desk at +91 44 30234000 or mail to: sales@heidenhain.in “In HEIDENHAIN’S quest to provide customers worldwide with improved solutions, we stay closer to them with fascinating product lines and efficient and sincere technical support,” adds Abhilash Tripathi, General Manager (Sales & Service).

For more details contact: Heidenhain Optics & Electronics India Pvt. Ltd Citilights Corporate Centre No.1, Vivekananda Street Off Spur Tank Road, Chetput Chennai 600 031 Phone: +91-44-3023 4000 Fax: +91-44-3023 4001

COMPANY PROFILE www.mtwmag.com

Gurutzpe CNC Lathe Machine : Excellence with technology innovation

/s. Tornos Gurutzpe, S.A. Spain one of the leading Manufacturers of CNC Lathe Machines in the world. They have started their production activities way back in 1957 with conventional Lathes and with their dedication and hard work step-by-step they have increased their production range to latest generation and state-of-art CNC Lathe Machines by incorporating latest Technologies and Innovations available in the market from

time to time to comply with competitive quality and tailor made solutions required by its clients and they a ISO 9001 / 14001 certified company. Their range of productions includes 2 Guide-Ways and 4 Guide-WaysLathes, which include the most up-dated technological advances to satisfy the most demanding Machining request of their customers. Gurutzpe complements this broad range of products with teaching services, machine commissioning and

preventive maintenance capable of answering special requests of their customers. ORIENTAL MACHINE TOOLS CO., (Prop. Suraj Tools & Equipments Pvt. Ltd) Office No. 517, 5th Floor, Bharat Industrial Estate, T.J. Marg, Sewree (West) Mumbai-400015 (India) Phone No. 91 - 22 - 2416 1991/92 E-mail: omtc@omtc-online.com / omtc@vsnl.com

MTW DECEMBER 2015

TECH UPDATE

The specialist for tube machining

uitable for many different applications and offering outstanding value for money, KASTOwin has already successfully established itself with many customers from a wide range of industries. Now, however, its developer has extended the range to cater for a very specific application: The KASTOwin tube A 5.0 is a fully automatic band sawing machine which has been specifically optimised for machining tubes. The most important innovation: Compared to the other KASTOwin models, the direction of movement of the saw feed is rotated through 180 degrees and sawing is performed upwards from the support surface. This ensures efficient, precise sawing that reduces wear on the cutting tools. The cutting range of KASTOwin tube A 5.0 for round materials is 500 millimetres and the shortest possible cutting length is ten millimetres. Using the frequencycontrolled drive, it is possible to adjust

MTW DECEMBER 2015

KASTO Maschinenbau GmbH & Co. KG is extending its product portfolio: The sawing technology specialist is extending the KASTOwin band saw range that it first introduced in 2014 &, with the KASTOwin tube A 5.0, is introducing a model that has been specially designed for machining tubular material. With a saw feed rotated through 180 degrees, this fully automatic machine works in a particularly efficient way to reduce wear on the cutting tools. the cutting speed continuously between twelve and 150 metres per minute. Carbide saw bands, of the type required for various tubular materials, can be used with the KASTOwin tube A 5.0 without the need for any further accessories. The saw band is clamped in position hydraulically and is cleaned using a replaceable, electrically driven chip removal brush. The vice and saw feed are equipped with zero-play linear guides, and ball screw spindle drives ensure controlled cutting and material feed movements. The saw also boasts all the benefits that characterise the other units in the KASTOwin series. For example, they all offer outstanding value for money: Since all the models are built in accordance with the same design principle and the employed components are mostly identical, KASTO is able to offer its saws at considerably more attractive prices than comparable products marketed by other manufactur-

ers. And this leads to no loss of quality. On the contrary: All the elements that make up the KASTOwin series are top-quality products manufactured and assembled in Germany. The intelligent SmartControl sawing machine controller ensures easy operation. It contains all the material data, and automatically sets all the necessary parameters. What is more, the KASTOrespond system, which was developed specially for this system, continuously records the forces at the tool and uses an intelligent algorithm to convert these into feed movements. And when special requirements have to be met, KASTO can offer a wide range of accessories for the KASTOwin tube A 5.0: for example, a heating and cooling device for operation at temperatures over 40 or below zero degrees Celsius. For more information, Website: www.kasto.com

MACHINE TOOLS WORLD |

41 | December 2015

TECH UPDATE

Top cut 4 indexable holemaking platform from WIDIA: One high-performance tool series for many applications

he new Top Cut 4 indexable drilling platform from WIDIA is targeted to end users that machine a broad assortment of products and need one drill for a variety of drilling applications and workpiece materials. Expanded capabilities and improved performance combine for outstanding results in the new Top Cut 4™ indexable holemaking platform from WIDIA™. A true multi-problem-solver in one platform, Top Cut 4 is targeted to end users that need one drill that can be applied in a variety of drilling applications and different workpiece materials. Top Cut 4’s breadth of application capabilities include throughand cross-holes, inclined entry and exit opportunity, 45º corner, half-cylindrical, concave, and chain drilling. And four true cutting edges combined with WIDIAgrade technology results in notably higher speeds and feeds, higher metal-removal rates, and extended tool life, all of which means lower cost per edge.

MTW DECEMBER 2015

“Process stability is a significant challenge and the driver behind Top Cut 4 and its development,” says WIDIA Product Manager Vivian Pavlov. “What process stability simply means is the ability to quickly select and successfully apply a tool even in an unfamiliar or unstable condition. Users need one drill that can be applied in a variety of drilling operations and workpiece materials. Top Cut 4 addresses this challenge with cutting performance at higher speeds, which makes it the proven choice in lowest cost per edge.” Top Cut 4 periphery and center inserts each feature proprietary cutting profiles

for excellent centering capability and workpiece penetration. The inner and outer (center and periphery) inserts are clearly differentiated for no mixups, and are available in grades for high-speed applications, high toughness demands, and high metal-removal rates in general. Specific geometries are available with such features as reinforced cutting edges and a steep chipbreaker for steel, cast iron, and short-chipping materials, or an optimized chip groove for stainless steel, longchipping steels, and where low power consumption is required. In addition, Top Cut 4 is featuring highstability shanks in lengths of 2XD, 3XD, 4XD, and 5XD, in both metric and inch configurations. Diameter ranges from 12 to 68 mm (0.473 to 2.5 inches). Eight insert sizes cover the complete diameter range. The cutting edge profile of the central and periphery inserts works together, leading to high stabilization of the drill, preventing tool drifting even on irregular surfaces. Robust cutter bodies are marked by deep helix angled flutes for efficient chip evacuation even at 5XD length. Large coolant holes mean efficient coolant delivery and extended insert life. Moreover, Top Cut 4 is available through NOVO™, WIDIA’s digital process knowledge application. With powerful process knowledge available on iPad™ & other digital devices, NOVO provides far more useful process knowledge than any online catalog alone, all obtained in a fraction of the time. Website www.widia.com

TECH UPDATE

Ceramic Coatings in Machine Tool Industry By P T Bindagi, Technical Director, Spraymet Surface Technologies Pvt. Ltd. , Bangalore

achine Tool Industry has undergone major developments in providing longer lasting life to spindles , arbors and bearings. Ceramic coatings by Plasma spray process have been in use since 1960 in many industries. Since last decade this process and ceramic coatings are used to provide hard surfaces to seal areas of spindles, contact faces of arbors and electrical and heat insulation to bearings. Apart from OEM level coatings, many user industries are using ceramic coating for refurbishing of spindles and other machine tool parts.

WHAT IS PLASMA SPRAY?

The plasma spray gun comprises a copper

anode and tungsten cathode, both of which are water cooled. Pressurised plasma gas (argonor nitrogen with hydrogen 15% as secondary gas) flows through the anode and passes the anode. The plasma arc is initiated by a high voltage discharge between anode and cathode which causes localized ionisation. The resultant heating from the arc causes the gas to reach extreme temperatures, dissociate and ionise to form a PLASMA. Plasma arc ( flame) extends down the nozzlewith temp upto 15000 deg C and velocity upto 600 mts/sec. Fine Powder is fed into the plasma flame through an external powder port mounted near the anode nozzle exit. The powder softens and hits the target( grit blasted job) in semi molten state with high velocities creating well bonded and dense coating. Typical spray materials used with Plasma Spray

Metals and its alloys : Steels, Ni alloys, Co Coating selection

Plasma sprayed Ceramic-coating on spindles and other machine tool parts (best-suitable for parts and areas that require wear and corrosion resistance) Tipycal Base material of spindles/Arbor high carbon chromium bearing steel (SUJ2) chrome molybdenum steel (SCM415, 435) carbon steel for machinery (S45C) martensite stainless steel (equivalent to SUS440C )austenite stainless steel (SUS303, 304)steel alloy for tools (SKS3, SK4) aluminum chrome molybdenum steel (SACM645)

Choice of ceramic Coatings Chromium Oxide( Black) : 72 Rc Very hard and low on impact Alluminum Oxide( white) : 62 Rc Good wear and thermal and electrical insulation Al oxide + TiO2 ( Grey/Black) 58Rc Widely used as it is easy to grind and less brittle and takes high finish ( 0.2 Ra)

Ceramic coating on New spindle or refurbish + coating procedure :

Under cut the diameter to be coated

Normally 0.4 mm on dia

Grit blast the surface

Get Clean rough texture

Plasma spray ceramic coating

To required thickness + Grinding stock

Finish by diamond grinding and super finishing

To required size and finish Upto 0. 1Ra finish can be achieved

MTW DECEMBER 2015

Spindle bearing/seal area/parts coated with ceramics - Picture courtesy: Unionchemnitz

Arbor & sleeve ceramic coated â&#x20AC;&#x201C; Al Oxide = Tio2

Split Babbitt or bronze bearing Thermal sprayed/ machined

alloys, Moly, bronze, copper, Babbitt, etc. Ceramics: Chromium Oxide, Aluminum Oxide, Al Oxide + TiO2 , ZrO2 , etc. Carbides: Tungsten carbide, Chromium carbide, TiC Hardness range of coatings: From SOFT 60 Rb( Bronze) to HARD 70 Rc ( tungsten carbide.) BENEFITS OF PLASMA SPRAYED CERAMIC OVER HARD CHROME

Environmental: Less hazardous as there is no Hexavalent chrome involved Dust disposal easier than bath liquid. Performance: 3-4 times wear resistance than Hardchrome Micro porosity holds lubricationSelective area coating is possible Higher thickness upto 300 microns per side is possible Limitations : Ceramics are brittle & to be handled carefully Process not as widely available as hardchrome

TECH UPDATE

Automation in sheet metal cutting and welding The paper examines welding and cutting process trends in the sheet metal and plates used in various industries like automobiles, infrastructure, ship building, aerospace industries, wind tower manufacturing etc. Productivity gains in arc welding are reviewed, and the increasing use of laser cutting and welding, as well as laser-arc hybrid welding, particularly in Europe, is discussed and explained. Some friction technologies are already widely adopted, but they could make more impact with further development. Electron beam welding could also be used with economic benefit in some situations, but as with all non-arc processes, it will only be adopted if significant gains in productivity and cost reduction can be created to justify the more specialist welding equipment required. Many productivity improvements can come from non-welding activities in the fabrication process. 1. INTRODUCTION

Leadership in manufacturing (welding and Cutting) can come from addressing the factors of QUALITY, COST, PRODUCTIVITY, SAFETY and CONTINUAL UPGRADATION OF TECHNOLOGY. Inflection in Metal Fabrication Technology has taken place in the Manual / Semi-Automatic Welding Power Sources - (Digital control inverters), Welding Automation - (Developments in HNG SAW, HNG MIG, Tandem MIG / SAW, Friction Stir, Electron Beam, Saddle Welding Automation, Robotics, Laser spot welding, Hot wire TIG, Orbital systems, automation with hybrid welding systems like Plasma â&#x20AC;&#x201C; MIG, Laser - MIG) and major advances in the cutting processes (Precision Plasma, Laser Cutting, Waterjet cutting etc.). This paper reviews current trends in arc welding and cutting processes used for Sheet metal processing and will discuss some of the newer processes which are beginning to replace arc welding for such steels, or have potential to do so in the next 10 years. 2. ADVANTAGES OF AUTOMATION

a. Consistency in weld result - Error Proofing: A welding supervisor

MTW DECEMBER 2015

can limit the amount of changes an operator can make during a program, preventing him from accessing the override screen through the use of a key switch or password. b. Multiple parameters for multiple weld-run: In addition to the ability to adjust parameters between weld passes, operators of microprocessorbased welding machines can also program changes to weld parameters during each pass, which offers distinct advantages for certain applications. c. Store parameter for sharing on other machines with same applications: A microprocessor-based power source can store programmed welding procedures on data cards. This allows the operator to easily transfer programs developed on one machine to other machines being used either in the same facility doing the same type of work. d. Quality control: Microprocessorbased machines can immediately alert the operator if weld parameters fall outside pre-selected limits. Parameters can be directly to a quality-control computer program for storage or statistical analysis. This eliminates time-consuming radiography in many

applications. e. Date storage and records: It is now very easy to display a set of welding parameters and operator or supervisor can observe the welding procedure. Moreover, the data can be printed in the form of reports, which can be presented to the customer as quality assurance procedure. f. Quicker Weld-Fault diagnostics lower repair time: The system can be stopped if the measured values cross a certain preset variation limit. It is possible to stop the machine in out-oftolerance conditions. This enables the operator to perform timely functions and take necessary steps to prevent the deposit of faulty welds. 3. TANDEM MIG AND ROBOTIC WELDING

Significant improvements in productivity are nowadays hard to gain in this mature process. In gas-shielded MIG/MAG processes, the growth of tubular wire over solid wire is still slow despite the deposition and bead shape benefits of the former although tubular wire usage is higher in the USA and Japan compared to other parts of the world. The lower price of solid filler wire, particularly in Europe, is still a dominant factor that continues

TECH UPDATE www.mtwmag.com

to favour their use. Self-shielded cored wires are still widely used in the USA but less so in Europe because of the fall-off in fabrication of large offshore installations. Care is always needed in selecting selfshielded wires if weld metal toughness is a critical design factor. Schematic of Equipment for TANDEM MIG

Japan still leads the work in new robot installations per annum, but generally robot take-up for welding is still majorly for the automobile sectors. Robots are being employed in situations where product repetition and/or tonnage throughput are high, combined with relatively standardised designs. Robot profile cutting is increasing in usage and in Japan, some building frames are now being welded on robot lines and agile robots are also used for site welding building column joints at height. The applications most suited to robot use involve butt and fillet welds in the fabrication of beams, welding of stiffeners to beams, welding of end plates and the assembly of panels or decking. A likely trend is to ‘take robots to the work’ and use them for large part and sub-assembly manufacture in cells which house autonomous vehicular robots. These robots, mounted on moving platforms are manoeuvred around the parts to be welded and are capable of all-positional welding using the MAG process with tubular wires, (Fig.2).

Fig. 1: TANDEM MIG

Advantages of TANDEM MIG: • Exceptional welding speeds • High weld metal deposition rate • Superior weld quality: » Reduced heat input » Resists burn-through on thin materials » Maintains low spatter levels » Produces good penetration on thick materials » Improves bead wetting at weld toes » Resists undercut • Bead profile control • Lowers production costs • Increases productivity The greatest potential for productivity improvements comes from using robots.

Fig.2. Schematic diagram showing autonomous robot vehicle navigated by vision system, being used for all positional MIG / MAG welding

costs and distortion significantly. 5 . LASER – IN CUTTING AND WELDING

Low power CO 2 lasers were originally developed in the late 60s for cutting and welding operations, while Nd: YAG lasers entered the market only in the early 1980s. In the shipbuilding and off-road vehicle sectors, higher power lasers (3-10kW CO 2 and 2-4kW Nd:YAG) have become popular in the last decade because their use brings more precision in dimensional control, and greater accuracy in assembly, as well as the additional advantages of high cutting and welding speeds, and cleaner working. Laser cutting is now an essential route to accurate assembly in steel fabrication. Parts can be cut to a precision of ±0.3mm in 10 metres compared to ±1-2mm for conventional plasma cutting. Sub assemblies can then be arc welded to tolerances of a few millimetres in 15 metres, with the same lasers being used for marking and hole drilling on the cutting table. Even though arc welding is still regularly used for assembly of laser cut parts, cost reductions can be dramatic because of the improved accuracy of assembly and the potential for eliminating distortion correction and other processing operations downstream from welding. Direct costs have been cut by up to 50% using lasers for cutting in many shipyards, and this shows the extent of benefit which could follow from more widespread use of laser cutting in building, bridge and public infrastructure construction.

4.NARROW GAP SAW

In submerged arc welding, multi-wire, iron powder additions and narrow gaps are common ways to increase productivity. However, the use of tubular wires is increasing in popularity and can offer better weld quality compared to solid wires in some situations, e.g. when submerged arc welding of primed plate. In building and bridge construction MIG/MAG welding is more suited to automation and is now beginning to replace submerged arc welding, reducing

Fig.3. A typical laser welded sandwich panel and advantages over conventionally stiffened panels 6. LASER-ARC HYBRID WELDING

There is tremendous interest in the use of CO 2 laser-arc or Nd: YAG laser-arc for steel construction at the present time.

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TECH UPDATE

Fig. 5.Schematic diagram of the FSW process: (A) Two discrete metal work-pieces butted together, along with the tool (with a probe). (B) The progress of the tool through the joint, also showing the weld zone and the region affected by the tool shoulder. 7. FRICTION TECHNOLOGIES

Fig.4a. Nd:YAG laser - MAG hybrid process being developed for land pipeline girth welding. Picture of the welding head

Fig.4b. macro section showing MAG root and cap beads & central hybrid weld bead

The concept has been around since 1978 and was actively developed in Aachen in the late 90s using high power CO 2 lasers in combination with one or two MAG torches directed into the same weld pool in series with the laser. Already one shipyard in Germany has such a system in production on a panel line, the process replacing submerged arc welding. The advantages of moving from simple arc processes to a hybrid laser-arc system include higher joint completion rates and associated control of distortion. As noted above, laser systems alone are usually not sufficient to cope with variations in joint gap in large structures. However, where plates are thin, it is possible to produce stiffened panels successfully by laser welding.

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There have been many exciting developments in friction welding and probably more process innovation in the last decade than in the previous 40 years when friction welding first came on the scene. In the context of metal joining and construction, friction stud, radial friction and friction stir welding are good examples of more recent approaches, with friction stud already being used in the production of sandwich structures comprising steel skins and a concrete core and for welding attachments in high volume such as shear connectors and reinforcing bars to end plates. Attachment of anodes under water to offshore installations using steel studs and electrical connections to railway lines are other applications of friction stud welding. APPLICATIONS Shipbuilding and Offshore, Aerospace, Automotive, Railway Rolling Stock, Fabrication

8. ELECTRON BEAM TECHNOLOGY

There have been several key improvements in this process in the last decade

which have made EB welding increasingly attractive for large-scale fabrication of steel structures such as buildings and bridges. The two main areas of improvement are in gun development and reduced pressure technology. Reduced pressure electron beam welding system

Reduced pressure EB welding using chamber pressures of around 1mbar has been another major step forward

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TECH UPDATE

in simplifying EB welding operations. The beam shape and beam penetration at, say 5mbar, is identical to that at the more conventional pressure for EB welding of 5 x 10 -3 mbar. This reduced pressure option does away with the need for large vacuum chambers and worries about leaks and seals. Simple mechanical pumps and local seals are sufficient to achieve ~1 mbar. These systems are also more tolerant to fluctuations in working vacuum pressure, gun to work distance and work-piece cleanliness. 9. WIND TOWER MANUFACTURING – SPECIALIZED CUTTING AND WELDING PROCESS APPLICATIONS

Wind Tower fabrication employs extremely precision applications of metal cutting and welding processes like gas cutting triple torch, with Single pass three torch cutting Automatic setup which provides High accuracy, Capacitive height adjustment, Infinite rotation of cutting head, Automatic angle adjustment 20 - 50° (Option for 30 - 60°). In addition, plasma cutting system is used with Automatic Setup, Highest Accuracy, and Bevel angle adjustment: +/- 52°, Initial height setting with tactile sensor, Cutting height adjustment via automatic arc voltage sensing process. Precision High end CNC Plasma cutting process is utilized with high degree of automation needed to guarantee consistent quality. Programming software, Numerical control and Automatic rotat-

MTW DECEMBER 2015

ing bevel tools are used to dispense with manual tasks. Automated SAW systems with Twin Wire, Tandem, Tandem – Twin and Multi – wire systems are used along with customized welding heads, wire feed systems, joint tracking systems, Column and Booms, TELBO systems, Rotators and Positioners. In addition, Tractors and Fit – up units are all used for this application and also for many other welding applications.

improvements can come from many different areas in the total fabrication process, e.g. general design, detailed design, contract drawings, CNC instructions, cutting and profiling, welding, inspection, finishing etc. It needs to be realised that optimising the welding process and procedure in isolation may have only a small effect on overall productivity. As an example, fabricators in the bridge and building sector continue to make big improvements in reducing the cost per tonne of steel fabricated by focussing on efficiency improvements in non-welding operations. These non-welding areas will continue to receive much attention in the next few years. For example, 3D solid modelling is expected to be at the heart of the improvement process enabling virtual assembly, direct instruction of cutting and welding machines, computer modelling of metal processing and welding operations and optimising of welding sequences. In addition automated inspection and data gathering will increase in usage to give more comprehensive Quality Assurance. Productivity improvements could also come from greater standardisation in steel specifications and in joint details and from modularisation of large structures to reduce the time spent on site fabrication and erection. Use of new welding processes and an increased use of automation and robots will take place slowly and gradually, only being justified where the introduction creates significant gains in productivity or cost reduction. As such, these changes can be expected particularly in situations where skilled labour is short, where welding cells can be kept fully occupied or where customised, made to order components are needed. (Contributed by Ador Welding Ltd.)

10. CONCLUDING REMARKS

Where will engineering construction be in five years time? Productivity

For more information Web: www.adorwelding.com

TECH UPDATE

MAX-PAC Advanced CAM Software for Manufacturing Turbo-machinery Components

or over 50 years, Concepts NREC has been partnering with the world’s leading OEMs to improve the performance and manufacturability of their turbomachines. We are the only company in the world whose in-house capabilities span the entire process - from conceptual design through manufacturing, testing, and installation. This unique perspective creates powerful synergies that drive innovation across

www.mtwmag.com

Concepts NREC is also the leader of the global Advanced Centrifugal Pump and Compressor Consortium for Diffuser and Volute Design, an internationally sponsored research venture dedicated to advancing diffuser and volute design. The company pushes past what has been done to explore what can be done. Concepts NREC has the vision to create great designs and a hard-earned reputation for delivering them. Industry-Leading Software

Concepts NREC’s Agile Engineering Design System® is a complementary suite of programs for Computer-Aided Engineering (CAE) and Computer-Aided

our entire offering. Our clients benefit from having a trusted partner who can see the big picture and provide valuable insights that save them time and money. Advancing the State-of-the-Art in Turbomachinery

Concepts NREC maintains a robust in-house research and development program. We hold over 70 patents worldwide, with numerous patents pending.

Manufacturing (CAM). The seamlessly integrated CAE modules cover the entire design process - from preliminary sizing through fluid dynamics and mechanical stress and vibration analysis. Final designs can be easily imported into our industry-leading CAM software, MAXPAC to create efficient 5-axis machining strategies. MAX-PAC — Specialized for Turbomachinery

Based on decades of experience and incorporating several patented methodologies, MAX-PAC has long been recognized as the best software for 5-axis milling of turbomachinery impellers, blisks, and rotors. MAX-PAC is used worldwide by turbomachinery manufacturers, job shops, and 5-axis machine-tool manufacturers who are passionate about producing the highest-quality parts.

MTW DECEMBER 2015

TECH UPDATE Better, Faster, Cheaper

MAX-PAC Add-On Modules

The manufacture of turbomachinery components is often a challenge due to hard materials, thin blades, tight tolerances, smooth surface-finish requirements, or difficult tool access. Concepts NREC’s MAX-PAC CAM software was built from the ground up to address these challenges. MAXPAC enables users to produce highquality components in less time and at lower cost. Compared to other general CAM tools, MAX-PAC is faster to learn, easier to use, and requires less programming and machining time. It’s choice of cutting strategies ensure that each client has a solution tailored to their specific milling requirements. The most important attribute of MAX-PAC is its ability to produce higher-quality turbomachinery components.

MAX-PAC offers several different addon modules that are focused on specific milling needs. Clients can purchase any combination of modules to meet their specific machining requirements.

surfaces with optional nonruled edge constructions. MAX-5 includes options for roughing, plunge milling, hub finish, flank-milled blade finish, leading edge, fillet finish, and tip milling. MAX-AB for Point Milling

MAX-5 for Flank Milling

MAX-5 creates 5-axis CNC machining instructions for flank milling of ruledsurface turbomachinery components. Typical applications include centrifugal compressors, pumps, inducers, turbochargers, stators, fans, radial-inflow turbines, expanders, and torque converters. With MAX-5’s patented algorithm, dramatic cost savings can be realized using ruled-surface designs and

MAX-AB creates 5-axis CNC machining instructions for point milling of turbomachinery components with arbitrary (free-form) blade surfaces. Typical applications include axial compressors and turbines, pumps, compressors, turbochargers, radialinflow turbines, and inducers. MAX-AB emphasizes smooth machining instructions that are compatible with high-speed milling applications.

MAX-PAC Advantages

• Specialized for turbomachinery production • Easy and fast to learn • Supports a broad selection of tool geometries • Faster machining times with optimized cutting strategies • Smooth 5-axis toolpaths for high-speed milling • Collision-free toolpaths for difficult geometries • Superior surface finish and tight tolerances using a patented flank- or point-milling approach • Produces high-quality parts that don’t require hand finishing or other reworking

MTW DECEMBER 2015

production with a flank-milling process. Flank milling efficiently finishes the entire blade surface with one pass using the side of the cutter. Compared to other CAM systems, MAX-5 is often capable of generating flank milling toolpaths with an 80% to 90% error reduction. The alternative, point milling, requires many finish passes to leave a suitably small cusp height between consecutive passes. MAX-5 supports ruled blade

MAX-AB is generally applied to the class of components that are designed with arbitrary surfaces but can also be used with a high-speed milling process for ruled-surface components. MAX-AB is particularly suited to today’s CFD-influenced blade shapes that can be difficult or impossible to cut with other general CAM systems. MAX-AB includes advanced Continue on page no.55

TECH UPDATE Continued from page no.52

capabilities for roughing, plunge milling, hub finish, point-milled blade finish, leading edge, fillet finish, and tip milling.

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tions for the milling of single blades. Our MAX-SB module generates tool paths for quickly machining single blade parts with smooth 5-axis motion. It is specifically designed for flat/torus cutters that are more efficient than a ball tool. MAXSB also provides optimized angles for the smallest cusps to avoid gouging in concave areas. MAX-SB uses 5-axis milling for efficient material removal, but 4.5 and 4 axis cutting is also possible. Single blade parts are fixtured with the stacking axis aligned with the machine rotary axis. MAX-PAC Features

MAX-SI for Integrally Shrouded Impellers

MAX-SI creates 5-axis CNC instructions for milling integrally shrouded (enclosed) turbomachinery components for expanders, pumps, process compressors, turbines. It can also generate machining instructions for large axial compressors and blisks using a side-entry machining approach.Onepiece shrouded impellers have many advantages over parts produced as an assembly of separate hub and shroud components (or even individual blades). These include less raw material required and fewer manufacturing process steps. Also, integrally shrouded components avoid heat distortion and have stronger shroud joints than fabricated assemblies. MAX-SI includes strategies for pocket roughing, plunge milling, box passes for finish/semi finish, and flow-direction finish milling. MAX-SB for Single Blades

MAX-SBâ&#x201E;˘ creates 5-axis CNC instruc-

MAX-PAC and its add-on modules share these advanced features:

fillets, and blade thinning. Splitter blades are also supported. The part model can be exported in IGES format ready for CAD systems. Cutter Geometry

MAX-PAC can specify cutter shapes that include cylindrical and conical ball endmills, flat mills, corner-radius mills, plunge mills, barrel cutters, and burr (lollipop) cutters. The cutter holder/ spindle geometry can also be specified for collision checking. The tools are defined with graphical 2D and 3D display. A master tool library can also be created to easily import existing tool definitions to a new case. Automatic Tool Selection

The MAX-PAC interface allows even the novice to become a power user. It guides the programmer to enter machining operations and specify parameters for each operation. Input values are checked for validity and on-line help is available. Inputs are stored and can be used for similar applications.

MAX-PAC can select cutter sizes from a cutter catalog for each operation, or confirm user-specified cutters. The cutters are checked against specific parameters such as operation depth and stock offsets. To optimize material removal, the program selects the largest cutter that will fit in the specified blade pocket.

Geometric Modeling

Data Conversion

MAX-PAC can be applied to a wide range of turbomachinery components including centrifugal and axial bladed parts. The software can scale components, rotate coordinate systems, and create many turbomachinery-specific design constructions as required. These can include leading- and trailing-edge shapes, constant and variable-radius

MAX-PAC can import many different tabular engineering data formats such as camberline and thickness definitions as well as non-streamline data grids. An optional CAD Translator module is also available for importing CAD files.

User-Friendly Interface

Multi-Axis Output

MAX-PAC generates continuous 5-axis toolpaths that are required for most turbomachinery components. When the part geometry permits, 4.5-axis, 4-axis, and 3-axis toolpaths can also be generated. Milling Strategies

MAX-PAC offers toolpath templates derived from years of experience and customer feedback. Depending on the licensed module, strategies are available for roughing, hub finish, blade finish, leading edge, variable fillet, tip chamfer, and shrouded pocket milling.

MTW DECEMBER 2015

TECH UPDATE Programmers select the method, cutter size, step-over specifications, and material stock, and then MAX-PAC automatically generates the cutter paths. There is no need to construct complicated drive surfaces. Tool Orientation

MAX-PAC includes a patented collision detection and avoidance module. This ensures collision-free and smooth machining instructions. MAX-PAC’s algorithm allows larger cutters for more efficient milling and often can produce

fixed-cutter reference. MAX-PAC also generates toolpaths and stock models that can be loaded directly into industrystandard VERICUT® solid-modeling simulation software for which Concepts NREC is a reseller. Machine Compatibility

Standard output from MAX-PAC contains APT GOTO commands that are compatible with commercially available postprocessors. Direct postprocessors can also be developed upon request and include custom commands for each user. a toolpath for difficult blade shapes that cannot be processed with general CAM systems. Also, cutter orientation is automatically calculated by the program to provide a major programming productivity improvement compared to other CAM systems. Graphical Simulation

MAX-PAC can render blade surfaces and show dynamic tool motion. Tool tip, tool center, path points, and cutter vectors may be displayed. The animation uses a fixed-part reference or a patented

Integration with Concepts NREC’s AxCent® Blade Design Software

A key benefit for customers who design impellers, blisks and single blades with AxCent, is the seamless link between our design and manufacturing software. With just a single button click, the entire geometry can be transferred from AxCent to MAX-PAC. This enables designers using AxCent to quickly determine manufacturing feasibility and reduce the cost of each part. This unique one-click functionality eliminates the time consuming process of transferring designs from a design system or CAD model to CAM. It also removes the risk of associated errors that can happen during the manual transfer of geometry. For more information: Concepts NREC No. 17, 7th Main, Indiranagar 2nd Stage, Bangalore 560038 INDIA Mobile +91-98452-66221 Website: www.conceptsnrec.com

MTW DECEMBER 2015

PROJECTS www.mtwmag.com

Aviation Directorate of Municipal Administration

Machining

“Gulbarga Airport connectivity package - road from over bridge to Afzalpur road ( from over bridge of New Jewargi road via Biddapur colony to Afzalpur road).”

Manufacturing

Place: Gulbarga Karnataka

Aviation Electricals & Electronics Iron/Steel

PROJECT

Ports & Shipping Railways

Contacts: “R P Jadhav,

Transport

Executive Engineer, Mysore, Karnataka. T: 08472-278675, 260775, M: 9343834521”

Ceramic Tiles

Pawan Hans Ltd

UPDATE

Steel Tubes

and accessories. The commissioning is expected by the end of 2016.

Place: Haridwar Uttarakhand Contacts: Aradhana Dubey, DGM HR, Plot 1A/1B, Sector 8 B, IIE, SIDCUL Ranipur, Haridwar-249403, Uttara- khand. T: 01334-322951/991, E: aradhna.dubey@anchorworld.com

Iron/Steel Tata Steel Ltd

Plans to set up engineering training and helicopter pilots training institutes in NorthEast region.

Plans to increase capacity of its Kalinganagar steel making facility to 16 MTPA by 2025. As part of irst phase, the company is commissioning three mtpa capacity. This unit will be ready shortly.

Place: Guwahati Assam

Place: Odisha

Contacts: Sanjay Kumar,

Contact: “Rajiv Kumar, Vice President (operations), Kalinganagar Project, General Ofice, Block no-2,Duburi, Jajpur-755026 , Odisha. T: 0674-5510104, 0657-2426992, E: communications@tatasteel. com, W: www.tatasteel.com

Head (ER), Ground Floor, Manoramaloy VIP, LGBI Airport Road. Opp. : Hotel Airport Nest, Guwahati-781015, Assam. T: 0361-2342175, 2842177, F: 2842176, E: gm_er@pawanhans.co.in

Electricals & Electronics

Machining

Anchor Electricals Pvt Ltd

Aequs Pvt Ltd

Plans to set up new manufacturing plant at Haridwar. The proposed plant would produce complete range of switches

India’s leading global precision machining companies plans to set up a new facility in joint venture with Precihole. The facility

MTW DECEMBER 2015

PROJECTS

will come up at its SEZ in Belagavi by August 2016.

Place: Belagavi Karnataka Contact: Sandeep Jadhav, Marketing Man- ager, Aequs Special Economic Zone, No 437/A, Hattargi Village, Hukkeri Taluk, Belagavi – 591243, Karnataka. T: 0831-3090000, F: 3090001, E: sandeep.jadhav@aequs.com

Manufacturing Karbonn Plans to set up a mobile phone manufacturing plant at Tirupati in Andhra Pradesh. The unit will churn out 500,000 units a month. Place: Andhra Pradesh

Place: Rajasthan

in 6 months.

Contacts: Manoj Jain ,

Place: Kollam Kerala

Asst. Regional Manager, Udyog Bhawan, Tilak Marg, Jaipur-302005, Rajasthan. T: 0141-5113240, 2227751, 5113216, M: 9414188348, F: 5104804 E: bhiwadi2@riico.co.in

Steel Strips Wheels Ltd The company is setting up a modern manufacturing facility at Mehsana, Gujarat in partnership with Kalink Company. The plant will have a capacity of 1.5 million alloy wheel rims per annum with sizes ranging from 14” to 19”. So far land acquisition is in place. The work is likely to start from next month.

Place: Mehsana Gujarat Contacts: Basappa Muttur, Sr. Manager (Product Planning & Management), NAL Wind Tunnel Road, Murgesh Shpalya, Old Airport Road, Bangalore-560017. T: 080-40894804, E: basappa@utlinks.com

Rajasthan State Industrial Development & Investment Corporation (RIICO) RIICO has signed a MOU with Glo-Tech Enterprises for setting up a manufacturing unit in Bhiwadi industrial region of Alwar district. The proposed unit will manufacture cell phones, LED TVs and related products.

MTW DECEMBER 2015

Contacts: Naveen Sharma, Senior Manager - Projects, S.C.O. 49-50, Sector 26, Madhya Marg, Chandigarh-160019. T: 0172-2792385, 2793112, F: 2794834, E: info@sswlindia.com, naveensharma@sswlindia. com

Ports & Shipping Harbour Engineering Department Plans to undertake development of Kollam port comprising upgradation and strengthening of the port road from Vadi to Kollam port. The completion is targeted

Contacts: P.K.Anilkumar, Kamaleswaram, Manacaud P.O, Thiruvananthapuram-695009, Kerala. T: 0471-2459365, F: 2459365, E: ce.hed@kerala.gov.in

Inland Waterways Authority of India The authority has plans to build inland shipping port at Jalore.

Place: Jalore Rajasthan Contacts: P K Srivastava, Hydrographic Chief, Head Ofice, A-13, Sector -1, Noida-201301, U.P. T: 0120- 2521667, 2521744, 2544036, 2521684, 2522798, F: 2544041, E: iwainoi@nic.in, hc.iwi@nic.in

Vizhinjam Interna- tional Seaport Ltd (VISL) VISL is the special purpose vehicle (SPV) created to implement the proposed Vizhinjam International Deepwater Seaport. VISL had recently received bids from 16 infrastructure companies for the requirement of independent engineer (IE) for this project.

Place: Vizhinjam Kerala Contacts: Ajit S, Chief Project Coordinator & Head

(EHS & CSR), First Floor, Vipanchika Towers, Near Govt.Guest House, Thycaud, Thiruvananthapuram 695014, Kerala. T: 0471-2328614, F: 2328616, E: ajit@vizhinjamport.in, mail@vizhinjamport.in

Railways Rail Vikas Nigam Ltd Plans to assign construction of roadbed bridges, supply of ballast, installation of track, electrical.works as part of the doubling of track between Kidiyanagar and Chhansara and Diyodar and Chhansara. The completion period is 1620 days.

Place: Gujarat Contacts: B B Gamit, Joint General Manager, 61, 2 nd Floor 4-D Squire Mall Opp-Iit Gandhinagar Visat-Gandhinagar Highway Motera, Ahmedabad-380005, Gujarat. T: 079-66170271/72, F: 66170270, E: piurvnladi@gmail.com

North Western Railways (NWR) NWR and its Jaipur division had already given in-principle approval for the skywalk project to the Jaipur Metro Rail Corporation (JMRC). It is proposed to construct skywalk from the Jaipur Metro railway station to Jaipur railway station.

PROJECTS www.mtwmag.com

Place: Jaipur Rajasthan

Kudgi-Gadag route.

Contacts: Anil Singhal,

Place: Gadag Karnataka

General Manager, HQ Ofice, Near Jawahar Circle, Jaipur, 302017, Rajasthan. T:0141-2725800, M:9001195000, E: gm@nwr.railnet.gov.in

Mahanadi Coalields Ltd. IR aims to complete the 52 km-long Barpali-Jharsuguda line by June 2016. The railway line is likely to enable faster evacuation of coal from Mahanadi Coalields Limited (MCL) coal mines.

Place: Jharsuguda Odisha Contacts: A.K.Pandey, GM(Civil)/HOD, Mahanadi Coalields Limited P.O. Jagriti Vihar, Burla District, Sambalpur -768020, Orissa, T:0663-2542779,2542049, F:2542180, M:9437479156, E: cgm-civil.mcl@nic.in

Indian Railways The Cabinet Committee on Economic Affairs (CCEA) has recently approved doubling of the Hotgi-Kudgi-Gadag railway line at an anticipated cost of Rs.1618 crore and completion cost of Rs.2058 crore. Hotgi-Kudgi-Gadag route is a single line rail link between Guntakal-PuneMumbai and Hospet- HubliGoa rail routes. A number of Integrated Steel Plants/Power Plants/ Cement Plants are coming up along the Hotgi-

Contacts: Anil Saxena, Additional Director General (PR), Room No. 310, Rail Bhavan, Raisina Road, New Delhi-110001, T: 011-23381332, 23303665, M: 9810046241, 9868679525, F: 23385215, E: dpr@rb.railnet.gov.in

Steel Tubes Rama Steel Tubes Ltd. The company has recently started commercial production at its Khopoli plant, near Mumbai. With this the company aims to double its capacity to 72,000 tonnes of mild steel tubes.

Place: Mumbai Maharashtra Contacts: Kapil Datta, Company Secretary, 7th Surya Niketan, Vikas Marg, New Delhi-110092, Delhi. T: 011-43656667, 43656671, M: 9810411533, E: info@ramasteel. com, accounts@ramasteel.com

The two metro corridors will come up between Pimpri Chinchwad (PCMC) to Swargate and Vanaz (Kothrud) to Ramvadi.

Place: Maharashtra

Pimpri Chinchwad Municipal Corpora- tion (PMC) The Centre has asked the PMC to submit revised estimates for the metro project proposed for the twin cities Pimpri Chinchwad.

Plans to develop 18.6 km Dahisar West to D.N.Nagar Metro corridor project. The World Bank has shown interest in project funding.

Contacts: Rajeev Jadhav, Pimpri Chinchwad Municipal Commissioner, Pimpri Chinchwad Municipal Corporation Main building, 4th foor Pimpri 411018, T:020-27426331, 1101, M: 8308066111, E: rr.jadhav@pcmcindia.gov.in

Mumbai Metro Rail Corporation (MMRC) As part of its Colaba-SeepzBandra underground metro project, MMRC plans to construct stations at Sahar Road, domestic and international airports. Airport operator Mumbai International Airport (MIAL) has agreed to provide Rs 777 crore as its contribution towards the construction of these three stations. Recently an MOU has been signed between MMRC and MIAL in this regard.

Place: Mumbai Maharashtra

Transport

Mumbai Metropoli- tan Region Develop- ment Authority (MMRDA)

Contacts: S. K. Gupta, Director (Projects), MMRCL Building, E Block, BKC, Bandra (E), Mumbai-400051, Maharashtra, T:022-26381604, 26384602, 26384604, E: subhod.gupta@mmrcl.com

Place: Mumbai Maharashtra Contacts: Manoj Dandare, Sr Transport Planner, T& C Division, 8th Floor, MMRDA Building, BandraKurla Complex, Bandra(E), Mumbai-400051, Maharashtra. T: 022-26594111, M: 9833627498, E: manojdandare@gmail.com

Ceramic Tiles Bharat Flooring & Tiles The company is contemplating plans to set up a production facility at Delhi. As of now the company is looking forward to acquire unit in Morbi, Gujarat in the next six months.

Place: Delhi Contacts: â&#x20AC;&#x153;Komal Gilder, Marketing Manager, 32, Ground Floor, Mumbai Samachar Marg, Next to Stock Exchange, Fort, Mumbai-400023, Maharashtra. T: 022-40574423, E: Komal.gilder@ bharatforings.com Variava@gmail.com

MTW DECEMBER 2015

PRODUCTS

PRODUCT SHOWCASE KING CUT PRO – The Large Gantry Type CNC Cutting Machine Ador’s KING CUT PRO is a CNC portal cutting machine which is very precise and reliable. The machine has one head for plasma sheet metal cutting and one head for flame cutting of sheet metal with a dual side longitudinal drive with AC motors. The standard equipment comes with a basic machine package with CNC controller, one torch, central gas diffusion with manometers and a remote flame ignition.

The following equipment are supplied as required by the customer: Additional Equipment: • Plasma power source KJELBERG with machine torch • Programming software MOST 2D • Support table for sheet metal with segment extraction system • Extraction-filter system • Laser position indicator for determining the cutting point Optional : • Extension of the longitudinal rail • Additional cutting head

The CNC Controller – Phantom:

For Product Enquiry Contact Ador Welding Limited Akurdi Chowk, Chinchwad, Pune 411 019 Tel.: 020- 4070 6000 Email: cmo@adorians.com Web: www.adorwelding.com

MTW DECEMBER 2015

The Phantom brings you the performance of a cutting edge CNC that is built on more than 40 years of experience in the motion control and cutting industries. This controller is designed for multiple axis cutting machines and features the latest advances in CNC technology on a proven platform engineered to increase productivity, reduce costs and enhance profitability. The software provides flexibility, ease of operation and technologies that put Ador’s experience and expertise in your operator’s hands, resulting in extremely good cut quality and high productivity. The Phantom can operate any cutting machine and interface with virtually all plasma systems. Following are its standard features: Bright touch screen interface, Touch screen interactive display, Expandable shape library, True multi-tasking environment, Fast Dxt file conversion, Go to(Job interrupt), Quick plate alignment, and Monitor & track consumables. Advanced Plasma Process Control (Plasma Process Wizard) is available as optional extra. Ador offers cost-saving height control unit for simple plasma cutting applications. The KHC1 system provides all the essential functions that are needed for good cuts and optimum utilization of work-piece.

PRODUCTS www.mtwmag.com

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

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

Hangsterfer’s neat cutting oil CC10 is recommended for Deep Hole Drilling /Gun Drilling application. CC10 (Viscosity 10) has all the capability to outperform. Hangsterfer’s neat cutting oils are recognized by various machine manufacturers around the world. These oil improves tool life and surface qualities to the large extent. In addition to the lubricity provided at the cutting zone, Hangsterfer’s cutting oils provide excellent lubrication for the machine’s slides, guide bushings, bearings, and spindles. For Product Enquiry Contact Hangsterfer’s Laboratories, Inc. USA Sanjay Tools & Adhesives Mobile : +91 9822028518, +91 9892516810 E-mail: hangsterfers@sanjaytoolsnsk.com Web : www.hangsterfers.com

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

Han® B Snap Cap: Bulkhead mounted housing with self-closing cover

For Product Enquiry Contact HARTING India Pvt. Ltd. 7th Floor (West Wing), Central Square II Unit No.B-19 Part, B 20&21, TVK Industrial Estate Guindy, Chennai - 600032 INDIA Tel : +91 44 43560415, Fax: +91 44 4356 0417 Email: abhishek.bimal@HARTING.com Website: www.HARTING.in

HARTING is launching a new Han® B bulkhead mounted housing on the markets: it is equipped with a hinged cover which automatically closes when the connector is removed. The hinged cover protects the interior effectively from external influences. A special spring on the bearing pedestal presses the hinged cover against the housing with sufficient pressure to prevent water spray and dust from entering the interior. The new housing is locked with the Han-Easy Lock® bracket which impresses with easy use, a good sealing effect and low operational force. In an unplugged condition the new bulkhead mounted housing meets IP44, in the plugged condition, such as in combination with a suitable Han® B hood, it complies with the IP65 protection class. The Han® B connector range, with its housings and inserts, covers the entire range of industrial requirements for professional connection technology. Introducing the new Han® Snap Cap Mechanism, HARTING is extending the options for protecting electrically powered applications against external influences. The application possibilities of the bulkhead mounted housing with hinged cover range from wind turbines and wind energy systems, cranes and switchgear and all the way through to trains and trams, as for motor connections in areas exposed to water spray, for example. In all these applications, the Han® B bulkhead mounted housing ensures reliability of operation - also under extreme conditions. Users can choose from standard sizes ranging from 6B to 24B.

MTW DECEMBER 2015

PRODUCTS

Renishaw Launches New CARTO Software Solution For Calibration Systems Renishaw is launching a new free software suite for Renishaw calibration systems at EMO 2015. The suite includes Capture and Explore, which provide data capture and analysis for the XL-80 laser interferometer system. CARTO release 1.1 supports linear, angular and straightness measurement with a choice of keypress, position and remote (TPin) triggering. CARTO features a new database system which automatically stores and organises data for the user, simplifying operation and allowing users to quickly and easily compare data with historical results. Capture has been introduced to the CARTO suite as an improved and updated data capture application with the following features: • The orientation of machine movement is detected automatically, reducing the chance for human error in the process. • The intuitive user interface allows new users to begin capturing data quickly with less requirement for training. • All the core functions are available on one screen for efficient navigation. • ISO-10360 target sequences can be automatically created, simplifying a challenging test set-up. • Explore brings the advances of XCal-View data analysis software to the CARTO suite with the following features: • Tests in the database can be searched by different criteria (such as machine name, operator, and date etc.). This enables users to review historical test data conveniently. • Multiple data sets can be overlaid on the same screen for visual comparison. • Linear error compensation files can be created from test results. • Customisable test reports can be created with choices such as graph line thickness and adding company logos. 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

User-friendly interface The intuitive CARTO user interface allows new users to begin capturing and analysing data quickly, without the need for training or reading lengthy manuals. The capacity for customisation throughout the suite means that both Capture and Explore can be tailored to suit an individual user’s requirements.

Welding Carriage

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

MTW DECEMBER 2015

These Welding carriage are used for Automatic Welding of Fillet, Butt, Joints in different Welding Position. GMAW/FCAW process is normally used along with these kind of carriage. These carriage uses permanent magnet to hold on to the Job and can be used in different Welding position depending on the Tractor Force of the magnet used. Either guide wheel or the track are used to move the trolley along the Weld Seam. Weaving & Weaving pattern are available on some model to realize the required Weld Beads.

PRODUCTS www.mtwmag.com

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

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

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

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

Precihole Introduces An Innovative And Cost Effective Solution For Gun Drilling Of Surgical Implants

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

Precihole Machine Tools, a leader in deep hole drilling and hole finishing technology introduced a new dedicated gun drilling solution for the medical implant industry. This machine packs in all the features needed for surgical implant gun drilling at fantastic value to the consumer. Gun drilling range extends from Φ 2mm to Φ8 mm with drilling depth of up to 600 mm. L/D ratios of 100 are supported on this machine for such small diameters. Machine supports drilling of Stainless Steel and Titanium materials most commonly used in implant industry. The machine is offered in single spindle or twin spindle variants. The machine features use of linear motion guide ways for table motion. Four tool steadies are provided for maximum tube support to prevent any whipping of slim drill tubes. Spindle rotation is a maximum RPM of 10000. The work piece is counter rotated to offer maximum accuracy and straightness. A high-pressure coolant delivery and filtration system is provided to ensure the coolant enters the drill at optimum pressure and is filtered appropriately. This machine provides maximum tool life and productivity for all surgical implants like Bone screws, Cannulated nails and drills. 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.

MTW DECEMBER 2015

PRODUCTS

Pramet Unravel Turning Dilemma With New Ranges

For Product Enquiry Contact Dormer Pramet Unit 4 Lindrick Way S43 4XE Barlborough, Chesterfield, United Kingdom T: 0870 850 4466 F: 0870 850 8866 Website: www.dormerpramet.com

Pramet has introduced two new positive geometries and grades for turning applications in difficult to machine materials.Suitable for a variety of turning applications, the SF and SM geometries have been launched to support the machining of materials such as high temperature alloys and stainless steel. Part of Dormer Pramet’s second product launch of 2015, the SF geometry features a sharp, positive rake of 14.5°. It is suitable for finishing applications in continuous cut with very low forces. The SM geometry has a positive rake of 13° and is a wear-resistant, universal geometry for medium machining (finishing up to roughing) and suitable for continuous and interrupted cut. Both geometries are available in a variety of grades and have been designed to promote low cutting forces and prevent work-hardening. This helps to reduce the risk of vibration when turning thin-walled components. In addition to the new geometries, two new turning grades have been unveiled by the global cutting tool manufacturer. The PVD coated T6310 grade features a special sintering process which enhances cutting edge reliability and strength. Its new substrate with intermediate Cobalt content provides additional hardness and increased abrasion resistance to offer greater reliability and prolonged tool life. The T6310’s triple coating provides durability for higher cutting speeds used when machining stainless steel, heat-treated and hardened materials. It is suitable for use with the new SM and SF geometries, as well as Pramet’s existing NF and RM geometries, with a total of 89 inserts now available. Josef Bittner, product manager for turning at Dormer Pramet, said: “The thermal conductivity of stainless steel, nickel and titanium tends to be low, but with high cutting speeds and feeds required during machining, the cutting edge can quickly become overheated, shortening tool life. “Machining with coolant reduces these effects, but the constant change of temperature at the cutting area causes heat stresses, resulting in thermal cracks and, again, poor tool life. “We therefore saw a need to create a new grade with the right combination of substrate and coating to enhance resistance to thermal cracking. Our new T6310 grade achieves that objective.” Meanwhile, Pramet’s new H07 uncoated grade offers good heat conductivity and high wear resistance required for turning titanium and alloys. Its fine grain substrate with low Cobalt content offers resistance to pitting as well as plastic deformation. It is available in the new SF geometry. Josef added: “These latest products will be of use in extreme environments where they are subjected to tremendous heat and corrosion, for example in the general machining, oil and gas, automotive, medical industry, marine and power generation sectors.” An overview of all the new indexable ranges launched by Dormer Pramet in November 2015 is available in its latest product brochure. To order a printed copy or for more information contact your local Dormer Pramet sales office.

Looking for industrial Products for your plant/workshop ??? Connect to right manufacturers & suppliers http://www.mtwmag.com/enquiry/product 64

MTW DECEMBER 2015

ADVERTISERS INDEX COMPANY NAME

PG. NO.

A 45

ADOR WELDING LIMITED

C BACK PAGE

D DOWEL ENGINEERING WORKS

PG. NO.

ACMEE - 2016

CNC SOFTWARE, INC.

COMPANY NAME

E 17

ENGITECH EXPO - 2016

ERWIN JUNKER MASCHINENFABRIK GMBH

PG. NO.

GRIND MASTER MACHINES PVT. LTD.

PRC SUPPLIES PVT. LTD.

H HAAS AUTOMATION INDIA PVT. LTD.

HARTING (INDIA) PVT. LTD.

HEIDENHAIN OPTICS & ELECTRONICS INDIA PRAIVATE LIMITED

INSIDE FRONT COVER

RENISHAW INDIA (PUNE)

EFFICA AUTOMATION LIMITED

COMPANY NAME

JYOTI CNC AUTOMATION LTD.

INSIDE BACK COVER

MACHINE TOOLS WORLD |

19 & 49

SEE LUBE TECHNOLOGIES PVT. LTD.

SPRAYMET SURFACE TECHNOLOGIES PVT. LTD.

M MACHAUTO EXPO - 2016

SANJAY TOOLS & ADHESIVES

65 | December 2015

UNITY CONTROLS PVT. LTD.

Mr.

Arjun

Inside Story

Prakash Director, Effica Automation Ltd.

My Lifeâ&#x20AC;&#x2122;s Goals

Aim & Ambition: The 90s and 2000s were the age of office automation which has made us productive and prosperous in many ways. The 2020s will see automation and robotics play a big role in the factories and homes of poor countries. We aim to be a big part of this. Vision: I always believed productivity and equality were the key to prosperity of any nation. Equality is in the hands of politicians and individual people themselves. Productivity is in the hands of engineers like us. Prosperity with Productivity is our vision for India. Social Goal: I have always believed that education is the only solution to upliftment of the people and the nation. Why give a man a fish. when you can teach him how to fish. Inspired by the German model of deep integration between the Industry and educational Institutes, I devote time towards such initiatives. Business Goal: To make our robotic solutions affordable, easy to implement, use and maintain by any small organisation or individual. This will make robotics a scalable business and enable us to sell in thousands in the future.

My Leisure Choices

Favourite Tourist Spot: Rome. The greatness of what they built and achieved almost 2000 years ago is surreal. Favourite Leisure Activity: Spending time in the jungles of Mudumalai and Bandipur with nature and wildlife. I read a lot on very diverse non-fiction subjects. Music I Like: Western and very diverse from modern hip-hop and reggae to instrumental classics. Sports I Love: I love watching motorsport especially Formula 1 Racing.

Ask my Taste Buds

Favourite Food: Continental and Mediterranean. Favourite Drink: Long Island Ice Tea.

In Awe of

I Admire and Follow: Elon Musk the founder of Tesla and SpaceX. The man actually believes that humanity is destined to be a multi planetary species & that his job is to enable it! Now thatâ&#x20AC;&#x2122;s what you call a visionary!

MTW DECEMBER 2015

Publishing Date : 10th of every month RNI No. MAHENG/2015/64267

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