Control cabinet: Š FeinBlechSysteme Lentz GmbH
Material. Machine. RAMPF.
RAMPF offers you material and machine from a single source:
VISIT US AT IMTEX FORMING 2016 HALL 2A, BOOTH B107
RAMPF Production Systems offers you a wide range of innovative dispensing machines and automation for PU gasketing on metal parts. RAMPF Polymer Solutions offers you first-class PU foam gaskets for your applications in the automobile, packaging, and electronics industries.
RAMPF Production Systems E production.systems@rampf-gruppe.de www.rampf-gruppe.de
Our local service partner in Pune for consulting, subcontracting, and support: Sanika Engineering & Consultancy Pvt. Ltd. Mr. Ulhas Peddawad T +91 (0)2135-278856 | E upeddawad@gmail.com
FIRST-CLASS SHAFT GRINDING
CYLINDRICAL GRINDING Versatile, rugged, long-lasting – the cylindrical grinding machines of the Numerika series meet any requirements for the series production of a broad range of workpieces. A torsion-resistant machine bed, hydrostatic guides and grinding spindles mounted on rolling or hydrostatic bearings provide for perfect grinding results.
www.zema.com.br JUNKER PREMIUM-SERVICE: • Guaranteed servicing • Fast and competent • 24 hours a day, 7 days a week • Worldwide service network
ZEMA Zselics Ltda. Estrada do Capivari 741 Cep 09835-450 S.B. do Campo, São Paulo Brazil
Erwin Junker Maschinenfabrik GmbH India Branch Office Office No. 104, City Square 29-2, K.M. Gandhi Path, Bhamburda Shivaji Nagar, Pune 411 005
+55 11 4397 6000 zema@zema.com.br
+91 20 255 33 896 info@junker.in
Contents
www.mtwmag.com
Vol 1 Issue 8 | JANUARY 2016
Publisher
CASE STUDY
Shirish D.
CEO
38
Shekhar D.
Editor
HAAS: The strong & silent type
Shilpa Dongre
Marketing Team Ladoji Pendurkar, Amol Powle, Bhavin Shah, Bharat Shah, A.Purohit, Vinod Surve, Kavita Chaudhari
40
Rinspeed’s “Etos” concept cardeploys HARTING MICA
Designer & Layout Arun P. Shinde, Nandan S. Moghe, Dinesh S. Gawade
42
Online Division Ganesh M., Pradeep M. Pillalamarri
World’s most powerful all-electric pipe bending machine swings into action at Norwegian shipyard
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
COVER STORY
28 CERATIZIT: Cognitive heritage of cutting tools technology excellence Mr. A.K. Sareen, Managing Director, CERATIZIT India Pvt. Ltd.
EAST
WEST (Maharashtra & Gujarat) Pune S.Kadam - 09833373371 Gujarat Dinesh Shah - 09327344559 Rajkot (Saurashtra) Swapnil Bhatia: 09227909005
Head Office : Divya Media Publications Pvt. Ltd., 3rd Floor, Harmony Tower, N.S. Road, Thane-400 602. Maharashtra Tel: +91 22-25380574/75, Telefax: +91-22-25418254 E-mail: shekhar@divyamediaonline.com, Website: www.mtwmag.com. Printed & Published by Shirish Dongre on behalf of DIVYA MEDIA PUBLICATIONS PVT LTD., Printed at Anitha Art Printers 29/30, Oasis, Next to Vakola Market, Santacruz(E), Mumbai-400055, published from 303/304, Harmony Tower, N.S.Road, Court Naka, Thane West, Thane-400601. Editor : Shilpa Dongre
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MACHINE TOOLS WORLD JANUARY 2016
BUSINESS NEWS
52
IN FOCUS
10
Ador Welding marked presence at WELD INDIA 2015
12
Open House Pfronten 2016: Into the new year of trade fairs with answers to the question of digitisation & 6 world premières
14
Mastercam named official CNC software of Roush Yates Engines
16
HaasTec Pune draws over 3000 visitors
Laser factory GmbH Picosecond laser for carbides and ceramics
TECH UPDATE
Kochi Sanjeev Nair : 09846249568 (Kolkata & Other regions) S. Roy - 09433097806
46
32 ROSS Controls: Leadership in Pneumatic Safety
COMPANY PROFILE
RAMPF highlights expertise for gasketing on metal surfaces
54
Ceramic Coatings from Spraymet for Refurbishing Machine Tool Parts
56
PRC Industrial Supplies
34
“Technology Provider with High Productivity”
64
Ease your vacuum generation with SMC
67
36
Effica’s Robotic solutions
PROJECTS
70
PRODUCTS
Editorial Board
Editorial Index A Ador Welding B Birla Precision Technologies Bonfiglioli
Mr. A.P. Jayanthram Managing Director Heidenhain Optics & Electronics India Pvt. Ltd
Mr. Arjun Prakash Managing Director Effica Automation Ltd.
Mr. GK Pillai Managing Director & CEO
Walchandnagar Industries Ltd.
Ms.Samina Khalid Marketing Manager
Renishaw Metrology Systems Ltd.
Mrs. Mohini Kelkar Managing Director Grind Master Machines Pvt. Ltd
Mr. MIHIR Baxi President – Global Sales Jyoti CNC Automation LTD
10, 70
72, 74 58
K KASTO
62
L Lakshmi Machine Works
74
M Meiban Engineering
34
P PRC Supplies
56
52 32
C CERATIZIT India Mastercam Concept Laser
28, 76 14, 17 48
D DMG MORI Dormer Pramet
12, 46 25
R RAMPF Group ROSS Controls
E Effica Automation
36
S Setral Chemie Shell Lubricants SMC Pneumatics Spraymet Surface Technologies
F FARO Technologies
20
H Haas Automation Hangsterfer’s HARTING Heidenhain Hypertherm
16, 38 71 40 73 22, 60
I Inorbit Tours
24
73 21 64 54
U Unison Unity Controls
44 72
Z ZF Friedrichshafen
18
For editorial contribution contact editor@divyamediaonline.com
MTW Overseas Associates Mr. Dinesh Khambhayta President MTMA-RAJKOT
Mr. Ayaz Qazi Director
Precihole Machine Tools Pvt. Ltd.
Mr. Suhas Belapurkar Director - Sales & Marketing ( Industrial Products) Sanjay Tools & Adhesives
Mr. P.K. Balasubbramaniian President VBS Corporate Support
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.
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
JANUARY 2016
MACHINE TOOLS WORLD
7
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PRC Industrial Supplies and www.prc.in is the leading supplier & distributor of industrial supplies, consumables, tools, through online order booking on our website and on phone, we provide the right solutions for your company and 12pm IST. PRC is continuously in the process of adding more & more brands to meet your requirements with 100%
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BUSINESS NEWS
Ador Welding marked presence at WELD INDIA 2015 Ador Welding Ltd. put up an impressive show at WELD INDIA 2015, the National Welding Seminar-cum-Exhibition organized by the Indian Institute of Welding at the CIDCO Exhibition Centre, Navi Mumbai during Dec. 9-12, 2015. Ador Welding Ltd. (formerly known as Advani-Oerlikon Ltd.), has been synonymous with welding in India for over 64 years. Regarded a pioneer and leader in the welding industry, AWL has progressively extended its knowledge and expertise to cater to a sophisticated range of user needs in India, the Middle East, Africa and South-East Asia. Carrying the sobriquet, ‘Welders to the Nation’, AWL provides a comprehensive range of products, services and solutions to ensure excellence in welding and fabrication at the customer ends.
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Strategic Business Units • AWL operates through its following Business Units: • Welding & Cutting Equipment • Welding Consumables • Spares, Gas Cutting Products & Personal Protection Accessories • Welding Automation Products & Systems(WAPS) • Project Engineering Business(PEB) • Ador Welding Academy(AWA) AWL’s range of products includes: Consumables and equipment for SMAW/ MMAW/MIG/MAG. FCAW, TIG and SAW/GTAW welding, cutting products and welding automation systems. The Project Engineering Div. provides customized solutions for multi-disciplinary projects
and contracts. Areas of specialization include the manufacturing of flares, incinerators and select environmental engineering products. Fabrication of a variety of special equipment for Power and Oil & Gas industries has been added to the growing product portfolio. AWL’s Knowledge Centre is in the vanguard of welding education in the country. The product range offered by the company is complemented by a host of training and knowledge services. Ador Welding Academy is regarded as an invaluable resource by customers. It helps them in the development of welding techniques and to ensure that correct welding procedures are followed. With four manufacturing plants, three technology development
centres, eleven sales offices and more than a hundred distributors across India, AWL strives to ensure the highest level of customer service. Ador plants are certified for Designing, Developing, Manufacturing & Supplying welding products that are high on quality. This includes ISO 9001:2008, ISO 14001:2004, OHSAS 18001:2007, ISO 14001:2004 and U,R,NB Certifications. AWL aims to be a market leader and the most respected brand in the welding industry, thereby becoming the preferred choice of total welding solutions provider for the nation building activities.
For more information, Web: www.adorwelding.com
BUSINESS NEWS
Open House Pfronten 2016: Into the new year of trade fairs with answers to the question of digitisation & 6 world premières DMG MORI will once again underline its high level of innovation at the Open House at DECKEL MAHO in Pfronten. As has become tradition, the focus of the DMG MORI Open House event at DECKEL MAHO Pfronten from 26th to 30th January 2016 will be on the latest innovations and groundbreaking technologies.On an exhibition area of 7,400 m², the machine tool manufacturer will be showcasing in total 90 high-tech exhibits live in operation, thereof the DMG MORI best-sellers as well as six worldpremières featuring turn-mill complete machining, universal milling, XXL parts machining and new technologies. Besides innovative production and automation solutions, with CELOS® and DMG MORItechnology cycles, DMG MORIwill be giving answers to the question of digitisationon the path to intelligent production in Industry 4.0.
CELOS® & DMG MORI Technology cycles for Industry 4.0 With CELOS®, DMG MORI is offeringa cutting-edge
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programming is hardly needed and complicated DIN programming are avoided. Therefore, DMG MORI technology cycles are ideal for application-specific shop floor programming.
World première: CTX gamma 3000 TC2Generation
user interface that canbe expanded with new APPs and updates and which provides an immediate solution to Industry 4.0. CELOS® is as easy to use as your smartphone, networks all machines within a manufacturing organisation and therefore simplifies the process from the idea to the finished product. 16 APPs help the operator prepare, optimise and process production jobs without any errors and enables the consistent administration, documentation and visualisation of order, process and
machine data, consequently holisticallyimproves the profitability of production. With 31 DMG MORI technology cyclesas another highlight, DMG MORI is presenting software solutionson thecutting-edge5-axisandturnmillmachiningcentres to make complexmachining processes an effortless reality.Thanks to parameterised context menus, complex processes can be directly programmed on the machine up to 60 percent faster. For theeasy to learnand readymade windows to enter data,
A turning length of 3,050 mm makes the CTX gamma 3000 TC 2nd Generation the largest turn & mill complete machining centre in the now completely revised CTX TC series from DMG MORI. Like its smaller sister models the machine tool manufacturer has also equipped this latest machine with a new compactMASTER® mill-turn spindle, which with 220 Nm achieves a 120 percent higher torque. With a diameter of 202 mm the length of the compactMASTER® spindle has been reduced by 70 mm so that it now measures only 450 mm. The interplay of the 150mm larger X-axis (-25 / +175 mm) and the 20-mm longer Y-travel of ± 210 mm brings an enormous gain in freedom for users. This enables, for
BUSINESS NEWS www.mtwmag.com
example, the radial machining of workpieces with maximum diameters of 700 mm with 170-mm long tools (with the B-axis in a vertical position). With regard to other equipment features, the CTX gamma 3000 TC 2nd Generation is equipped with 36 tool pockets in its standard version. This capacity can be increased optionally to 80, 120 or 180 tools. Maximum tool length here is 550 mm.
World première:DMU 160 P duoBLOCK® 4th Generation The world premièreof the DMU 160 P duoBLOCK® 4thGeneration impressively complements the successful duoBLOCK® series from DMG MORI and excels for its world premièrewith remarkable improvements in precision, performance and efficiency of around 30 percent.In addition the revised machine concept offers a clear plus in versatility. Added to this the high level of rigidity, extensive modular spindle range and innovative cooling measures ensure perfect machining performance and a high degree of long-term accuracy.Equipped with CELOS® the machine also guarantees user-friendly production. As a highly stable universal 5-axis machine the DMU 160 P duoBLOCK® 4th Generation unites outstanding precision
with maximum performance. With travel paths of 1,600 x 1,600 x 1,100 mm in X, Y and Z it has more than sufficient space for a wide spectrum of components, with workpieces weighing of up to 4,500 kg.The innovative wheel magazine with (depending on expansion stage) space for up to 453 tools (SK40/ HSK63) ensures the necessary flexibility where tools are concerned. With regards to the spindles, the high-tech modular spindle range of the DMU 160 P duoBLOCK® 4th Generation offers the greatest choice on the market.The offer ranges from the powerMASTER® motor spindle with 1,000 Nm to a gear spindle with up to 1,800 Nm and on to include the speedMASTER® spindle with high speeds of up to 30,000 rpm.
World première: DMU 210 P 2nd Generation The DMU 210 P 2nd Generation with its optimised work area, which now measures 2,100 x 2,100 x 1,250 mm, is the prelude to the new generation of portal machines from DMG MORI.A considerably higher level of rigidity and an intelligent cooling concept that includes a spindle growth sensor ensure maximum long-term accuracy for the DMU 210
P2ndGeneration, making it significantly more accurate than itspredecessor does. The DMU 210 P 2nd Generation is quick and simple to install thanks to its 3-point support and impresses in day-to-day production with 30 percent reduced energy consumption.The modular concept of the new portal machine includes an innovative wheel magazine that can hold up to 303 SK50 tools and the widest possible choice of spindles.The 1,000-Nm powerMASTER® motor spindle and the torqueMASTER® gear spindle with up to 1,800 Nm are available here especially for heavy-duty machining.
World première: DMU 600 G linear In the XXL Centre at DECKEL MAHO in Pfronten – the most cutting-edge large machine production in the world – DMG MORI designed and constructed the DMU 600 G linearfor best surface quality and high dynamics. These are achieved through the use of the innovative contactless linear-motor drive technology. The design of the machine has been optimised with regard to static and dynamic rigidity and ensures consistent temperature stability thanks to extensive temperature control measures
for the structure, components and guides. Energy-efficient consumption is achieved by the use of innovative cooling technology and needs-based activation of units. The DMU 600 G linearis designed for workpieces weighing up to 30 t, with a point load of 15 t/ m². The table measures 5,000 x 3,000 mm in a work area of 6,000 x 3,500 x 1,500 mm in the standard configuration.The plunger with optimised interference contour enables travel of optionally up to 2,000 mm in the Z-direction. The modular spindle range includes a torque spindle with 12,000 rpm and 300 Nm, a vertical head gear spindle for maximum torques of up to 2,500 Nm and a motor spindle with a high speed of up to 28,000 rpm.
World première: DIXI 125 DMG MORI has extended the high-precision machining centres in the DIXI series to include the smaller DIXI 125 for workpieces with diameters up to 1,250 mm.Like its bigger sister models the DIXI 125 also impresses with a unique volumetric accuracy of less than 15 µm.The basis for this are the manually scraped guide contact surfaces that achieve a flatness and straightness of three µm when mounted, perfect
JANUARY 2016
MACHINE TOOLS WORLD
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BUSINESS NEWS
machine geometry and on-site volumetric measurement and compensation. A 980-liter coolant unit with reference-guided temperature control and a powerful (also reference-guided) machine cooling unit for the main drive, feed drives, guides and machine structure together with a thermo shield that insulates against ambient influences guarantee the extreme thermal stability
of the DIXI 125.This is further optimised by the individual thermal compensation of every single machine and the use of the spindle-growth-sensor (SGS) for direct measurement and compensation of spindle rotor displacement.
World première: ULTRASONIC 20 linear 2nd Generation Even externally, the completely
revised ULTRASONIC 20 linear2nd Generation with its new, functional design and a reduced footprint of just 3.5 m² is impressive compared to its predecessor. The diverse technological optimisations include the now optional 60,000 rpm speed of the spindle, the up to 47 percent (A-axis) more powerful drive motors, a 15-kg higher load weight and the use of larger tool diameters of up to 50 mm.Another highlight is the high-speed C-axis (1,500 rpm) for high-precision and productive internal and external cylindrical grinding of rotational-symmetric workpieces made of advance materials. Where control is concerned,
the ULTRASONIC 20 linear2nd Generation supports users with a multitude of new functions. The ULTRASONIC parameters are automatically determined and tracked during processing. In the clearly arranged CELOS® control a CELOS® APP expressly developed for the purpose shows the ULTRASONIC technology cycles and key process parameters such as frequency, amplitude and output, thus enabling maximum utilisation of the ULTRASONIC and machine performance.
For more information, Website: www.dmgmori.com
Mastercam named official CNC software of Roush Yates Engines Roush Yates Engines is pleased to announce a partnership with world-renowned CAD/CAM software company, Mastercam. In this partnership, Mastercam will be the “Official CAD/CAM Software” of Roush Yates Engines. “Mastercam’s commitment to innovation and first class customer service perfectly align with Roush Yates Engines’ vision,” said Doug Yates, President & CEO of Roush Yates. “Their dedication to providing state-of-the-art software tools for CAD/CAM manufacturing and superior software products are why Roush Yates has partnered with Mastercam.” Corporate wide, Roush Yates has over 50 machines that are programmed with Mastercam products in their three facilities
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including Roush Yates Engines, Roush Yates Manufacturing Solutions, and Roush Yates Performance Engine Group in Mooresville, NC. These software products assist in machining engine components for the NASCAR FR9 and the IMSA twin-turbo 3.5L Ford EcoBoost V6 racing engines. Thousands of components are
milled, drilled, and inspected to strict quality standards prior to engine assembly. “We are thrilled to be partnering with one of NASCAR’S largest and most respected engine builders,” said Meghan S. West, President of CNC Software, Inc. “Mastercam has been an integral part of many performance racing
companies since the 1980s and it’s exciting and rewarding to contribute to the sport in an official capacity with Roush Yates Engines.” An industry leader for over 30 years, Mastercam prides itself on meeting the demanding needs of its customers by providing excellent products at affordable prices. Their strategy of combining superior software programming with practical shop floor experience is why industry professionals alike choose Mastercam. Through their dedication of providing superior customer service and product expertise is why they have remained at the forefront of the CAD/CAM industry. For more information, Website: www.mastercam.com
RELIABILITY. PRICE. REPUTATION. RELIABILITY. PRICE. REPUTATION. RELIABILITY. PRICE. REPUTATION.
Haas VF-2SS Super Speed Vertical Machining Center
= TOTAL CUSTOMER VALUE. Haas Factory Outlet
Haas VF-2SS Super Speed Vertical Machining Center | www.HaasCNC.com
= TOTAL CUSTOMER VALUE. = TOTAL CUSTOMER VALUE.
Haas VF-2SS Super Speed Center
Sales: Ahmedabad: 079-32405007, Bangalore: 080-41179452/53, Chennai: 044-65156052, Coimbatore: 0422-2413924 Vertical Machining Delhi: 0124-4367619, Kolhapur: 0231-2677979, Mumbai: 022-61392800, Pune: 020-32935433 Service: North: 09312550550, West (Guj) and Central: 09376150150 West (Mah) and East: 09325150150, South: 080-41179452/53
Haas Factory Outlet
| www.HaasCNC.com
Sales: Ahmedabad: 079-32405007, Bangalore: 080-41179452/53, Chennai: 044-65156052, Coimbatore: 0422-2413924 Delhi: 0124-4367619, Kolhapur: 0231-2677979, Mumbai: 022-61392800, Pune: 020-32935433 Haas Factory Outlet | www.HaasCNC.com Service: North: 09312550550, West (Guj) and Central: 09376150150 Sales: Ahmedabad: 079-32405007, Bangalore: 080-41179452/53, Chennai: 044-65156052, Coimbatore: 0422-2413924 West (Mah) and East: 09325150150, South: 080-41179452/53 Delhi: 0124-4367619, Kolhapur: 0231-2677979, Mumbai: 022-61392800, Pune: 020-32935433 Service: North: 09312550550, West (Guj) and Central: 09376150150 West (Mah) and East: 09325150150, South: 080-41179452/53
BUSINESS NEWS
HaasTec Pune draws over 3000 visitors HAASTECs are synonymous with CNC machining technology showcasing the very best and latest in technology for milling, turning, measuring and more helping CNC machine shops the world over become improve performance, productivity and profit !!! The recently concluded HAASTEC Pune from 9th to 12th December 2015, was a grand event managed by the local Haas Factory Outlet (HFO)– A Division of CNC Servicing & Solutions (A Phillipscorp Group Company). “Pune is home to a large number of industries, the most popular ones being Automotive andGeneral Engineering, therefore it was a perfect fit to host this year’s HaasTec here” says Nikhil Modi, Marketing Coordinator for the local HFO. With over 3000 attendees over 4 days, this latest edition of the popular HaasTec show held at Auto Cluster Exhibition grounds in Chinchwad was an action packed event with live demos on the 8 HAAS machines on display. Visitors from Kolhapur, Aurangabad, Nasik, Mumbai and of course Pune and adjoining areas came in large numbers with 3096 attendees from over
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1600 companies directly or indirectly connected with CNC machining. “On behalf of the HAAS team, I would like to thank all our customers and partners who attended our HAASTEC in huge numbers proving once again that the focused format of the HAASTEC shows provide the best value in terms of sharing knowledge, ideas and best practices for the CNC machine shop fraternity.” says Terrence Miranda, Managing Director, HAAS Factory Outlet Mumbai. HaasTec included machine demonstrations, extensive technical tours displaying a HAAS VF-2 showcased in an open condition and live floor presentations of various productivity options such as through spindle coolant, probing systems and our new barfeeder, all for the benefit
of our customers to truly see what makes HAAS unique!!! The UMC-750 Universal 5 axis Machining Centre, the large, powerful VF-7/50 and the compact, flexible ST-10Y, Y Axis turning center stole the show featuring some aggressive cutting parameters and innovative machining strategies. A full range of HAAS spindles and rotary products on display and a HAAS INFO BAR completed the round up. With 15 exhibitors displaying their latest products and technical experts in attendance from major Tooling,Workholding, Accessories, CAD/CAM, Measurement and Probing manufacturers the PUNE HAASTEC truly lived the theme: PERFORMANCE, PRODUCTIVITY, PROFIT. Customers visiting the event
were able to discuss their queries with experts from HAAS Automation Inc USA: Chris McHugh – Business Manager & Ernesto Flores – Product Specialist. HaasTec Pune 2015 received rave reviews from visitors andexhibitor vendor partners alike. The Delcam spokesperson had this to say: “The event is unique in the sense that our customers and prospects get to see solutions here, rather than just products’’. TheRenishaw spokesperson described the event as, “A great platform to display our technology.’’ The feedback from the event was extremely positive and this naturally poses an even greater challenge for the HAAS team already planning the next HaasTec in Bangalore in February 2016 as the bar has been set very high indeed!!!
BUSINESS NEWS www.mtwmag.com
Mastercam travels to India
CNC Software’s President, Meghan West, along with Graham Hargreaves (Marketing) and Dave Moskey (Sales) traveled to India from December 3 – 11 to visit Mastercam Reseller Onward Technologies and visit Engimach, a leading engineering and machine tool show in India. It was originally scheduled for the trip to include a visit to Chennai to meet with the AMT and Mastercam Reseller SIM Technologies, but the flooding in the region forced a change in their itinerary. After traveling from Mumbai to Pune, they visited Onward Technologies for a special event consisting of loyal customers in both the Educational and Industrial sectors, for an introduction with Meghan Summers, newly-appointed President of CNC Software. At the event, Meghan presented Onward with a 25th Anniversary plaque for all of their hard work and dedication to Mastercam. The next stop on the trip was to Ahmedabad and a visit to Engimach 2015. Engimach showcases engineering products and services, and
it knows to attract visitors from around the world. At the show, Meghan had the chance to meet customers and prospects, conduct an interview with the show organizer, and meet many business partners that were also exhibiting at the show. After leaving Ahmedabad, they had the pleasure of visiting the Agra and the Taj Mahal, one of the World’s Wonders. It was a very aggressive trip for the group, and eight days did not seem like it was enough to take in all that beautiful India has to offer.
For more information, Website: www.mastercam.com
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BUSINESS NEWS
ZF Friedrichshafen aims to further strengthen its presence in India through localization of technology and futuristic products ZF Friedrichshafen AG, the global global leader in driveline and chassis technology as well as active and passive safety technology is constantly strengthening its presence in India. With the expansion of its operations in India, ZF is well prepared to effectively meet the local market requirements and provide their customers with the most innovative and high quality products, solutions and services. India being considered as the prime destination for low cost products, localization has been the biggest challenge for ZF. The major challenges faced are the manufacturing technology, meeting the highest quality standards and the low volume within the scope of low cost. The organization has streamlined its efforts in this direction in order to achieve the highest quality standards and the degree of performance that today’s market demands. Over the past few years, ZF has worked very closely with their suppliers teamed
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with German engineering to deliver quality products and services to their customers and have also been successful in localization a sizeable percentage of their products. Localization of technology and cost makes ZF’s product portfolio ideal for the Indian market. Keeping focus on expanding the market ZF’s offhighway products also cater to other market segments like Pick and Carry crane, Selfloading concrete mixers etc. With the view of establishing ZF in India as the sourcing hub for ZF’s global portfolio, and to constantly innovate and provide top-notch products to its customers, ZF is developing products that are futuristic. Mr. Suresh KV, President for ZF in India said, “With the inaugurating of two manufacturing plants in a rather short span, we intend to strengthen ZF’s presence in India. Riding the ‘Make in India’ wave, we are consistently streamlining our efforts towards the localization of our products to perfectly
fit the needs of our customer while maintaining the highest quality standards and futuristic technology. In the coming years, we hope to make India a sourcing hub for ZF’s global portfolio”
About ZF Friedrichshafen AG, ZF is a global leader in driveline and chassis technology as well as active and passive safety technology. The company, which acquired TRW Automotive on May 15, 2015, is now represented at about 230 locations in some 40 countries. The two companies, which were still independent in 2014, achieved a sales figure exceeding €30 billion with 134,000 employees. As in previous years, both companies have invested approximately 5 percent of their sales in Research and Development (recently €1.6 billion) in order to be successful with innovative products. ZF is one of the top three automotive suppliers worldwide. ZF Services ensures that ZF
systems expertise is carried forward consistently into the aftermarket. With integrated solutions and the entire ZF product portfolio, the business unit guarantees the performance and efficiency of vehicles throughout their lifecycle. Driveline and chassis technology by ZF is offered in the aftermarket business using the well-established product brands Sachs, Lemförder, Boge, ZF Lenksysteme, and ZF Parts. With its global service network and portfolio tailored to customer requirements, ZF Services has also become a popular partner in the nonautomotive sector.
For more information, Website: www.zf.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.
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and Asia Pacific. So leave power quality and energy management to the experts – Unity Controls. With our nationwide network we are only a phone call away!
Contact us for Power Quality & Harmonic Audits to Conserve Energy and Save Costs.
405, Sapphire Arcade, 42 M.G. Road, Ghatkopar (E), Mumbai 400 077, India
The power quality & energy experts
+91-22-2501 3832 / 33 sales@unitycontrols.in www.unitycontrols.in
Ahmedabad l Bangalore l Chennai l Delhi l Gurgaon l Hardwar Indore l Jalandhar l Jamshedpur l Kolkata l Kanpur l Mumbai l Pune l Rajkot
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BUSINESS NEWS
FARO® Launches Smart Entry-Level X-Series Laser Scanner: The Focus3D X 30 FARO Technologies, Inc. (NASDAQ:FARO), the world’s most trusted source for 3D measurement, imaging and realization technology, announces the release of the new FARO Laser Scanner Focus3D X 30. The Focus3D X 30 completes the FARO X-series range of powerful highspeed laser scanners. With a scanning range of 30 meters, the laser scanner is ideal for a wide range of scanning applications such as architecture, BIM, civil engineering, facility management, forensics and accident reconstruction. The ultra-portable Focus3D X 30 enables fast,
straightforward and accurate measurements of interiors, such as small architectural façades, complex structures, production and supply facilities and accident sites. Combining the highest-precision scanning
technology with true mobility and ease-of-use, the new device offers reliability, flexibility, and real-time views of recorded data. As the whole range of laser scanners from FARO, the Focus3D X 30 grants highest safety with a class 1 “eye-safe” laser. “Usability and high return on investment are at the core of FARO’s Focus3D X 30 product” says Joseph Arezone, Senior Vice President and Managing Director of FARO Europe and Asia. “With its feature set and price point tailored to short range scanning projects, it is the best choice 3D laser scanner for all customers working in challenging economic
environments.” With the introduction of the Focus3D X 30, FARO offers its customers a choice between short-range Focus3D X 30 (30 meters), mid-range Focus3D X 130 and long-range Focus3D X 330 (330 meters) laser scanners with state-of-the-art technology at the best return on invest in the market.
For more information, Website: www.faro.com
IPTEX & GRINDEX -Gears & Grinding Technology Expo to be held at Mumbai in March 2016 The twin exhibitions - Iptex & Grindex – 2016, will create a platform for exhibitors to showcase their innovations in Gears, Power transmission, Grinding and Surface finishing technologies, amongothers. The event aims to create a networking forum for exhibitors, visitors and vendors tocome together for enabling the growth of manufacturing industry in India. The Fourth edition of Iptex – 16 and the Second edition of Grindex – 16 will focus on gear engineering and grinding technology. IPTEX- the International
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Power Transmission Expo has emerged as one of the most promising platforms in the gears and power transmission industry. Along with this edition, Grindex – 16 will exclusively focus on grinding and surface finishing technology and showcase the major the developments in the grinding industry. This expo is designed to meet the emerging demand for precision-drivenapplications, as manufacturing industry needs to scale a new high in technology, solutions and applications with an increasing focus on economy
in manufacturing costs and time. The two events will be spread over an area of 7,000 sq. mts, and see participation from over 150 globally brands like, TIMKEN, GLEASON, KLINGELNBERG, SHANTHI GEARS, BONFIGLIOLI, ROSSI, 3M, HITACHI, NIMBLE and REXNORD. Visitors will comprise of corporate decision makers, managers and key members from the relevant industry segment. The latest products will be displayed in all gears transmission products, gear processing equipment, cutting
tools, gear in-spection/testing/ measuring instruments, chain/ belt drives, grinding machines, tool grinding machines, abrasives, software and other finishing products and processes. Both the events expect a shared participation from across the two industries, with a blend of the entire gears and grinding industry. Professionals like technical heads, purchase engineers, product managers, managing directors and entrepreneurs from various industries such as aerospace, aluminium plants, automotive, aeronautical,
BUSINESS NEWS www.mtwmag.com
cement, chemical, coal plants, cooling tower, construction, defence equipment, earth moving, food processing, waste water treatment, grinding mills, heavy transportation, hot/ cold rolling, machine tools, marine, material handling, medical/pharmaceutical, micro assembling, mining, off road vehicles, paper, packaging, petro-chemical, plastic, power
generation, printing, railways, robotics, rubber plants, stamping presses, steel, sugar, surface mining, textile, thermal plants, wind turbine, machine/cutting, to name just a few, will derive excessive business benefit from the expo. During the Expo, a technical seminar –“Modern Technology trends for gears, heat treatment, grinding” will
also be held on March 03rd – 04th 2016. The seminar brings together speakers from well-known national and international companies to share their expertise and latest developments in gears, heat treatment and grinding technology. Visitors will have an opportunity to interact directly with the speakers to enhance their knowledge.
Highlights • Best platform to win new business • Discover how Gears & Grinding industries help to improve manufacturing quality & cost efficiency • Participate and leverage the opportunity For more information, Website: www.iptexpo.com Iwww.grindexpo.in
Shell Lubricants chosen as Tata Hitachi’s lubricant supplier in India Shell Lubricants, the global market share leader in finished lubricants, announced its association with Tata Hitachi as the approved supplier in India. Under this association, seven Shell Lubricants products will be used across the entire Tata Hitachi product range. The announcement was made by Shell Lubricants at Excon 2015 - the 8th International Construction Equipment and Construction Technology Trade Fair organized by CII in Bangalore. Shell Lubricants’ products that have been approved by Tata Hitachi are Shell Tellus S3V 46, Shell Spirax S4 TXM, engine oils like Shell Rimula T3 15W40, Shell Rimula T4 15W40 and Shell Rimula T5 E 10W30, Shell Spirax S2G 90 gear oil and Shell Gadus S2V 220 2 grease. These products help in protecting the meticulously-designed Tata Hitachi machineries and contribute to efficient operation by reducing lubricant consumption and lowering the maintenance
cost. Following this association with Tata Hitachi, Shell Lubricants has further consolidated its presence in the Indian construction sector with product approvals from other leading OEMs including Schwing Stetter, L&T-Komatsu and Putzmeister. Speaking about the partnership, Mr. Nitin Prasad, Managing Director, Shell Lubricants India, said, “We are extremely proud of this association which reflects Shell Lubricants’ strong partnerships in the Indian market. Similar to our other OEM partnerships, our work with Tata Hitachi rides on our inherent philosophy of knowledge-sharing and collaboration. We are excited
to bring this announcement to Excon 2015, an excellent platform for interaction with customers and OEM partners. It provides us an opportunity to strengthen our knowledge base, showcase latest technological offerings and forge long-term partnerships with potential stakeholders.” Shell Lubricants understands that in the construction industry, customers are constantly striving to meet deadlines and lower operating costs. Keeping this in mind, the company has a wide range of lubricants and services designed to make a real difference to the entire operation which ensures reliable lubricant supply for remote projects and increased equipment availability. Commenting on the announcement at Excon 2015, Mr. Akhil Jha, Vice President Technical, Shell Lubricants India, who was present at the event to interact with key customers and OEMs said, “At Shell
Lubricants, we work closely with OEMs and customers to develop products to fit their needs. Construction is among the priority sectors for Shell; hence keeping this in mind, we participate at such forums. The objective is to showcase our technology, products and services which can offer significant value to our customers. With an expected traction of more than 850 exhibitors and 32,000+ business visitors, Excon 2015 is considered to be the largest construction equipment exhibition in South Asia. It is an ideal platform that presents dynamic opportunities for customers, OEMs, manufacturers as well as industry bodies. This year, we bring the news of our association with Tata Hitachi to Excon. Following a series of successful trials that proved our products were an ideal match for its equipment, seven of Shell Lubricants products have been approved by Tata Hitachi to be used across its product range.”
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BUSINESS NEWS
Hypertherm Presents Industrial Cutting Innovations at IMTEX Forming 2016 Hypertherm will once again reinforce its commitment to the India market at IMTEX Forming 2016, held from 21st to 26th January 2016 at the Bangalore International Exhibition Centre in Bangalore, India. In light of the “Make in India” initiative, manufacturing has grown to become one of the main drivers of the Indian economy, and manufacturers are increasingly looking for solutions to boost productivity and ensure sustainability. Visitors to Hypertherm’s showcase will be treated to an array of industrial cutting solutions that are designed to help customers cut more efficiently, effectively, and confidently. Plasma cutting has gained popularity over the years due to the various productivity gains conferred. At IMTEX Forming, manufacturers will also have the opportunity to witness the plasma advantage through live manual and mechanized cutting demonstrations at Hypertherm’s booth.
Powermax30® AIR The main highlight of
Hypertherm’s showcase is the recently launched Powermax30® AIR, the newest addition to Hypertherm’s Powermax family of air plasma cutting systems. Powermax30® AIR is the world’s best in class portable air plasma system that features an internal compressor and is able to operate on both 120- and 240-volt lines, making it a highly versatile system for on-the-go cutting. Weighing just 13.5 kg, the Powermax30 AIR provides 30 amps of output and has the highest power-to-weight ratio of any system in its class. Benefits of this system include high portability with the addition of a patent-pending internal air compressor that eliminates the need for an external compressor unit; greater versatility and convenience with a ‘Plug-andUse’ model that allows the system to be used anywhere with just an electrical power point, even in remote and non-industrial environments; and cost reduction with the elimination of additional costs associated with the use of an external compressor.
About Hypertherm Hypertherm designs and manufactures advanced cutting products for use in a variety of industries such as shipbuilding, manufacturing, and automotive repair. Its product line includes plasma, laser and waterjet cutting systems, in addition to CNC motion and height controls, CAM nesting software, and consumables. Hypertherm systems are trusted for performance and reliability that result in increased productivity and profitability for hundreds of thousands of businesses. The New Hampshire based company’s reputation for cutting innovation dates back nearly 50 years to 1968, with Hypertherm’s invention of water injection plasma cutting. The 100 percent associate owned company, consistently named one of the best places to work in America, has more than 1,300 associates along with operations and partner representation worldwide. For more information, www.hypertherm.com
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BUSINESS NEWS
CIMES 2016 – The 13th China International Machine Tool & Tools Exhibition in June 2016 22 – 26 June 2016, Beijing By Om Prakash, Director – Inorbit Tours Pvt. Ltd., CIMES 2016 is a truly global machine tool trading and sourcing platform hosted in the world’s biggest machine tool market: China. As Asia’s leading machine tool exhibition for metal cutting tools and CNC machine trade, it also showcases the very latest highend metalworking and industrial automation technology. In 2016, CIMES will showcase the world’s top industry giants and international pavilions from key manufacturing countries. In order to maximize the ROI for exhibitors and buyers at this Industrial automation exhibition, the organizers will invite an unprecedented array of VIP buyers from key Asian application industries including aerospace and aviation, medical equipment, shipbuilding and new energy. Accurate product segmentation and highly efficient marketing solutions will allow facilitate the establishment of powerful, direct connections with
matching business partners. • Exhibition Area(sqm):120,000 • Number of Exhibitors:1300 • Supporting Associations & National Pavilions:30 • Number of Visitors:150,000 • Total Turnover (RMS/million): 2840
Exhibit Profile • Machine Tool, Tools and Accessories • Metal cutting machinery • Metal forming machinery • Sheet metal and plate processing machinery • Metal tube and pipe processing machinery • Special purpose machinery • Special purpose machine tool • Cutting tool, fixture, accessories, parts and components • Electrical tools, hydraulic tools, pneumatic devices, • Abrasives, precision measuring technology and devices • Automation and Motion • Flexible manufacturing
technology and equipment • Numerical control systems, embedded systems and servo systems • Industrial robots • Frequency conversion and timing, sensors and motors • Programmable logic controller and related technology • Electronic drives and control systems • Mechanical, hydraulic and pneumonic driven devices • Heat Treatment and Other Technology • Foundry technology and equipment • Forging technology and equipment • Heat treatment technology and equipment • Welding and cutting-off technology and equipment • Other Manufacturing Technology and Equipment • Bearing manufacturing technology and equipment • Gear generating technology and equipment • Mould processing technology
and equipment • Other manufacturing technology for the making of auto parts
Highlights for Int’l Visitors: • Source from 3200 pieces of Equipment and Tools, displayed onsite • Factory Visits • New Robot Pavilion and more than 60 technical seminars and workshops
Special travel package by INORBIT - Official travel agents in India: A special travel package is arranged to visit above trade fair in China. Further details can be obtained from Om Prakash – Director, In ORBIT Tours Pvt. Ltd.
email: omprakash@inorbittours. com
69th Annual General Meeting of Indian Machine Tool Manufacturers’ Association: P.G. Jadeja Elected as New President Indian Machine Tool Manufacturers’ Association (IMTMA) held its 69th Annual General Meeting (AGM) on 10 December 2015 at the
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Bangalore International Exhibition Centre in Bangalore. At the Executive Committee meeting following the AGM, Mr. P.G. Jadeja, Chairman and Managing
Director, Jyoti CNC Automation Ltd. was elected as the President of IMTMA and Mr. P. Ramadas, Managing Director, Ace Manufacturing
Systems Limited as the Vice President of the Association. The new Executive Committee of IMTMA for the year 2015 – 2016 was formed.
BUSINESS NEWS www.mtwmag.com
New chip-breaker offers more choice & accuracy Pramet aims to increase the accuracy of indexable holemaking with the launch of a versatile new chip-breaker. Suitable for machining low carbon and soft stainless steels, the SD geometry supports both Pramet’s SCET and XPET ranges. The SD (soft drilling) chip breaker has been specifically designed to provide improved stability and productivity when drilling low strength soft and long-chipping material, where the balance of forces between the inserts becomes more difficult to maintain. Part of a wider launch of new products announced by Dormer Pramet in November 2015, the chip-breaker’s positive geometry with stabilizer provides reliable chip evacuation, minimal vibration and low cutting forces. This results in a quieter and more stable machining process. The addition means Pramet can offer a greater choice of grades, geometries and designs of inserts for indexable holemaking. Its existing UD (universal drilling) geometry is suitable for machining most medium and high strength steels, while grades D8345, D8330 and D9335 provide a number of options for Pramet’s 800D line of 2D-5D indexable drills. Marcel Nunes, product manager for indexable hole-making at Dormer Pramet, said: “A key requirement for any indexable drilling task is accurate hole-tolerance and straightness. This is best achieved when the cutting forces on the inner and outer inserts are balanced. “However, the cutting conditions for both
inserts are typically very different. The outer insert cuts smoothly at maximum speed, while the inner insert has to work closer to zero cutting speed, shearing rather than cutting and enduring higher impact forces. “When this in-balance gets too large the drill starts to move, deflecting it off course. This results in greater vibration and poor-hole quality, unreliable chip evacuation & reduced tool life. “When machining low strength soft and long-chipping steel and stainless steel the balance of forces becomes even more difficult to maintain. Our new SD chip breaker has been specifically designed to provide better stability and productivity when drilling these materials.”” 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
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COVER STORY
CERATIZIT : Cognitive heritage of cutting tools technology excellence
Mr. A.K. Sareen, Managing Director, CERATIZIT India Pvt. Ltd.
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COVER STORY www.mtwmag.com
Q1. CERATIZIT has gained substantial market share in Indian machine tool industry, please brief its journey from the inception & share some its milestones? For over 90 years, CERATIZIT has been a pioneer in developing exceptional hard material product for cutting tools and wear protection. The family owned company, headquartered in Mamer, Luxembourg, develops and manufactures highly specialized tungsten carbide cutting tools, inserts and rods. The CERATIZIT GROUP is the market leader in several wear part application areas and develops successful new types of hard metal, cermet and ceramic grades used in the wood and stone working industry. CERATIZIT India Pvt. Ltd., the Indian operational hub is ISO 90012008 and OHSAS 18001-2007 certified company with a modern state-of-the-art manufacturing facility, which in terms of technology is at par with CERATIZIT Europe. The company is a leader in segments like automotive, aerospace, energy, transport, bearings, bar peeling, roll machining, die &mould, tube machining, etc. Globally, CERATIZIT was formed in 2002 when CERAMETAL and Plansee Tizit merged; Both companies are pioneers in advanced carbide products. Together, with a history of over 90 years, the two companies have been developing and producing sophisticated hard material cutting and wear protection solutions: from highly specialized cutting tools, indexable inserts and carbide rods to new types of carbide and cermet grades for wood and stone working.
Q2. Please brief us about company’s global reach & what are the global alliances that has been made in order to out-front the competition? CERATIZIT – A passionate pioneer in the hard metal industry With over 5,800 employees at 24
production sites and a sales network of over 50 branch offices worldwide, CERATIZIT is a global player in the hard metal industry. The leader in material technology is continuously investing in research and development and holds over 600 patents. Innovative hard metal solutions from CERATIZIT are used in machine and tool manufacturing and many other applications including automotive, aerospace, oil and gas. The internationally recognized CERATIZIT GROUP unites the four competence brands Cutting Solutions by CERATIZIT, Hard Material Solutions by CERATIZIT, Tool Solutions by CERATIZIT and Toolmaker Solutions by CERATIZIT. The hard metal expert also includes the subsidiaries WNT, Günther Wirth and CB-CERATIZIT, as well as the solid carbide tool manufacturers PROMAX Tools, Klenk and Cobra Carbide India.
Q3. What are the market prospects for the CERATIZIT tools products in India and How do you plan to position these products? When there is a talk of “positioning”, this means the market position held by a company or a product. The positioning is also the basis from which the claim for a brand can be derived. It is important here to know the perception and preferences of the customer. This is because each product must offer the customer (at least) one benefit, so that he will buy it. A good positioning not only explains to the customers which benefits are offered, but also contains unique features. These features are crucial, because they distinguish us from our competitor’s offerings. The Indian market is mainly dominated by the automotive sector, followed by other segments like Aerospace and Energy. After merger of GW India and Cobra Carbide with us, we have positioned ourselves to offer complete
range of tooling solution to the customer who are engaged in manufacturing in different segments. We also provide solution to the tool makers.
Q4. Can you brief us about the marketing strategies that were applied in order to stand out in the competition of carbide tool industry? We offer many products and serve many markets. With such an extensive range of products, it is important to address the individual industries in a targeted manner. For this reason, we have created four “competence Brands” that will be classified under our corporate brand, the CERATIZIT GROUP. As per the relevant skills and competence from the different areas of our business activities are grouped together under the following competence brands: SSCutting solutions by CERATIZIT is concerned with cutting tools that are delivered to an end customer ( e.g. a manufacturer of automotive parts or turbines) SSUnder the name Tool Solutions by CERATIZIT, we offer to develop and produce products for our customer’s own brands. SSToolmaker Solutions by CERATIZIT regroups the competence for wood and stone as well as rods and preforms. With this brand, we primarily offer products for manufacturer who produce tools for the machining of composites, metal, wood and stone. SSHard Material Solutions by CERATIZIT delivers products of wear protection.
Q5. Please elucidate in brief about the CERATIZIT’s infrastructure & what are the measures that are being taken from the product manufacturing to distribution? We develop, produce and market
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COVER STORY
products that are based on the hightechnology materials like tungsten. For more than 90 years, we have produced powder metallurgical products that stand out in terms of their quality and availability – products that have enabled our customers to increase productivity and make major technological advances. Our production technologies cover every step of the value chain. It is our customers who determine how much value addition our products bring. We ensure to remain the preferred partner of our customers by continuously investing in training our employees, about the latest technology, and in increasing our production capacity from powder production through metal recycling. We have grown at a very steady rate over the years and we believe this is just the beginning of our growth story. We have our manufacturing plant in Kolkata where we have been manufacturing tungsten carbide inserts, tool holders, milling cutters and various special tools, which are at par with the global standard. Our round tool manufacturing facility is based with GW India and Cobra Carbide in Bengaluru. Along with our Head Office, which is in Kolkata, our regional sales offices are situated in Gurgaon, Pune, Bangalore and Chennai. We also have our highly experienced team located at all of the major hubs across the country and I can say that we are equipped to provide our customers the best of our services.
Q6. Brief us about the R&D and Quality policy for your business? As a part of R&D, our technical experts tailor made the products to meet the customer need. markets. In order to best serve our different markets, we group our activities into business units. This ensure that we can achieve strong working relationships with all of our customers, while offering them made-tomeasure product solutions. We continue
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this focused customer relationship management during the development and production stages. We follow the quality circle, QC policy and do strict check in every step of manufacturing process to maintain zero defects.
sector is now not available in India and is available only via Multinational Organization. Indian machine tool industries have to come up in terms of accuracy, quality, workmanship and aesthetics to become a global player.
Q7. what are the key technological trends that are driving tool industry?
Q11. How do you perceive the future of the Indian machine tool industry ?
We believe that our continuous effort to offer our customers a wide range of products ( ranging from indexable carbide cutting tool to solid carbide round tools ) is the way to move forward. We are constantly in development of new grades; geometries and coatings for higher parameters during metal cutting operation to achieve long tool life. We have launched many new grades like Silver Star and Black Star which have shown outstanding performance.
Q8. Could you brief us on Indian & Global perspective of tools manufacturing industry? What are the distinguishing factors? All the carbide cutting tool manufacturers are Multi-National Companies as the complicated technique, expertise to produce these products and the raw materials are not available in India, till date.
Q9. Please comment on the current machine tool scenario in India? India is a growing market and the economy is bound to grow. It is also the hub of automotive component manufacturing. So, the requirement for cutting tools will keep on increasing. The demand in last one or two years has been slightly flat but we expect that the demand will grow up based upon the economic growth.
Q10. In your opinion how can the Indian machine tool industry become globally competitive? Manufacturing technology in this
There is a bright future as India is the hub for automotive manufacturing sector and is also keeping in feet for Aerospace. So a lot of opportunities will spring up for manufacturing companies. This will increase the need of cutting tools too.
Q12. How far the factors like government norms, excise duty, taxation, exim policies are affecting carbide tools business? In carbide tool industry, the raw material has to be imported. Duty and tax structure over the years have been improved however if it is streamlined further, it would help the manufacturing sector to flourish further.
Q13. What are the best possible remedies you can advise in order to maintain the high profitability in the shrinking margins market of India? The world is becoming more competitive with lots of new players entering the market. The competition is poised to grow further. We have to keep on innovating new methods and processes to reduce our manufacturing cost and at the same time develop new products which gives the customer maximum return.
Q14. What is your vision for Ceratizit? We are working towards the aim of a preferred one stop solution provider for our valued customers.
IN FOCUS
ROSS Controls: Leadership in Pneumatic Safety
Mr. Jay Dalal Managing Director Ross Controls India Vice President Global Engineering ROSS Controls
Headquartered in Troy, Michigan, ROSS CONTROLS® is an international manufacturer of pneumatic valves, controls systems, and safety products for the fluid power industry. Since being established in 1921, ROSS has always been one of the industry’s strongest leaders in pneumatic valve technology. ROSS’ focus is to continue to be a formidable competitor in key industries where its tailored technology offers customers a distinct value advantage.
Q. Please brief us about company’s Indian & global reach? ROSS Controls has its headquaters in the United States with manufacturing & sales offices located in Germany, United Kingdom, France, Brazil, China, Japan & India. Our Indian facility is located in Chennai with sales engineers in Chennai, Coimbatore, New Delhi, Pune and Kolkata.
Q. Please also highlight the latest initiatives in your industry domain? Safety awareness is the key initiative.
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Business leaders are realizing they cannot afford to have their employees operating in an unsafe work environment. When I talk about safety, it is two things. It is not only protecting employees that are interacting with equipment, it is also protecting the equipment itself from possible damage and things not functioning the way they are designed to work. Some countries are behind others, but even countries new to safety are beginning to understand the importance of safety not only to their people and machines but to the bottom line.
IN FOCUS www.mtwmag.com
Q. What are the market opportunities for your company’s products in India?
Q. What is the top line product range & Is there any plans to launch new products?
The greatest market opportunities are in our focus industries; glass, metals, press and pneumatic safety. Our focus is to drive our poppet and safety technology into these key industries, such as mechanical power presses, hollow glass and steel processing, that value longterm reliability and productivity. The growth in infrastructure investments offers opportunities for our steel and aluminum focus products, while the increase in consumer consumption creates demand for our hollow glass products.
We have many top line product ranges, depending on the industry. One product I would like to highlight is the DM2 valve used on mechanical power press clutch/brake applications. The DM2 is a patented 3/2 normally closed valve distinguished by CrossflowTM passages. This arrangement provides outstanding flow characteristics and an integrated monitoring capability with total memory. The valve provides dynamic monitoring and dynamic memory which is unique in the industry. We are continuously developing new products, for example the Crossflow Size 6 (CF6). The CF6 is also used on mechanical power press clutch/ brake applications but was designed in India for the unique requirements of this market. The valve uses CrossflowTM passages for enhanced flow and offers external monitoring options.
Q. What is future prospect for your industry? India is a growing market for both pneumatic automation and pneumatic safety. With the focus on “Make in India”, industry is beginning to invest in higher level automation and worker safety which bodes well for long term growth opportunities.
Q. Is there any plans for expansion & new investment in terms of product development or new technology adoption to cater the demand of the industry? Yes, our Indian engineering team is developing products for both the local and global markets. We look at certain industries that we think value our expertise and product portfolio. What we want is our field engineers or sales
ROSS Controls India
CF6 PANEL engineers to know as much about the equipment that our product is going on as the customer knows. We want them to look to us on how to handle the pneumatic circuitry on their equipment. Companies have put a great deal of effort into streamlining processes, and people do not have time or experience to think about the pneumatic circuitry of their equipment. In a perfect environment, they look to us to help design their equipment. In certain industries, we certainly have that ability to help them, but we are not trying to be that expert in every industry. We are focused on where we know we can be successful - where productivity is important to a customer and critical to them making money. When that is the case, we have a lot of success.
Q. What is your vision for your company? ROSS Controls will continue to pursue being the full safety solution provider to our customer base along with being the global technology leader in our focus industries. What is great about ROSS is that we are very focused on what we do well - we are the pneumatic leader at providing safety solutions and enhanced productivity for our customers.
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COMPANY PROFILE
“Technology Provider with High Productivity”
Mr. A. V. Srinivasan Chief Executive Officer Meiban Engineering Technologies Pvt. Ltd.
M
eiban Engineering Technologies Pvt. Ltd. An associate company of, M/s. Murata Machinery Limited., Japan a leading manufacturer of CNC machines with high end technology was started in 2004 by A.V. Srinivasan along with Murata Machinery Limited., Japan Meiban Engg has just completed 10 years of operation and has achieved a consistent growth and received accolades from customers, which includes a best supplier award from a multinational company. Meiban Engineering Technologies Pvt. Ltd. is a solution provider in the field of automation and turn key projects for manufacturing
Automobile and Sheet metal components. Meiban Engg serves with Muratec high end automated twin spindle chucker’s for manufacturing automotive components, hydraulic components and bearing components. Meiban Engg supplies and services sheet metal machines which include CNC Servo Turret Punch presses of various capacities, punching and shearing machines, and panel benders. Meiban Engg has customers from various application industries and we have over 300 satisfied customers in a wide spectrum of both SHEET METAL AND AUTOMOTIVE industries. Meiban Engineering Technologies Pvt. Ltd. is based in Bangalore, with a Sales & Service branch office in Chennai, Delhi
and Sales and Service representatives in Mumbai. All our sales & service engineers are factory trained to support the customer with technical and application information. Consists of a 28-member strong team and growing... This includes 10 factory trained Engineers for pre-sales application and after sales service support along with Specialist exclusively to support CAD/ CAM for sheet metal application. Factory trained agent’s engineers are available with our partner to serve our customers better. Muratec Technical Center - Bangalore & Local Turnkey center
Meiban Towers & Muratec Technical Center at Bangalore, Inaugurated by Mr. Yosuke Murata –Executive Vice President. Murata Machinery Ltd., Japan on June 22, 2011
With the addition of technical center in Bangalore, we are now able to do trials and demos on our machines for our potential customers. We have started undertaking local Turnkey in India. Total solution is Turning machine with loader plus peripherals and options to achieve full automation for unmanned operations on 24X7 basis. M-2048TE and MW 100, MW 120 & MW180 have been installed in 2 separate show room spaces. With this new facility, Muratec has launched its five-year plan implementation of supporting Indian customers for greater satisfaction. State-ofthe-art built-in solar panels for common area lighting and rain water harvesting systems installed enhance our contribution to the ecology. For more information, Website: www.meibanengg.com
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COMPANY PROFILE
Effica’s Robotic solutions
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oimbatore-based Effica Automation, incorporated in 2005, is today in the focal business of materials handling automation encompassing machine tending, palletizing and conveying, making the most of robots. Under the stewardship of Mr. Arjun Prakash, President, who is the grandson of late Dr. G.R. Damodaran – a statesman, educationist, humanitarian and founder of the legendary PSG Tech, Effica is eminently poised to take industrial automation in India to subliminal heights. A mechanical engineer from PSG, Mr. Arjun pursued an internship and intensive training and experience in the field of mechatronics. The education and insights he received in mechanical engineering, electronics, robotics, computers and software applications helped him build a strong foundation for Effica Automation which is today in the forefront of integrating robotic systems to enhance operational efficiency, productivity & profitability in Indian industry which is poised to join the big league using robots for automation and manufacturing excellence. Effica started off in 2005 designing and manufacturing special purpose machines (SPMs) for a plethora of applications. It even developed robotized special plasma cutting systems for marking and precision cutting power transmission poles of 60
ft long. Way back in 2009 it executed a project worth Rs. 2 crores in Houston. This was a complex job involving different disciplines – mechanical, electrical, electronics, robotics, machine vision and so on. It involved handling, rotating, holding and cutting of poles where cost of error was very high and forbidden. Present focus
Over the years, the company has changed its focus. Since 2011, to be precise, its focus is on materials handling automation which includes machine tending, palletizing and conveying. The company offers robot based CNC and machine tending systems. These include multiple CNC, forging presses, sheet metal pressing machines and other process machine loading and unloading using robots. It offers conveyors – roller, belt, overhead, slat and special food grade; we provide servo-based 2, 3, 4-axis pick & place systems with flexible gripping solutions for CNC & machine loading and unloading, secondary packing and palletizing systems; and machine vision based picking and intelligent gripping solutions for packing and inspection. It also offers gantry machine tending to replace articulated machine tending projects for payloads from 40 grams to 100 kg. This is an economical solution, and with this the existing plant layout need not be disturbed. It also does bag conveying &
Effica’s state-of-the-art production facility in Coimbatore
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A customized robot engaged in machine tending palletizing automation. This is a robotbased high speed palletizing system with a speed of 20 T per hour. Effica’s automation systems are used by machine tool, forging, plastic injection molding, sheet metal fabrication and FMCG segments. “We have made our systems modular and user-friendly so that in the event of a failure, the user can also fix it. This way we have removed the fear of breakdown and consequent downtime from the mind of the end-user,” reveals Mr. Arun Prakash. Modern facilities
Effica has a sprawling manufacturing facility housed in a land of 10,000 sq. mtrs. It has an in-house Machine shop, Assembly shop, Design & Dev. Dept., Quality Control section and so on. The Controls Dept. has multiple robots and PLCs. The company has a dedicated workforce of 35 people. Marketing is done directly. However, it has channel partners in strategic locations like Coimbatore, Chennai and Bangalore to extend its reach to the customer. Automobile industry and automobile ancillaries are its major customers. Its growing client list includes some big names like Ford, Nissan, L&T, LGB, LMW, Saint-Gobain, Amara Raja, Pricol, Roots, etc. Effica is highly customer-centric in its operations. “When we offer tailor-made solutions, we go beyond the call of duty to satisfy the customer and entail him the benefits of flexibility, efficiency, safety, savings and quicker ROI,” states Mr. Arun Prakash.
CASE STUDY
HAAS: The strong & silent type
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ven if you’re a big fan of highperformance cars and motorsport, chances are you have never heard of wheel manufacturer and Haas customer 2Elle Engineering, based a stone’s throw from Venice, Italy. “Our customers are big name companies,” says 2Elle founder and owner Luigi Lucaora. “For example: BMW, Mercedes, Audi, German tuning house Brabus, and several race teams in different categories, from F1 to Paris Dakar. But, you won’t see the ‘two L’ name on any of our products. We like to keep our brand below the radar, so we can work for all the big marques without compromise. We supply some of the best high-performance wheels in the world, and almost no one except the customer knows they come from here.” Mr. Lucaora is at pains to stress that despite its low profile, 2Elle is much more than a busy CNC machine shop. “I spent eighteen years as an engineer in the industry,” he says, “so first and foremost, we develop new materials, new technology – such as hybrids, and lighter, stronger wheel designs for the fastest cars in the world.” Before the company moved to its current premises in 2008, 2Elle didn’t make anything in-house. “We only did the engineering, development, and quality control,” explains Mr. Lucaora. “We subcontracted machining for 2 years, and then, when we invested in our first CNC machine tools, we decided immediately to start up with Haas CNC machines. Our subcontractor already used them and we’d
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heard many good things. We bought three Haas CNC lathes – two ST 40s, an ST-30, and a Haas vertical machining center, a VM-6.” So, choice of machine tools aside, how does a company like 2Elle – an engineering start-up in a very competitive global niche – get a foothold and thrive in the midst of one of the most severe financial and economic crises in history? “It was one particular order that really kick-started the company,” Mr. Lucaora reveals. “An important German tuning company offered me a large contract if I promised to meet certain delivery criteria. I went to the bank with their letter of intent, and that was enough of a business plan for them to lend us the money to move to this new factory. Since then, we have grown at least twenty percent each year. Last year, we managed forty percent! In just 7 years, we’ve come from nothing
CASE STUDY www.mtwmag.com
to a turnover of around five million Euros!” The 2Elle factory may appear cavernous, but the empty space soon will be filled, as deliveries of blank wheels arrive from the company’s forging supplier in the U.S. “We receive three or four shipping containers every month. In total, we currently produce between 1000 and 1200 finished units a month.” When it comes to developing new designs and new materials, Mr. Lucaora’s technical background and experience enables the company to compete with the very best wheel manufacturers. “We do a lot of laboratory tests and comparison tests,” he says. “We also look at how much the tyre and wheel can be distressed when we do finite element analysis, and we also fit tyres to the wheels and do practical tests to understand better how the wheel will behave in real-life.” The company’s Haas VM-6 operates for at least two and a half shifts a day, mostly manned. “During the day, we load the machine with just one wheel at a time,” says Mr. Lucaora. “But, at 10 p.m., we load two wheels and set the machine working overnight, ’til 4 a.m. The next shift comes in & unloads the parts at 6 a.m.” The Haas VM-6 is a 40-taper mouldmaking machine with 12,000-rpm spindle and travels of 1626 x 813 x 762 mm. The Haas-built 12,000-rpm inline directdrive spindle, combined with the Haas high-speed control with full look-ahead,
provides the accuracy and fine surface finishes mould makers and other highprecision industries demand. “The shapes we’re machining are similar to moulds, so the VM-6’s highspeed spindle and feeds are perfect,” says Mr Lucaora. “The table is T-slotted in X and Y, which makes it easy to secure our parts. We’re also buying a smaller Haas VM-3 mould-making machine, for some new hybrid wheel projects we’re working on. These wheels will be made using alloy hubs coupled to carbon fibre rims, so the engineering and machining challenges will be interesting.” With his growing fleet, Mr. Lucaora has also noticed a few other advantages that come with investing in Haas CNC machine tools. “The machines are very easy for the operators to programme and use,”
he says. “This is important. They have to work on different machines, so they need to be comfortable with the control. “Not only are the Haas machines easy to use, but we have also noticed that, in comparison with other machines – and we have several types in our factory – the service and support are far superior. The Haas Factory Outlet in Milan, operated by Celeada, supplies the machines, and both the commercial and also the technical service are extremely quick and efficient. I can’t afford for any of the machines to stop for any reason. We have a full order book for the next year, so if I stop one or two machines for a month, it is a nightmare!” Mr. Lucaora makes regular trips to the company’s forgings supplier, in the U.S. “I was there on a visit when it was Haas’ 30year anniversary celebration,” he says, “so I dropped by the factory and had a guided tour of the facility. I was very impressed with the company’s organisation and quality. They use hundreds of their own machines to make new Haas machines, in a very high-volume production environment.” If your plan is to supply the world’s best high-performance automotive companies, knowing your CNC machine tools are up to the job is essential. “I think the fact that Haas use their own machines says a lot about their belief in the product.” For more information, Website: www.HaasCNC.com
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CASE STUDY
Digital innovation for a clean future – emissions monitoring in vehicles
Rinspeed’s “Etos” concept cardeploys HARTING MICA
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ARTING IIC MICA from HARTING is a modular platform comprising openhardware and software components whichcan be adapted quickly and cost-effectively to many industrial areas of application. The Swiss automotive manufacturer Rinspeed is now also deploying HARTING IIC MICA. Rinspeed’s “Etos”concept car is fitted with HARTING IIC MICAfor independent emissions and status monitoring. This digital innovation therefore aimsto ensure a clean future. The intelligent mini-industrial-computer MICA manufactured by the industrial connectivity specialist HARTING illustrates how drive and engine data can be continually recorded and transmitted and then evaluated and processed by an independent, neutral body (Dekra),as agreed beforehand by the customer and contracting partner. It also allows statements on the credibility of mileage status to be made. “MICA can be quickly and easily integrated into a wide range of vehicles. Its installation in the Etos is an excellent example of this,”remarked Dr. Jan Regtmeier, Director of Product Management at HARTING IT Software
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The HARTING IIC MICA is being installed in Rinspeed’s “Etos” concept car for independent emissions and status monitoring. Development. The MICA will embark on a roadshow over the coming weeks and will be on display at the CES in Las Vegas (5 to8 January 2016), the Hannover Messe Preview (27 January 2016), the Geneva Motor Show (3 to13March 2016) and the Hannover Messe (25to 29 April 2016).
checkout zones, components for electric mobility as well as hardware and software for customers and applications in the fields of automation technology, robotics and transportation amongst others. Around 4,200 employees generated revenues of € 567 million in 2014/15.
About HARTING:
The HARTING Technology Group is a leading global supplier of industrial connection technology for the three lifelines of power, signal and data with 13 production sites and subsidiaries in 43 countries. The company also produces
For more information, Website: www.HARTING.com
CASE STUDY
World’s most powerful all-electric pipe bending machine swings into action at Norwegian shipyard Handles precision bending of 10-inch diameter thick-walled carbon steel pipes!
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nison has installed and commissioned the world’s largest and most powerful allelectric pipe bending machine, at the Norwegian offshore and maritime services company, Westcon Yard AS. Capable of generating a colossal 660,000 Nm of continuous, servo-controlled torque, the custom-designed machine will be used for precision bending of thick-walled carbon steel pipes up to 10 inches (273 mm) in diameter. This is the second all-electric pipe bender that Unison has supplied to Westcon’s pipe production facilities in Ølensvåg, Norway. The first, a 90 mm single-stack model from Unison’s Breeze range, was installed at the beginning of 2015 and enabled the company to bring fabrication of all pipe sizes up to 60.3 mm in diameter in-house. It has also helped Westcon to simplify and accelerate its production process dramatically, by allowing parts to be fabricated from single-piece piping stock, instead of from multiple cut-tolength straight sections and pre-formed bend parts bought-in from external suppliers. Westcon has similarly high expectations for its new 10-inch machine. The company now intends producing virtually all the pipe sizes that it needs for its outfitting, service and repair operations entirely in-house, without having to use pre-fabricated bend sections. This application of all-electric bending technology to pipes up to 10 inches in diameter is without precedent. Although
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The engineering workshop’s new automatic materials handling system features 9-metre high pipe storage racks and robotic feeders. Unison’s bending machines are used by a number of the world’s leading ship and submarine builders to produce large pipe and tube assemblies, this is by far the most powerful that the company has ever designed and built. It highlights the inherent scalability of Unison’s machine architecture and underlying motion control technology – the company’s range of all-electric bending machines now extends all the way from 16 mm (5/8 inch) to 273 mm (10 inches). The order for both pipe bending machines, which also called for Unison to supply CAD support software, was placed through P Meidell AS, the specialist machine tool company that acts as Unison’s representative in Norway. Westcon specialises in building and repairing ships for the offshore and fishing sectors, and in servicing, maintaining and repairing
CASE STUDY www.mtwmag.com
semi-submersible and jack-up rigs used by the offshore oil and gas industries. It operates four shipyards in Norway, with its headquarters and pipe production operations forming part of a modern and well-equipped yard near Ølensvåg. This enjoys a unique sheltered position on the Ølensfjord with deepwater access to the North Sea. The yard’s facilities include two floating docks, deepwater quays for three drilling rigs and a number of high payload cranes. In recent years, Westcon has invested heavily in its pipe fabrication operations for ship and rig outfitting, with the intention of becoming a world leader in this industry. The Ølensvåg site now has a large 3,650 square metre purpose-built engineering workshop, with more than 1,500 square metres allocated to pipe production. The new facilities include a fully automated materials handling system – based on 9-metre high pipe storage racks and robotic feeders – together with an automatic pipe cutting machine and the two Unison CNC-controlled all-electric tube benders. Most of the pipes that Westcon produces are one-off items for new systems, rerouting and maintenance purposes. They are typically manufactured from carbon steel,
Tommy Nilsen (centre, blue hardhat), Head of Prefabrication at Westcon’s Ølensvåg facility, believes that the Unison 10-inch pipe bender provides a major competitive advantage.
Steffen Feder of Westcon Yard shows the type of pipes that can be bent on the new Unison machine. with each pipe spool normally being up to 6 metres in length. The pipes usually form part of fresh or sea water systems, hydraulic systems, diesel fuel distribution networks or other special systems. They often involve very tight radius bends, to as little as 1.5 times outside diameter, and need to be constructed to millimetre accuracy. Until about six months ago, Westcon fabricated all pipes in sectional form, using multiple cut-to-length straight sections and bought-in preformed bend parts. The individual sections, bends and end connection flanges were then welded together to create the final assembly – with each weld requiring cleaning, inspection and non-destructive X-ray testing. This was an expensive and time-consuming process that was also heavily reliant on outside suppliers meeting tight delivery schedules. Rapid turnaround time is critical for repair organisations like Westcon, where the out-of-service costs of ships and rigs can be astronomical. Following delivery of its first Unison bending machine, Westcon has produced all pipes up to 60.3 mm in diameter in-house, from straight piping stock. This has eliminated the need to buy-in preformed bend parts for these pipe sizes, and reduced the number of cutting, welding and testing operations needed for each assembly substantially. The pipes are currently cut slightly over-length before bending, to allow for any changes introduced by the process.
After bending, they are re-measured, cut to final length and welded to the necessary flanges. The company intends further improving the process by cutting the pipes to length prior to bending, as its expertise develops. As Tommy Nilsen, Head of Prefabrication at Westcon’s Ølensvåg facility, explains, “We have only been using our first Unison machine extensively for a few months and are still on a learning curve. Despite this, we are already achieving superb bend accuracy and repeatability with good throughput – and we are confident of increasing this even further when we change the process sequence. In fact, based on our experience so far, now that the larger bending machine is in place, we expect to substantially reduce production times for all pipe sizes. It’s like going from 1930 to 2016 in one stride! We are now effectively a year ahead of the rest of the world in terms of our pipe fabrication capabilities.” Unison all-electric pipe bending machines feature servomotor-driven motion axes and fully automated software-controlled setup. Simplicity of operation and the fact that Unison was prepared to develop custom pipe bending solutions were two of the key reasons behind Westcon’s original order. Both the 90 mm and the 273 mm machines are fitted with Unison’s innovative laser springback system, which automatically measures and adjusts bend angles to compensate for
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CASE STUDY Nordic countries offers significant growth potential. “Norway, Finland, Sweden and Denmark all have major shipbuilding interests, which nowadays have to compete with lower labour cost manufacturers in Asia. Automation like Unison’s all-electric tube and pipe bending machines can help companies to meet the challenge of these competitive trading conditions, by significantly improving the efficiency of their production operations.” About Unison
This 273 mm Unison all-electric bending machine – the world’s most powerful – was installed at Westcon Yard’s Ølensvåg facility in November 2015. the tendency of tubular parts to spring back slightly after being bent. The machines also both feature quick-change tooling, which is a major advantage for applications that involve bespoke, oneoff manufacturing. The Unison machines’ unique mechanical design, combined with the precision axis control capabilities of Unison’s Unibend software – especially with respect to carriage and pressure die boost – makes it easier to achieve very accurate and repeatable results, with minimal changes to the wall thickness or ovality of the pipe that is being bent. These attributes are ideal for manufacturers of marine, offshore and subsea equipment, who invariably need to work to tight tolerances and strict process guidelines. The material storage/retrieval system, pipe cutting and bending machines at the Ølensvåg facility are fully networked. The engineering department creates the necessary machine control programs from customer-supplied drawings or CAD files, or from data derived directly from a physical pipe using a laser-based coordinate measuring machine (CMM). To help simplify the process, Unison has also supplied Westcon with Advanced Tubular Technologies’ powerful VTube software. This generates production-
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ready programs for tube and pipe benders direct from CAD data, and also translates CMM data for reverse engineering purposes. Alan Pickering of Unison underlines the significance of the Westcon application, “Our all-electric tube and pipe bending technology is starting to make major inroads into territory that was once regarded as the sole preserve of hydraulic benders. This has huge implications – and not just for marine vessel and offshore rig outfitting and repair organisations, though these are currently driving the take-up of our larger bending machines. Industries such as nuclear and fossil-fuel power generation, oil and gas refining, and chemical processing also make extensive use of large diameter precision-bent pipes. Accurate and repeatable bending – especially if it involves expensive corrosion resistant alloys – are as important to these industries as any other. Last year, the largest machine that we produced was capable of bending 9-inch diameter tubes and pipes. This year it’s 10 inches. We are now entering the domain of process pipe-work, which is an entirely new market.” Bjørn Garvik, Sales Manager at the Bergen office of P. Meidell AS, Unison’s sales support partner in Norway, adds that the machine tool market in
Unison started in business by developing control systems for metalworking machinery – supplying a number of prominent UK machine manufacturers in the 1970s and 1980s. In 1991 the company moved into machinery design, focusing on machines for tube bending. At that time, tube bending machines were powered hydraulically. In the early 1990s Unison invented a range of machines employing electrical servo-motors for controlling bending motion. These were the world’s first ‘all-electric’ machines for tube bending. The performance of Unison’s new machine design – with its fast and repeatable software-controlled set-up, right-first-time action, low power consumption, and quiet and clean operation – was an instant success. The company has progressively led the tube bending machinery industry by increasing the tubing diameters that can be formed using all-electric motion and is now one of the world’s leading manufacturers of tube and pipe bending machines and associated software. In 2014, Unison took another quantum leap in tube bending machine performance by developing a servomotor-powered machine architecture that is capable of bending thick-walled piping with diameters of 10 inches/273 mm and more. The company opened its own direct support centre in North America in 2015. For more information, Website: www.unisonltd.com
CASE STUDY
Laser factory GmbH Picosecond laser for carbides and ceramics
Michael Köppel and Björn Büchel established Laser factory GmbH in Rebstein, Switzerland, in 2002. The company has become firmly established in the area of precision laser removal within just a few years.
Laser factory uses state-of-the-art LASERTEC machines from DMG MORI in the manufacture of complex & filigree 3D moulds for tool & mould construction.
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stablished in 2002 in Rebstein, Switzerland, Laser factory GmbH has become firmly established in the area of precision laser removal within just a few years. The innovative service provider now manufactures complex and filigree 3D moulds for customers in the clock industry, the automotive industry and the tool and mould construction industry using injection moulding and stamping in two locations on a total of ten LASERTECH 40 Shape machines from DMG MORI. The laser sources that are available in manufacturing consist of lamp-pulsed and diode-pulsed lasers, fibre-guided lasers and picosecond lasers, meaning that an extremely wide range of materials can be economically machined, including carbides and ceramics. With many years of experience in tool construction and cold forming, Björn
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Büchel and Michael Köppel recognised the potential of laser removal at an early stage. With the aid of modern laser technology, the Laser factory founders were in a position to manufacture sophisticated 3D moulds economically and with high precision, even in small quantities. “In those days we were one of the first companies on the market to manufacture in this way”, recalls Michael Köppel. This gave the company a head start in knowledge that Laser factory is continuing to maintain. Björn Büchel adds: “As technology advances, our processes are also being continuously optimised, meaning that our performance spectrum is in a continuous state of development”. The special thing about the performance spectrum at Laser factory is the wide range of products. “Laser removal is mainly used for in-house manufacture in bigger companies, where the number of
CASE STUDY www.mtwmag.com
applications is usually limited”, explains Björn Büchel. However, as a service provider you have to meet new challenges all of the time. He refers to the wide range of materials and complexity of the 3D moulds. “Because of the laser technology, we can work in an extremely economical and customer-oriented way”. The advantages of laser removal as compared to conventional manufacturing procedures such as vertical eroding are obvious: Even the most complex moulds are generated directly on the basis of 3D data, without having to carry out complicated and expensive electrode manufacture as an intermediate step. Laser factory is therefore already operating profitably from batch sizes of 1. The moulds are also easy to reproduce. “This means that throughput times and development times can be reduced considerably”, says Michael Köppel. Many customers send in 3D data in the morning and pick up the finished mould in the evening. Performance spectrum increased thanks to picosecond lasers
The further development of laser technology has led to a situation whereby Laser factory has been able to continuously increase the quality of its 3D moulds. Contours become finer, walls become steeper and the quality of surfaces improves. With the modern picosecond laser, even carbides and ceramics can be efficiently machined with maximum precision, unlike the situation in conventional manufacturing.
Since 2012, Laser factory has been machining sophisticated components with a picosecond laser, which DMG MORI uses in the LASERTEC 40 Shape. Michael Köppel regards this as a major bonus for customers: “Carbide tools have a significantly longer service life during stamping and embossing”. The surface quality of Ra 0.15 to 0.20 is also so high that the amount of polishing can be minimised by up to 70 percent. Laser factory has been using the picosecond laser since 2012. Björn Büchel reflects: “The innovative laser source has opened up new possibilities to us, but also gave us some major challenges in the beginning”. Suddenly, additional parameters had to be taken into consideration in the manufacturing process. Because as well as current intensity, frequency, speed, tracking offset and layer removal, in this case the focus also has to be adjusted by means of a height adjustment in order to monitor the high intensity of the picosecond laser. In the beginning, it was also necessary to suppress the initial pulse in order to avoid
Laser machining of deep 3D contours in carbide using a picosecond laser.
removing too much material. “You are treading a fine line when the amount that you are removing is just 1/10,000 mm”, adds Michael Köppel. Laser factory has long since overcome the initial challenges of the picosecond laser. “With the aid of LASERSOFT 3D we can work extremely comfortably and achieve optimum manufacturing results”, says Björn Büchel about the software developed by DMG MORI. This also applies to the control of the laser. “Thanks to 6-axis technology, vertical walls can also be created using the LASERTEC 40 Shape”. Overall, Michael Köppel regards the use of the picosecond laser as a major step in the development of the business: “We have managed to win back many customers, because carbide machining using laser removal has considerable advantages”. As in previous years, Laser factory will continue to grow together with the laser technology, and meet new challenges. The two managing directors would also like to extend the performance spectrum, if technical progress permits it. For example, Björn Büchel and Michael Köppel are pinning their hopes on laser structuring, which DMG MORI already uses successfully on larger machines: “Even if the technology works on a small scale, it could result in more applications that are interesting to us”. For more information, Website: www.dmgmori.com
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CASE STUDY
Innovation with additive manufacturing strategy: printing is “Ready to Fly”
3D
Industry needs guiding beacons. People and projects act as models for innovations which symbolize change and modifications. Frank Herzog, founder and President & CEO of the machinery and plant manufacturer Concept Laser, was recognized as part of the prize ceremony for the “German Future Prize 2015” together with his two project partners as being among the “group of the best.”The official ceremony for all three nominated teams was held on December 2 in Berlin in the presence of thePresident of the Federal Republic of Germany Joachim Gauck.A permanent exhibition at the German Museum in Munich will showcase the projects of the nominated teams. Frank Herzog, President & CEO of Concept Laser
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T
he project team, consisting of Peter Sander, Head of Emerging Technologies & Concepts at Airbus, Hamburg, Prof. Dr.Ing. Claus Emmelmann, CEO of Laser Zentrum Nord GmbH, Hamburg,and Frank Herzog, founder and President & CEO of Concept Laser GmbH, were included among the “group of the best” with their project entitled “3D Printing in Civil Aircraft Manufacturing - a Production Revolution is Taking Off.” Frank Herzog: “Belonging to the ‘group of the best’ is a great honor for our team and for me personally. Even though we
would have dearly loved to have won the ‘German Future Prize 2015,’ being affiliated with the “group of the best” is an exceptional honor, in particular also recognizing the hard work of my dedicated employees. In addition, the high-profile nomination has resulted in a further boost to the profile of our company Concept Laser.” 3D lightweight construction in the aviation industry honored as being “among the best”
The project entitled“3-D printing in commercial aircraft engineering – a
CASE STUDY www.mtwmag.com
manufacturing revolution is taking off”persuaded the jury for the German Future Prize 2015 in respect of its level of innovation and commercial application. The project is in essence about the first, additively manufactured titanium component, known as a “bracket,” on board the Airbus A350 XWB. This is a “bionic” retaining and connecting element which is regarded as making a vital contribution to the lightweight construction of aircraft. The team made 3D printing “ready to fly.” Background information on Frank Herzog and the LaserCUSING process
Success by means of pioneering spirit Frank Herzog is regarded as a pioneer in the field of powder bed-based laser melting. The existing plastic sintering technology led to development of the LaserCUSING method in 1998. During his studies Frank Herzog thought that what worked with plastics should also work with metals. Part stress and the failure of metal powder to fuse completely were initially the greatest challenges in the process development. However, these problems were overcome by the hard work put into the development of stochastic exposure and the application of a solid-state laser. This pioneering work resulted in the
founding of the company Concept Laser in the year 2000, which presented its M3 linear prototype machine to the public at the Euromold in Frankfurt in 2001 and, in this way, celebrated its world premiere in the field of industrial 3D metal printing. Concept Laser, which is situated in Lichtenfels in Upper Franconia, were able to supply the first systems worldwide only a year later. Once an exotic outsider, this additive manufacturing strategy has taken over a wide variety of industrial fields and applications over the years.Over 400 systems installed worldwide speak for themselves. And 15 years of Concept Laser also means 15 years of successful process development with numerous innovations and patents. For example, the company now has its own research and development department with over 50 employees. Furthermore, Concept Laser GmbH is involved in numerous research and development partnerships with universities, technological and scientific institutes and industrial companies. And the company is also the owner of more than 50 granted patents. Concept Laser GmbH has currently approximately 100 pending patent applications and a majority of them will be granted in the near future. The number of inventions
applied for patents by the company has been steadily growing. Concept Laser’s 15th anniversary in 2015 is a brilliant performance – and it has the figures to prove it. The growth of + 75 % in 2014 is being consolidated by Concept Laser at a high standard. For example, a total of 110 laser melting systems were delivered in the year 2014. This figure is to rise to 150 systems in 2015. This means growth in sales of + 35% is expected compared to the previous already very successful year. The LaserCUSING process The term LaserCUSING, composed of the C from CONCEPT Laser and the English word FUSING (to fully melt), describes the technology. The fusing process uses 3D CAD data to generate components layer by layer. This process allows the production of complex component geometries without tools in order to implement geometries as components that are difficult or even impossible to achieve with conventional manufacturing methods. The LaserCUSING process is used to create mechanically and thermally stable metallic components with high precision. Depending on the application, it can be used with stainless and tool steels, aluminum and titanium alloys, nickelbased superalloys, cobalt-chromium alloys or precious metals such as gold or silver alloys. With LaserCUSING, finely pulverized metal is fused using a high-energy fiber laser. The material is solidified after cooling. The component contour is created by directing the laser beam by means of a mirror deflection unit (scanner). The component is constructed layer by layer (with each layer measuring 15-150 μm) by lowering the bottom surface of the build space and then applying and fusing more powder. Concept Laser systems stand out due to their stochastic control of the slice segments (also referred to as “islands”), which are processed successively. The patented process significantly reduces tension during the manufacture of very large components.
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CASE STUDY resource conservation with simultaneous improvements to the cost structure.
General aspects of an additive manufacturing strategy Numerous options for lightweight construction and an increase in the performance of components are opened up by an additive manufacturing strategy. Key words include: functional integration, lightweight construction potential, bionics and topology, conservation of resources, waste reduction, geometrical freedom, single shot production, reduction of assembly work, timely production, also “on-demand” and improvement of the cost structure, e.g. by unmanned manufacturing 24 hours a day. The laser melting process has been made first choice in numerous sectors in relation to conventional machining strategies by the current challenges posed by manufacturing. According to manufacturing experts, automation, quality, a wide range of materials, integration in the production environment and potential build speeds are essential characteristics of additive manufacturing in the digital era. Additive manufacturing in a digital process chain is consistently based, not least, on the “Industry 4.0” strategy. Background information on the importance of laser melting for the aircraft industry
Significance of laser melting to aircraft construction Laser melting with metals is gaining in significance in aircraft construction as part of an additive manufacturing strategy. Here too, the typical reasons
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for the selected process are quicker throughput times, more cost-effective components and previously unknown freedom of design. Two new key words, “lightweight” and “bionics” point to an emerging trend: The design approaches of developers in aircraft construction are changed by an additive process. In terms of aircraft design, future components will be able to absorb specific lines of force and yet still be able to fulfill the demands of a lightweight construction approach. In general, laser melting technology is capable of manufacturing safety-related components that are even better, lighter and more durable than conventional components manufactured today. Moreover, the material properties are slightly different. Prof. Dr.-Ing. Claus Emmelmann, CEO, Laser Zentrum Nord GmbH, Hamburg: “Materials produced using laser additive manufacturing have greater rigidity while, at the same time, less ductility; however this can be enhanced with the right heat treatment.” Furthermore, the process is distinguished by sustainability and
Geometrical freedom and lightweight construction potentials as driving factors The arguments for the laser melting of metals in aircraft construction are geometric freedom and weight reduction. The “lightweight construction” approach is intended to help airlines operate their aircraft more economically. The achievable weight reduction results in a tendency towards lower fuel consumption or the potential to increase load capacities of aircraft. A new aircraft design requires thousands of flight test installation (FTI) brackets, produced in very small quantities. Additive “layer manufacturing” allows designers to come up with new structures. The additively manufactured components are in fact more than 30 % lighter than conventional cast or milled parts. In addition, the CAD data are the direct basis for an additive build job. The omission of tools reduces the costs and shortens the time until the component is available for use by up to 75 %. Since tools are not required in the process, it is now possible at an early stage to produce functional samples of components that are similar to series produced components. This is done without upfront costs for tools. This means that sources of error can be identified in the early stages of the design process in order to optimize the processes within the project. Peter Sander, Head of Emerging Technologies & Concepts, Airbus, Hamburg: “Previously we budgeted around six months to develop a component – now, it’s down to one month.” Bionics in the component or product design Laser melting with metals allows extremely fine, even bone-like, i.e. porous structures to be produced. “Future aircraft components will therefore have a “bionic” look“ is what Peter Sander expects. It is not without reason that over millions of years nature has produced optimized functional and lightweight construction principles which minimize the amount of
CASE STUDY www.mtwmag.com
resources required in a clever way. Airbus is currently analyzing solutions found in nature in a structured manner with regard to their applicability. By relying on “intelligent exposure strategies” of the laser, it can apply layers to a component in a strategic manner in order to produce custom properties in terms of structure, rigidity and surface quality. Peter Sander: “Initial prototypes indicate great potential of a bionically motivated approach. The process is expected to launch something of a paradigm shift in design and production.” Quality as a significant parameter For aircraft manufacturers, monitoring during the component’s build process is one of the most important aspects of the industrial application. Peter Sander: “In practice, “inline process monitoring” with the QMmeltpool QM module from Concept Laser means the system uses a camera and photo diode to monitor the process within a very small area of 1x1 mm². The process is then documented.” In 2016 this module will be extended by QMmeltpool 3D. The former, timerelated 2D monitoring of the build process becomes a position-related 3D landscape. Instead of exclusively time-related data, the system now additionally delivers position-related signals for definitive allocation, comparable to a computer tomography (CT). These signals make it possible to generate 3D datasets of the
part and its structure. A highly accurate 3D landscape of the component is thus created. This allows QMmeltpool 3D to provide local indication of defects in the component. As a result, subsequent inspections and tests can be reduced to a minimum. Furthermore, the data are available directly after the build process, which also saves time. Other QM modules for active quality assurance are QMcoating, QMatmosphere, QMpowder and QMlaser. They measure or monitor, for example, the laser output and also the optimum layer structure of the metal powder and document the entire manufacturing process seamlessly. An additional feature in terms of quality assurance is the capability to work in a closed system to ensure the process remains free of dust and contamination. All disruptive influences that could have a negative influence on the process are intended to be eliminated this way. Frank Herzog: “These days it’s accurate to call this a regulated manufacturing process that provides repetition accuracy and process reliability.” Prof. Dr.-Ing. Emmelmann emphasizes by saying: “The QA software now enables us to monitor and document key data, such as laser parameters, melt pool parameters, as well as the composition of the inert gas atmosphere. Disruptions due to contamination can be eliminated.”Concept Laser can call itself a pioneer in this field too, since the company has been working on different quality
improvement/monitoring modules since 2004. “Green technology” conserves resources Milling of aircraft parts results in up to 95% recyclable waste. With laser melting, the user receives components with “nearfinal contours,” and the process produces only about 5 % waste. “In aircraft manufacturing, we work with the “buy to fly ratio”, and 90 % is a fantastic figure. This is, of course, also reflected by the energy balance”, according to Prof. Dr.-Ing. Claus Emmelmann. This makes the process especially attractive when using valuable and expensive aircraft materials, such as titanium. A tool-less manufacturing strategy saves time and improves the cost structure. Targeted energy consumption and conservation of resources are features of the laser melting process. Frank Herzog: “LaserCUSING is a green technology and improves the often discussed environmental footprint of production.” Spare parts supply 2.0: Timely, decentralized and “on demand” Spare parts constitute a new playing field for “additive aeronauts”. In future it will be possible to manufacture them “on demand” at decentralized locations without the need for tools. In the event of a component failure, the spare part can be produced directly on site. Decentralized production networks can be created and global and regional strategies are possible. This minimizes transport distances and, above all, delivery times. As a consequence, maintenance-related downtimes and inspection times for aircraft are reduced. In future it will be possible to significantly reduce the large spare parts depots with parts rarely used that are currently essential given the long life cycles of today’s aircraft. A reduced capital commitment increases flexibility and especially the time needed to obtain safety-related components. This is especially attractive given the cost pressure in the aviation industry. For more information, Website: www.concept-laser.de
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TECH UPDATE
RAMPF highlights expertise for gasketing on metal surfaces IMTEX Forming 2016: Dispensing robot C-DR for cost effective automatic gasketing and dispensing of 2K PU-materials
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IPFG (Formed-In-Place-FoamGasket) systems stand for the cost-effective and easy automation of industrial manufacturing processes. The technology involves the application of a gasket directly to the workpiece using a two-component mixing and dispensing machine. Thequick-drying gasket reacts within a couple of minutes and facilitates quick joining and assemblies. FIPFG can be used for gaskets of practically any shape or form, and on a number of different surfaces – including metal. C-DR – cost effective entry into automatic gasketing and dispensing
“FIPFG seals and the associated automation are an unbeatablealternative to inlaid seals, as they provide an effective cost saving potential and guarantee the high-quality sealing of componentsin the metal forming industry,” emphasizes
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Hartmut Storz, Director of Sales & Marketing at RAMPF Production Systems. “Our compact and flexible dispensing robot C-DRoffers a cost effective entry into automaticgasketing and dispensing of 2K PU materials.” The C-DRrobot is characterized by a compact and integrated design and can be easily operated via graphical color touch screen with user-guided IPC controller. The integrated RAMPF dispensing equipment with servo-driven gear pumps and servo-driven dynamic mixer as well as the nucleation controller ensure a reliable high-quality production. Flow rate, mixing ratio (from 100:100 – 100:10), and processing parameters can be freely adjusted. DR-CNC – maximum flexibility for dynamic sealing, bonding, and casting
With more than 2,700 system solutions on the market, the product portfolioof RAMPF Production Systems ranges from the C-DR to the highly complex dispensing robot DR-CNC. With its separate material conditioning unit, the DR-CNC offers maximum flexibility for dynamic sealing, bonding, and casting. Variable X-Y-Z strokes also enable threedimensional material application. The Sinumerik 840D Solution Line control technology with OP08 operating panel means the DR-CNC combines the mixing and dispensing system with maintenance-free CNC linear axes. The result is flawless interplay between the dispensing process and axis motion sequences. Flexible automation solutions are also possible, from manual through to automatic part loading. There are a number of additional fit-out options, including rotary index tables, shuttle tables, conveyor lines, and customized automation.
TECH UPDATE www.mtwmag.com
Chemical and engineering competence from RAMPF
© FeinBlechSysteme Lentz GmbH
RAMPF Production Systems, a leading provider of systems for processing one-, two-, and multi-component reaction resin systems, as well as automation solutions, is presenting its expert knowledge for gasketing on metal surfaces at IMTEX Forming 2016 – hall 2A, booth B107. The focus of the trade fair for the Indian metal forming industry at Bangalore International Exhibition Centre will be the dispensing robot C-DR.
The international RAMPF Group based in Germany offers customers material and machine from a single source. Whilst RAMPF Production Systems offers customers dispensing machines and automation for PU gasketing on metal parts, sister company RAMPF Polymer Solutions stands for first-class PU foam gaskets for the automobile, packaging, and electronics industries. “For more than 35 years, we have been developing and manufacturing innovative sealingsystems based on polyurethane and silicone,” says Albert Schmid, Key Technology Manager Foam Gaskets at RAMPF Polymer Solutions. “Our products and solutions stand for efficient sealing, highest quality, and easy handling. Key features includelow water absorption, good adhesion, high long-term temperature resistance, andcost-efficient processing.”
market by its local service partnerSanika Engineering & Consultancy. The company uses dispensing machines from RAMPF Production Systems to manufacture sealing and bonding products for renowned customers amongst others in the automotive, electrics / electronics, energy, filter, and steel industry. “We are a leading end-to-end partner for materials, processing, & consultingon the Indian market and have been working closely together with RAMPF since 2009,” says Ulhas B. Peddawad, Managing Director of Sanika Engineering & Consultancy Pvt. Ltd. RAMPF Production Systems GmbH & Co. KG develops and produces lowpressure mixing and dispensing systems for bonding, sealing, foaming, and casting a wide variety of materials. The company also offers a wide range of automation skills relating to all aspects of process engineering. With its more than 2,700 systems solutions on the market, RAMPF Production Systems, based in Zimmern o.R., Germany, is one of the world’s leading suppliers of innovative systems forprocessing single, dual, and multicomponent reactive resin systems. In addition to the core competence of mixing and dispensing technology, customers are provided with a broad range of automation and conveyor systems for internal logistics, additional assembly and joining technology, as well as logistic and quality assurance solutions. The customer-specific solutions also include the integration of testing and measuring technology into production facilities to safeguard production processes. This added value enables RAMPF Production Systems to supply its customers with holistic system solutions for their production facilities. RAMPF Production Systems is a company of the international RAMPF Group based in Grafenberg (near Stuttgart).
Consulting, subcontracting, and support from Sanika Engineering & Consultancy
RAMPF is represented on the Indian
For more information, Website: www.rampf-gruppe.de/en/
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TECH UPDATE
Ceramic Coatings from Spraymet for Refurbishing Machine Tool Parts
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achine Tool Industry has undergone major developments in providing enhanced service life to spindles, arbors, bearings, etc. Ceramic Coatings by Plasma Spray have been in use in many industries since 1960. Since last decade, this process and ceramic coatings are being used to provide 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.
Typical Spray Materials used with Plasma Spray
Metals and its alloys: Steels, Ni alloys, Co alloys, Moy, bronze, copper, Babbit, etc. Ceramics: Chromium Oxide, Aluminium Oxide, Al Oxide + TiO2, ZrO2, etc. Carbides: Tungsten carbide, Cromium carbide, TiC
Hardness range of coatings: From SOFT 60Rb (Bronze) to HARD 70 Rc (ungsten 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 more wear resistant than Hard-chrome; Micro porosity holds lubrication; Selective area coating is possible; Higher thickness up to 300 microns per side is possible. Limitations: Ceramics are brittle and are to be handled carefully. The process is not as widely available as hard-chrome. Spraymet Surface Technologies
Bangalore-based Spraymet Surface Technologies Pvt. Ltd., headed by Mr. P.T. Bindagi, Technical Director and a veteran metallurgist, is engaged
in thermal spray, ENP plating and weld surfacing. While their main plant is in Bangalore, the second plant is located in Pune, to stay closer to its customers especially from the automobile sector which is demanding technical excellence, proximity and service all at the same time. Spraymet has the distinction of having pioneered the carbide coatings in the steel mills and galvanizing line roll coating. Spraymet owns a few proprietary coatings like Moly bend (Spraymet MoB) for metal-to-metal wear, and Ductile matrix carbide (Spraymet DMC) for plastic process feed screws. Mr. Bindagi is working towards expanding applications in turbine industry, medical implants, and other frontiers. In his quest to spread knowledge, Mr. Bindagi also picks students from universities for project work related to tribology and wear metallurgy. Spraymet has helped the industry save a lot of money and helped conserve its scarce resources. – P.K. Balasubbramaniian
Waste into wealth: Spraymet harnesses the best of surfacing technologies to reclaim machinery components and parts and conserve resources 54
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TECH UPDATE
P
RC.in is the ultimate source of Industrial Supplies Online. It is transforming the way businesses and factories buy their Industrial consumable, maintenance, repair and operational supplies. Started in 2015 by industry veterans, PRC operates its website www.prc.in and is all about providing its customers a frictionless experience by combining the best of both, online & offline worlds. Ensuring 100% genuine products, responsible sourcing practices with guaranteed Same Day Dispatch* and big discounts.
PRC offers a very large variety of products in each category it deals in; ranging from hand tools to power tools, safety supplies to measuring equipment and much, much more. Showcasing over 50 brands and over 1,00,000 products, the catalogue size is ever increasing. A “You Name It; We Have It” attitude is why it makes sense to buy from these guys. An Industrial “ONE STOP SHOP” for all your needs. No more logistic hang ups as they provide door step delivery. No more paper follow ups and No more wasting valuable time inquiring about prices and stocks. Each item displayed on the website comes very competitively priced along with its stock position and estimated dispatch time. Another plus point is that they accept bulk orders as well as individual orders so that you can order according to your needs. Product Portfolio
Some of the product categories the company operates in are listed below with other categories in the pipe line and soon to launch. • Hand Tools • Power Tools • Cutting & Machining Supplies • Woodworking Supplies • Safety Gear • Abrasives • Measuring Instruments & Equipment • Tape & Adhesives • Office Supplies (Coming Soon) • Packaging Supplies (Coming Soon) • HVAC (Coming Soon) • Material Handling (Coming Soon) • Fasteners (Coming Soon) • Power Transmission (Coming Soon) • Cleaning Supplies (Coming Soon) • and More....
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TECH UPDATE www.mtwmag.com
Focused Customer Solutions
The focus of the company is to not only add value to your operations but also to help you optimize your operations. The “Premium Account” is one such effort in which, even though you are buying online, PRC lets you negotiate the prices of the products you want and also offers monthly credit on your purchase. How this works is, once you are interested in buying from PRC regularly, their Offline sales team gets in touch with you at your works. You decide on the items you’ll buy regularly and commit certain value of business to PRC. They then give you a “Premium Account” through which when you order, the system books your order at the prices you have agreed upon with the offline team.
Supplier Diversity
Supplier Diversity helps them to bring a huge variety of product to customers and in turn, providing them with countless options to choose from. As a distributor, they help customers in their day-to-day businesses, offering the tools and products they need to keep getting the job done on a daily basis. One of the company’s greatest strengths, however, is that they have the people and products in place to help you when things take a turn for the worse, may it be a technical issue with a product or a logistics problem with a shipment. All people in the company are there to help and are easily accessible through their Customer Support efforts starting with a simple email to care@prc.in
Why PRC?
The high quality standards of their products and attention to a customer’s needs has made them the first choice of their customers. They don’t just sell products, they solve problems. Amongst other things you’ll experience when working with PRC you will definitely see the professionalism, efficiency and transparency in their way of doing things. This is a company that stands tall and puts all its efforts into making good on the promise it makes to you, the customer. “We are a company built on integrity, fair business dealing and focused customer solutions. Our expertise and industry insight along with the best in class supply partners, is what has led us to gain so much traction in so little time .” - M. Chowdhry, Director, PRC Supplies (P) Ltd. PRC is transforming the way we buy everyday factory use products with a transparency and fairness that our industry is yet to see. If the words of their customers are anything to go by, then they are headed to becoming the biggest Industrial MRO Suppliers in India. Website: www.prc.in
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TECH UPDATE
Bonfiglioli New TQF precision planetary flanged gearboxes series & TQF - BMD compact solution Bonfiglioli Riduttori S.p.A., a global designer and manufacturer of precision planetary gearboxes, announces the release of the TQF series of precision planetary flanged gearboxes.
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ighest torsional stiffness, tilting moment and compactness are the main characteristics of the TQF series. The compact servo solution TQF + BMD is a remarkably compact solution in which the overall length dimensions offer revolutionary, space-saving machine designs. Using an integrated solution, rather than a traditional gearhead / motor combination, the TQF+BMD series saves valuable space and gives machine designers a wider range of options and a higher performance due to the synergies between permanent magnets synchronous motor and precision planetary gearboxes technologies. Even more flexibility is available for the TQF + BMD series including: many feedback device options, different windings and optional brake and flywheel option to fit unique applications. Different levels of customization are available on request. The TQF precision planetary flanged
Bonfiglioli TQF Series
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gearbox is designed in five sizes (060, 070, 090, 130 & 160) and covers a wide spectrum of ratios with a torque range up to 800 Nm. Typical applications for TQF reducers include: precision rotary axis drives, traveling gantries & columns and material handling axis drives. The main industries served include industrial automation systems, robotics, machine tools, packaging machines, and a host of other applications requiring high performance servo drive systems. Equipped with high capacity output shaft bearings, the TQF is designed to satisfy requirements for the highest radial and axial force applications, ensuring a long lifetime and reliability. With the highest input speed on the market today, the TQF is the best choice when using the latest highest speed servo motors. While the total elimination of backlash is practically impossible in toothed gear transmissions, due to its design and innovative manufacturing process, it is possible to get the TQF series with a backlash lower than 3 arcmin. Two backlash classes are available for even more flexibility. With its unique housing design and optimized monoblock planetary carrier, the TQF series allows a markedly higher torsional stiffness – ideal for applications demanding high dynamics, and a high number of start-stops & reversals. Optimized full complement needle roller bearings allow for higher output torque, increased stiffness, reduced wear & backlash.
Bonfiglioli TQF+BMD Series
The TQF series is designed for continuous duty and cyclic operation. Universal Mounting Position and IP65 protection comply with high demanding environments and provide even more flexibility and benefit for specific applications. Smooth running, and low vibration of the TQF gearbox is confirmation of the successful application into advanced manufacturing processes. Reliable, accurate and clearly defined catalogue ratings, together with optimization with your application using our servo-sizing tool avoids over sizing, thus minimizing the initial system cost as well as optimizing the ongoing operating cost of the servo system.
For more information, Website: www.bonfiglioli.com
TECH UPDATE
New Plasma Cutting Electrodes help owners of Hypertherm HySpeed systems double their current consumable life
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ypertherm, a manufacturer of plasma, laser, and waterjet cutting systems, is introducing new SilverPlus® electrodes for its HySpeed® HSD130 plasma cutting systems. Like all versions of Hypertherm’s SilverPlus electrode, this electrode is proven in Hypertherm laboratory testing to last more than twice as long as a standard copper tipped electrode. In addition, the electrode delivers a very consistent range 4 and 5 cut quality throughout its life helping HySpeed plasma owners lower their operating cost and enjoy improved cut quality. The electrodes, protected by patent, are created by fusing a solid silver tip on to a copper electrode base and then inserting a hafnium pin into the tip. This serves to dramatically slow the electrode’s wear rate as silver disperses heat better than copper. Hypertherm’s electrodes are further differentiated by a superior bond between the hafnium and silver for more consistent wear rates,
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deeper pit depths, and more robustness to ramp down errors and hard failures. “Our SilverPlus electrodes have long been recognized for delivering proven performance benefits to owners and operators of our HyPerformance systems,” says Martin Geheran, a consumables product manager at Hypertherm. “Now HySpeed plasma system owners can enjoy that same benefit while reducing their overall operating cost through the purchase of fewer electrodes and even nozzles, as the increased electrode life also translates into double the nozzle life.” Using genuine Hypertherm consumables for your Hypertherm plasma cutting system is the only way to ensure optimal performance. Patented technology and precision manufacturing combine to deliver increased cut speed, better edge quality, and longer consumable life. In addition, genuine Hypertherm consumables are backed by industry-leading service and training through Hypertherm’s HySupport
program. Hypertherm designs and manufactures advanced cutting products for use in a variety of industries such as shipbuilding, manufacturing, and automotive repair. Its product line includes plasma, laser and waterjet cutting systems, in addition to CNC motion and height controls, CAM nesting software, and consumables. Hypertherm systems are trusted for performance and reliability that result in increased productivity and profitability for hundreds of thousands of businesses. The company’s reputation for cutting innovation dates back nearly 50 years to 1968, with Hypertherm’s invention of water injection plasma cutting. The 100 percent associate owned company has more than 1,300 associates along with operations and partner representation worldwide. For more information, Website: www.hypertherm.com
TECH UPDATE
Reliable feed process for heavy workpieces The sawing technology specialist KASTO is extending its product portfolio: The KASTOwin F 10.6 fully automatic band sawing machine is now available with a moveable material support table. This makes it possible to feed in and position heavy, bulky stock such as ingots, large tools or offset shafts easily and reliably.
The new KASTOwin F 10.6 is suitable for heavy, bulky stock such as ingots, large tools or offset shafts.
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versatile, robust and economical standard solution for a wide range of sawing applications – these are the properties that have already made the KASTOwin series of band saws, which was were first launched in 2014, extremely popular with many of the company’s customers. To expand the range of possible applications and simplify the sometimes laborious task of handling large workpieces, KASTO has decided to extend this product family: The KASTOwin F 10.6, which has a cutting range of 1,000 x 1,060 millimetres, is now available with a moveable material support table. The saw is particularly suitable for steel manufacturers, steel traders and large-scale toolmakers. Using the table, it is possible to feed, for example, ingots, permanent moulds or The saw possesses an electrically driven material support table which can be used to position the large workpieces quickly and reliably to meet process requirements.
materials with pre-forged geometries simply and reliably in a way that meets process requirements. The support length of the table is 2,600 millimetres, while the table has a travel distance of 3,700 millimetres and a bearing capacity of up to 18 tonnes. It can travel at a speed of up to three metres per minute – and do so with exceptional positional accuracy. The table is moved in the longitudinal direction by two linear guides, each equipped with four lubricated linear roller bearings. Precision feed is achieved by means of a zero-play ball screw spindle, while a hydraulic horizontal vice mounted on the outfeed side of the saw band holds the workpiece in place. Like all the models in the KASTOwin range, the saw excels thanks to its robust steel construction, a cutting accuracy of ±0.1 millimetres per 100 millimetres of cutting length, as well as cutting speeds of up to 150 metres per minute. To respond to special requirements, KASTO offers an extensive range of accessories for the KASTOwin F 10.6. This includes a laser to depict the projected cutting trajectory, a travelling hydraulic horizontal vice at the end of the table, support surfaces with wearing plates and infrared remote control. A wide range of individual stop, alignment and clamping devices are also available for the saw. For more information, Website: www.kasto.com
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TECH UPDATE
Ease your vacuum generation with SMC
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n response to increasing demand for integrated vacuum generation systems, SMC has launched its new Series ZHP vacuum pad with ejector. An energy efficient single compact unit, the ZHP can be easily mounted in confined spaces due to its innovative design that removes the need for further components, making it simple to order and maintain. SMC, the worldwide leading expert in pneumatics, has introduced a compact, single unit vacuum ejector and pad that is easy to fit and delivers optimum space savings, energy efficiency and reduces maintenance requirements. The new
ZHP Series minimizes the need to use several components and complicated design structures. The vacuum unit features an innovative lock-plate structure that allows easy one-touch replacement of the pad. This means that pads can be easily attached and detached for disposal, minimizing the need for maintenance. The use of an enhanced two-stage ejector improves vacuum generation efficiency, delivering an increase in suction flow rate of 50 % and a reduction of air consumption of 30 %. In addition, the ZHP offers a trio of vacuum port locations which provide a variety of connections to other equipment and creates the opportunity for daisy-chain piping, allowing for multiple devices to be connected in sequence, reducing piping requirements. The ZHP has further design qualities, including a through-hole silencer that significantly reduces noise levels and the risk of clogging. To improve its life span and reduce the risk of contamination, SMC has also included a strainer that prevents foreign matter from entering the pad suction port. The ZHP can be adapted for a range of applications, making it ideal for a variety of uses including robot handling in palletizing, sheet metal working in the automotive industry or case packers.
For more information, Website: www.smcin.com
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PROJECTS www.mtwmag.com
Aviation GMR Hyderabad International Airport Ltd.
Aviation Healthcare
PROJECT
Indutrial Park Manufacturing Mining Packaging Power
UPDATE
Transport
Plans to expand the passenger handling capacity at the Hyderabad airport. The company is in the process of finalising plans in this regard and awaits regulatory approvals.
Place: Hyderabad, Andhra Pradesh Contact: “Prashant Kumar, Manager (Corp Comm), Shamshabad – Hyderabad 500409 Telangana, T: 040-67394099, M: 09100934769, E: prashant.kumar@ gmrgroup.in Airports Authority of India Plans development of multi level car parking (MLCP) at Chennai and Kozhikode Airports.
Place: Chennai Tamil Nadu Contact: “L N Tatwani, Gm Engineering, Chennai International Airport, Chennai - 600027, Tamil Nadu. T: 044-22564027, 22561122, F: 22560512 E: apdchennai@aai.aero
Dholera International Airport Company The Gujarat Government is keen on Dholera airport project at Navagam village spread over 1,426 hectares of land in Dholera Special
Investment Region (SIR).The project near the city has received environmental clearance from the Centre.
Place: Dholera, Gujarat Contact: “Amit Chavda, General Manager, 6th Floor, Block No. 1 & 2, Udhyog Bhavan, Sector 11, Gandhinagar-382017. T: 079 232 26015-16, 9998976568 E: achavda@gidb.org Bangalore International Airport Ltd Plans to build second terminal and runway at the city’s Kempegowda International Airport. The project is in advanced stage of planning.
Place: Bengaluru, Karnataka Contact: Javed Malik, Senior Vice President Airport Operations, Administration Block, Devanahalli - 560300, Bangalore. T: 080-66782425, 25223344, F: 66783366 E: apdbangalore@aai.aero
Kannur International Airport Ltd Kannur International Airport is an upcoming International Airport located at Mattanur in Kannur District, Kerala. Recently the survey report was submitted to the District Collector with regard to identifying the areas to be acquired.
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PROJECTS
Contact: K.P Jose, Chief Project Engineer, New Municipal Building, 2nd Floor Maruthai Road, Mattannur, Kannur 670702, T: 04902474463, 2474464, F: 0490-2474464, E: kpjose@kannurairport.in
Healthcare Rajasthan State Road Development and Construction Corporation Ltd Plans construction of medical college campus and upgradation of district hospital Bharatpur into teaching hospital at Bharatpur. The project is in DPR stage.
manufacturing facility.
Place: Andhra Pradesh Contact: “Harinath Reddy, Asst Director (Industries), Chirag Ali Lane, Abids, Hyderabad - 500001. M: 09640909843 E: reddy.bhn@gmail. com”
Association of Indian Medical Device Industry (AIMED) The Centre has asked AIMED to work out the details and other modalities for setting up exclusive medical device industrial park at Mihan SEZ. AIMED has suggested allocation of 200 acre for this project.
Contact: Siva Kumar, Project Manager (Engg Dept), Survey No: 88 & 90, Meppur Thangal Road Madavilagam Village, Thirumazhisai, Chennai 602103, Tamil Nadu T: 044-43912800, E: v.sivakumar@ Johnsonelectric.com
Mining Government of West Bengal A special purpose vehicle Bengal Birbhum Coalfields Ltd is created to develop the mine at Deocha-Pachami in Birbhum district.
Place: Birbhum District, West Bengal
Place: Nagpur, Maharashtra Place: Bharatpur, Rajasthan Contact: Sushil Bhayana, Contact: A.B Panday, Project Director, Shiv Colony, Next to Nasia Jain Mandir, Cricular Road, Bharatpur - 321001, Rajasthan. M: 09414252029, 9414032774 E: pdbharatpur@rsrdc.com
Indutrial Park Depart- ment of Industries, Govern- ment of Andhra Pradesh The state government plans to develop an exclusive industrial park spread over 200 acre for the manufacturing of medical devices. The proposed industrial park would have a common
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GM (Materials), GL-3, Ashoka Estate, 24, Barakhamba Road, New Delhi - 110001 T:0129-4289000, 4061151 E: purchase@hmdhealthcare. com
Manufacturing Johnson Electric Holdings Ltd Plans expansion of its production facility located at Chennai. The plant produces motors for engine cooling fan modules and gear motors for window lift systems.
Place: Chennai Tamil Nadu
Contact: Durgadas Giswami, Director (Mines and Minerals) & Adl Sec (Commerce and Industry), 4 Camac Street, Kolkata - 700016 West Bengal, T: 033-22550506, M: 09830077713, E: adlsecyci@gmail.com Western Coalfields Ltd “Coal India Ltd subsidiary amalgamat- ed Pauni-II & III OC (Open Cast) coal mining project in Maharashtra will be commissioned shortly. The mining project has a production capacity of 3.25 million tonne per year.”
Nagpur - 440001, Maharashtra T: 0712-2510438, 2510532, F: 0712-2510532, E: dtpp@westerncoal.gov.in
Packaging Clariant Chemicals (India) Ltd Plans to set up a new healthcare packaging manufacturing plant at Cuddalore. This unit would manufacture moisture control products.
Place: Cuddalore Tamil Nadu Contact: Ketan Premani, Head (Healthcare), Reliable Tech Park, Thane–Belapur Road, Airoli, Navi Mumbai 400708. T: 022-71251000 F: 022-71251041, E: ketan.premani@clariant. com Tamil Nadu Newsprint and Papers Ltd (TNPL) The company is setting up 300-acre factory at Mondipatti, 35 km from Tiruchi. This plant would manufacture packaging board. The production capacity would be 2 lakh tonne a year. A captive power unit of 30 MW is also being set up.
Place: Tamil Nadu Place: Pauni, Maharashtra Contact: Binoy Kr Mishra, Director (Technical), Coal Estate, CIVIL Lines,
Contact: S J Vardarajan, GM (Projects), Project Management Division, Kagithapuram, Tamil Nadu.
PROJECTS www.mtwmag.com
T: 04324-277001 F: 277027. E: pmd@tnpl.co.in, vardarajan.sj@tnpl.co.in.
Power Wartsila Corporation / KSEB Finland based company will undertake the 40 MW Smart Power Generation Plant based on LNG. The project will be taken up on turnkey basis and handed over to Kerala State Electricity Board (KSEB).
Place: Kerala Contact: Susan Jacob, Chief Engineer, KSEB, Kalamassery T: 0484 2555075 M: 9496010000 E: cetpkseb@gmail.com Odisha Power Transmission Corporation Ltd The construction is on for 220KV transmission line existing 220/132/33 KV Grid substation at Balimela to 220/33 KV Grid substation at Malkan- giri and 220KV transmission line from proposed 220/33 KV GSS Malkangiri (from Gantry to Old A.P. No. 06). (Total length 21.596 KM). Around 60% of the compound wall construction is done.
Bohidar Nuapali, Sankarma, Remed, Sambalpur-768006, Odisha. T: 0663-2540974, 2542320 M: 9438907730 E: sgm.con2.sbp@optcl.co.in
Larsen & Toubro (L&T) The Power Transmission & Distribu- tion business has bagged an order from the Odisha Power Transmission Corporation Ltd (OPTCL). The order is for engineering, supply, erection and commissioning of several KMs of underground EHV & HV cable networks, compact substations and other distribution elements in the city of Bhubaneswar, Odisha.
Place: Bhubaneswar, Odisha Contact: S.N Roy, Sr VP (Power), Mount Poonamallee Road, Manapakkam, P B no 979, Chennai - 600089, Tamil Nadu. T:044-2528000 F: 044-22493888 NTPC Ltd Kudgi Super Thermal Power Project is under construction. The power plant based on coal is coming up at Kudgi village in Bijapur district. The project comprising three units of 800 MW each will be commissioned in 2017.
Place: Malkangiri, Odisha Contact: Uttam Kumar Samal, Sr. GM, Construction Zone-II, 132/33 KV Grid Sub Station, Ganesh Nagar,
Place: Bijapur District, Karnataka Contact: Deepna Mehta, DGM-Corp Comm, NTPC
Bhawan, Scope Complex, 7, Institutional Area, Lodi Road, New Delhi- 110003. Delhi T: 011-24387195, 24368283, 24360100 F: 24361018 M: 9650990565 E: deepna.mehta@gmail.com, info@ntpc.co.in
Transport Larsen & Toubro (L&T) The heavy civil infrastructure division of the company has bagged orders from Chennai Metro Rail Corporation for the construction of Chennai Metro line Package 3 Underground - Bal- ance works. The scope involves engineering, procurement and construction of 4 stations at AG-DMS, Teynampet, Nandanam, Saidapet and Saidapet ramp portion with associated tunnel works.
Place: Chennai, Tamil Nadu Contact: D.K Sen, Sr VP (Infrastructure), Mount Poonamallee Road, Manapakkam, P.B.No.979, Chennai – 600089 T: 044-22526666 F: 044- 22528724 E: info@lntecc.com
AP Transco and Southern Power Distribution Company Ltd Plans to appoint consultants soon to estimate the power requirement of the Amravati Metro Rail Project.
Place: Andhra Pradesh Contact: K Rajbapaiah, Chief Engingeer, APSPDCL,D. NO:19-13-65/ A,Srinivasapuram, Tiruchanoor Road, Tirupati, Chittur District, Andhra Pradesh, 517503 T: 0877-2237283 M: 9440811744, 9440817444 Kochi Metro Rail Ltd. (KMRL) Kochi Metro project is being managed by the Delhi Metro Rail Corporation (DMRC). The 25.65km metro line will run from Aluva to Petta and will include 22 stations. The project is implemented in phases. The first phase of construction began in June 2013 and will complete by 2016. L&T is undertaking the construction of elevated viaduct and elevated stations on Aluva-Petta. The project is a JV between the Central and State Government, will be operated under a build, operate and transfer (BOT) basis for a 30-year concession period. The trial run is expected in February 2016.
Place: Kochi, Kerala Contact: Reshmi CR, Senior Communication Manager, 8th Floor, Revenue Tower, Park Avenue, Kochi-682011. T: 0484-2380980, 2350355 F: 2380686 M: 09446418222, E: reshmi@kmrl.co.in
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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
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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
Missile Lube® 1, 1XL, 1XXL, 1XXXL Straight Cutting Oil for HONING FEATURES • Chlorine-Free • Original Synthetic and Vegetable EP Technology • Non-Staining • Easy to Recycle and Waste Treat • Can be used on all materials • Low Misting Missile Lube 1 XL is Approved by Boeing Aircraft, and Lockheed Martin
GENERAL DESCRIPTION Hangsterfer’s Missile Lube 1 series includes high quality’ high performance’ chlorine and sulfur free oils. The combination of synthetic and vegetable based Extreme Pressure additives increase tool life and improve surface finishes for a variety of metalworking operations. Composed of highly refined raw materials’ the Missile Lube 1 series helps keep the machine clean and minimizes operator exposure to mist and smoke. Offering superior lubrication for the machine tool as well as the tool-work piece interface’ the Missile Lube 1 series provides benefits in productivity and equipment life. The non-toxic and non-corrosive blend is designed for easy waste disposal and operator safety. Missile Lube 1- The highest viscosity of the Missile Lube range is suitable for abroad range of applications. Due to its viscosity it provides the maximum lubricity of the tool workpiece interface especially on demanding metal cutting and metal forming applications. Missile Lube 1 XL - The combination of low viscosity mineral oils and EP additives make it ideal for grinding carbide and high-speed steel. The wheels stay clean and last longer, while surface finishes improve. It is excellent for high speed machining of aerospace aluminums and other exotic materials. Missile Lube 1 XXL - With 100% more synthetic EP additives then the 1 XL, the 1 XXL has a much lower viscosity. It can be used for the same applications as 1 XL, but is more suitable for very small work, as 1 XXL is easier to deliver to the tool-workpiece interface.
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
Missile Lube 1 XXL and 1 XXXL are well suited for honing of ferrous and non-ferrous materials where chlorine additives are restricted. They are non-staining and leave little residue while providing rust protection. The extreme pressure additives in Missile Lube provide flushing and pickup protection for the abrasive while allowing fee cutting for superior finishes. Honing is a cutting operation with very small chips. Missile Lube 1 XXL and 1 XXXL are suited for use with solid and expanding hones in all type honing machines. Suitable for use on hone materials but not limited to; diamond’ supper abrasives’ ceramic and silicone carbide.
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AT3 Class Tool holders Birla Precision Technologies Limited, erstwhile Birla Kennametal Ltd is established in 1986 as a Joint Venture with Kennametal Inc USA, primarily to manufacture CNC Rotating Tool Holders and accessories. We have constantly endeavoured to acquire new skills and technical expertise to produce engineered products and become cost competitive for addressing the needs of our customers.
For Product Enquiry Contact Birla Precision Technologies 206 Dalamal House, 1st Floor, Jamnalal Bajaj Marg, Nariman Point, Mumbai - 400 021 Web: www.birlaprecision.org Email: himanshu.bhatt@birlaprecision.com
With BPT brand we are committed to provide; • AT3 Class Tool holders that ensure high precision, ease of operation and increased tool life • Products with unbeatable run out accuracy and balance quality • Full lot traceability of all tool holders for maximum reliability and process control. • Reliable & efficient engineering support to cater to your special requirements • World class quality at competitive prices. Our all Tool Holders are manufactured in AT3 Class accuracy, with Shank DV/BT/ CV/HSK & Front Ends - ER/DA & TG Collets Chucks, Drill Chucks, End Mill / Shell Mill / whistle notch / Morse Taper / Jacob Taper Adaptors & Shrink Fit Tool Holders. We also produce the angle heads & rotary coolant adapters.
Steady Volt Servo Voltage Stabilizers Frequent voltage variations are a menace that can damage electronic components like power supplies, drives, PLCs, controllers, etc. Their effects are widely felt in CNC, printing and textile machines as well as laboratory, data processing, medical & telecommunication equipment. Frequent breakdowns of such machines are costly to repair. This apart, the downtime and frequent interruptions in operation brings substantial loss of revenue. Steady Volt from Unity Controls is a state-of-the-art Voltage Stabilizer designed to protect such equipment from voltage variations and its ill-effects.
Following are some of its unique features: • • • • • • • For Product Enquiry Contact Unity Controls Pvt. Ltd 405, Sapphire Arcade, 42 M.G. Road, Ghatkopar (E), Mumbai 400 077 Phone: 022- 2501 3832 / 33 E-mail: sales@unitycontrols.in Web: www.unitycontrols.in
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Intelligent microprocessor-based system(available in new digital models) Digital interface with large LCD display and keypad Auto re-start, adjustable output voltage, trip bypass, fault list No hunting, oscillation and noise generation Innovative transformer design to minimize power loss Constant output voltage across a wide input voltage range Single phasing prevention, surge suppressor and EMI / RFI filter
With the best-in-class response time and correction rates, Steady Volt offers improved power quality and greater energy efficiency, thereby saving the cost of breakdowns and energy utilization. Apart from protecting your equipment from damage, Steady Volt also saves energy during continuous operations.
PRODUCTS www.mtwmag.com
LS 1679 Incremental Linear Encoder with Integrated Roller Guide
For Product Enquiry Contact 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
As the demands for measuring systems for press brakes change, so has the HEIDENHAIN product line. HEIDENHAIN’s specialized encoder for this application, the model LS 1679, is a sealed linear scale with an integrated roller guide making this unit both highly accurate and cost effective. The LS 1679 sealed linear encoder was specially designed for the high-force, vibration press brake machines. With the need for better resolutions increasing, this LS 1679 is available with a resolution of 5 µm or 1 µm after 4-fold evaluation. Space requirements have resulted in the LS 1679 having no pluggable cable assembly, so the LS 1679 is available with left or right cable exit to ensure mechanical compatibility with press brakes. In this encoder, the four ball bearings of the carriage are guided along two steel rails which are integrated in the aluminum housing. The combination of these two high quality materials makes for excellent wear resistance. The position of the guide in the encoder protects the bearing surfaces from dust or contamination. HEIDENHAIN’s LS 1679 is the next generation linear encoder for press brakes, improving upon the previous LS 6X9. Standard measuring lengths up to 470 mm are available, with longer lengths up to 720 mm available upon request. The LS 1679 is ideal for press brakes and other applications where a self-guided reader head is needed due the motion being measured.
Synthetic High Speed and Spindle Grease Especially designed for lubrication of rolling and plain bearings operate under high speed and / or low temperatures. Typical applications: spindle bearings in textile machinery and machine tools as well as small bearings and precision bearings in precision engineering applications and optical devices. Moreover recommended also for thread and ball spindles, linear drives and linear guidings, moving gears, toothed wheels of small gears and bearings of cable cars.
Characteristics • • • • • • • • For Product Enquiry Contact Setral Chemie GmbH Salzsteinstrasse 4 D-82402 Seeshaupt Telefon: +49 (0) 88 01 97 10 Telefax: +49 (0) 88 01 97 30 Email: info@setral.net Website: www.setral.net
Reduces wear and tear Steady also at very high speeds Wide application range Excellent corrosion protection Avoids stick-slip Very good low-temperature properties Wide temperature range Resistant to oxidation and ageing
Method of use • Application manually or by automatic dosing. • Clean and degrease lubrication points carefully prior to application. For this CLEANsetral• AN/U spray is specially suited. • The minimum shelf life in original sealed containers, stored in a cool and dry place • (no direct sunlight) is about 2 years.
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Threading Tap Holder Birla Precision Technologies Limited offers a wide range of Taps quick change for Transfer machines and machining centers.
Our production develops adaptors with the following categories: • Tapping to Double Compensation • Rigid tapping • Tapping with Axial displacement. Our company offers spindles with back tapers such as BT-MAS403, ISO 30/40/50 (DIN 69871) HSK (DIN 69893), the tap adaptors formers are available in sizes 0 - 1 - 2 - 3 - 4 – 7.
All items are also available with the following attachments: • Chuck Weldon according to DIN 1835, mainly used for control machines and transfer machines • Chuck Morse taper, according to DIN 228A and 228B, mainly used for machining centres and boring • Spindle Keystone, according to DIN 6327, mainly used for transfer machines and threading • Cylindrical and chuck VDI, DIN 69880, mainly used for control machines • Spindle with conical “B” according to DIN 238, mainly used for traditional machines such as drill presses or threading With the aim to provide better quality and longer life, the we use the best grades of steels and subject all products to rigorous quality assurance during each stages of manufacturing , assembly and testing.
For Product Enquiry Contact Birla Precision Technologies 206 Dalamal House, 1st Floor, Jamnalal Bajaj Marg, Nariman Point, Mumbai - 400 021 Web: www.birlaprecision.org Email: himanshu.bhatt@birlaprecision.com
JV Kraft-Vertical Machining Centre
For Product Enquiry Contact Lakshmi Machine Works Limited Machine Tool Division, Arasur Coimbtore 641407 Tel : +91 422 3021300, E-mail: mtd_marketing@lmw.co.in
LMW Machine Tool Division has introduced an All New Vertical Machining Centre “JV Kraft” in the X 800mm range which caters to the needs of diverse industrial segments from Aerospace to Job shops. The machine is equipped with robust spindle, constructed to minimize axial and thermal expansions and is dynamically balanced to ensure extremely low run-outs. The high precision feed mechanism provides high accuracy, rigidity and repeatability. The highly reliable swift Automatic Tool Changer (ATC) adds a new dimension to vertical machining. This state-of-the-art machine has been designed to meet the evergrowing demand for speed and accuracy of the user industry for high quality and high volume production. The machine is designed with the motto of best price-to-performance ratio and true to the goal of providing value creation through innovation, says I.N. Bhattacharya, General Manager-Marketing & Sales, MTD, LMW.
Looking for industrial Products for your plant/workshop ??? Connect to right manufacturers & suppliers http://www.mtwmag.com/enquiry/product 74
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ADVERTISERS INDEX COMPANY NAME
PG. NO.
A ACMEE - 2016
65
ADOR WELDING LIMITED
31
AMTEX - 2016
55
COMPANY NAME
PG. NO.
ENGITECH EXPO - 2016
59
M
ERWIN JUNKER MASCHINENFABRIK GMBH
5
MACHAUTO EXPO - 2016
GLOBAL INDUSTRIAL EXPO - 2016
FRONT GATEFOLD
BIRLA PRECISION TECHNOLOGIES LIMITED
11
C BACK PAGE
63
H HAAS AUTOMATION INDIA PVT. LTD.
15
HARTING (INDIA) PVT. LTD.
35
PRC SUPPLIES PVT. LTD.
8-9
45
E 41
INSIDE BACK COVER
L
INSIDE FRONT COVER
SANJAY TOOLS & ADHESIVES
17 & 25
SPRAYMET SURFACE TECHNOLOGIES PVT. LTD.
37
U UNITY CONTROLS PVT. LTD.
LAKSHMI MACHINE WORKS LIMITED
23
LAPP INDIA PVT. LTD.
26-27
MACHINE TOOLS WORLD |
RAMPF HOLDING GMBH & CO. KG S
J JYOTI CNC AUTOMATION LTD.
D
EFFICA AUTOMATION LIMITED
61
R
BECKHOFF AUTOMATION PVT. LTD.
DOWEL ENGINEERING WORKS
PG. NO.
P
G
B
CNC SOFTWARE, INC.
COMPANY NAME
75 | January 2016
19
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Inside Story
Mr.
A.K.
Sareen Managing Director, CERATIZIT India Pvt. Ltd.
My Life’s Goals Aim & Ambition: To be a good human being, an effective M.D. and an inspirational leader. Vision: To make CERATIZIT India into one of the top five cutting tool companies in India. Social Goal: Participate actively in CSR for the general improvement of people in and around our plant. Business Goal: To be a significant and profitable company in the field of cutting tools
My Leisure Choices Favourite Tourist Spot: Love to travel to different destinations. Prefer mountains and picturesque countries. Music I Like: I like classical music, mostly Gazals. My favorite artist is Jagjit Singh. Sports I Love: Like playing golf and watching cricket.
Ask my Taste Buds Favourite Food: Home cooked non vegetarian food. Favourite Drink: Single malts and Rum & Coke.
In Awe of I Admire: Jack Welch and Tiger Woods.
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RNI No. MAHENG/2015/64267 Postal Reg. No. THC/173/2015-2017. Posted at Mumbai Patrika Channel Sorting Office G.P.O. Mumbai 400 001 on 15th of every month and Published on 10th of every month
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
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