Machine Tools World - February 2016 by Divya Media Publications Pvt. Ltd.

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Contents

www.mtwmag.com

Vol 1 Issue 9 | FEBRUARY 2016

Publisher Shirish D.

TECH UPDATE

CEO Shekhar D.

Editor

Hangsterfer’s Crystal Brite EDM - Dielectric Fluid

Shilpa Dongre

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

Manufacturing and servicing rotary tools with VOLLMER: Efficient & Precise

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

Online Division Ganesh M., Pradeep M. Pillalamarri

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

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

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

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

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

Head Office : Divya Media Publications Pvt. Ltd., 3rd Floor, Harmony Tower, N.S. Road, Thane-400 602. Maharashtra Tel: +91 22-25380574/75, Telefax: +91-22-25418254 E-mail: shekhar@divyamediaonline.com, Website: www.mtwmag.com. Printed & Published by Shirish Dongre on behalf of DIVYA MEDIA PUBLICATIONS PVT LTD., Printed at Anitha Art Printers 29/30, Oasis, Next to Vakola Market, Santacruz(E), Mumbai-400055, published from 303/304, Harmony Tower, N.S.Road, Court Naka, Thane West, Thane-400601. Editor : Shilpa Dongre

MACHINE TOOLS WORLD FEBRUARY 2016

COVER STORY

NIKUNJ EDM wire specialist with technology excellence

20 MAKINO: Global Leadership in EDM Technology Arena

Mr. Sadananda Koppalkar Head Business Development - EDM, Die & Mold, Makino India Pvt Ltd

BUSINESS NEWS

Appointment of an Additional Member of the Executive Board of ZIEHL-ABEGG SE

Atlas Copco Ranked Top Machinery Company for Sustainability by Global 100

Water-Based Bonded Coatings for Improved Workplace Safety

Renishaw Launches New CARTO Software Solution for Calibration Systems

COMPANY PROFILE

Industry Expertise & Experience in helping machining customers make what matters

CHMER Precision Economical CNC EDM Machine

CASE STUDY

52 22

Effica’s Robotic solutions

Gurutzpe CNC Lathe Machine : Excellence with technology innovation

Solid stamp of trust and reliability of Godrej Locks reflects in Haas machines

SPRINT 50 for more flexible productivity

Renishaw – cranking down cycle time for Hope Technology

Lokesh Machines : Coherent Performance Driven Growth

PROJECTS

PRODUCTS

Editorial Board

Editorial Index A Atlas Copco

Mr. A.P. Jayanthram Managing Director Heidenhain Optics & Electronics India Pvt. Ltd

Mr. GK Pillai Managing Director & CEO

Walchandnagar Industries Ltd.

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

B BIEMH, International Machine-Tool Exhibition

Effica Automation Ltd.

Ms.Samina Khalid Marketing Manager

Renishaw Metrology Systems Ltd.

Mr. MIHIR Baxi President – Global Sales

M Makino India Mastercam

20, 44 33

D DIEMOULD INDIA 2016 DMG MORI

60 54

N Nikunj Group NUM Group

42 13

E Effica Automation ESPRIT

22 8

P PETRONAS Lubricants

F FARO Technologies

Mr. Arjun Prakash Managing Director

L Lokesh Machines

H Haas Automation HAIMER Hamd Machine Tool Solutions Hangsterfer’s Hauzer Techno Coating Henkel

52 36 27 34 6 16

R Radius Engineering 30 Renishaw 10, 38, 58 S Sanki Machine Tools SIEMENS Spraymet

46, 47, 48 49 32

T Tornos Gurutzpe

V VOLLMER Group

Z ZIEHL-ABEGG SE

Jyoti CNC Automation LTD

I IMTEX FORMING 2016 K Klüber Lubrication

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

FEBRUARY 2016

MACHINE TOOLS WORLD

BUSINESS NEWS

Appointment of an Additional Member of the Executive Board of ZIEHL-ABEGG SE

We have set ourselves major objectives for the future. For this reason and to further strengthen the tried and tested team of the Executive Board which has been operating successfully for many years, we have decided to adapt the organisational structure to the future market requirements from the functional aspect. We see ourselves as a

customer-orientated company which is moving away from business division structures in its orientation and turning towards a clear, function-based organisation. In the future our internal organisationwill be based on the four central pillars of development, production, sales, and finance. Therefore the previous areas of responsibility will be clearly aligned on these four groups. In order to meet this requirement, we have appointed Dr. Klaus Weiß as an addition to the existing threemember Executive Board. We are pleased to inform you that we have been able to find an ‘all-rounder’with many years’ experiencein our industry. Dr. Klaus Weiß is a native Westphalian who completed

his engineering studies at the Technical University Karlsruhe, specialising in fluid kinetic machinery and manufacturing technology. He then did his PhD at the Turbo Engine Faculty of the Technical University Darmstadt. Dr. Klaus Weiß has expanded and been in charge of various international production sites, for example at WILO SE (one of the world’s leading pump manufacturers) and EBRO ARMATUREN GmbH (industrial fittings). “I am pleased to be bringing this experience to bear in ZIEHL-ABEGG at such an important time”, saysDr. Klaus Weiß. “Working together with the many employees we will continue to expand the global production network.” Dr. Klaus Weiß is 52 years

old, marriedand has two daughters and two sons. With the appointment of Dr.Klaus Weiß, the division of responsibilities on the Executive Board is as follows: Chief Executive Officer: Peter Fenkl (Chairman of the Board) Chief Financial Officer: Achim Curd Rägle Chief Technology Officer: Norbert Schuster Chief Operations Officer: Dr. Klaus Weiß The aim of this alignment is to enable us to better meet the major national and international challenges and to set the course today for the continued strong growth of ZIEHL-ABEGGSE in the future.

Hauzer Acquires Cromatipic®, Ecological Chroming System for Automotive Market IHI Hauzer Techno Coating in The Netherlands is pleased to announce that it has acquired the intellectual property rights and trade marks for Cromatipic®, formerly owned by Sidasa Engineering in Spain. All responsibilities, ownership of process, technology and factory engineering have been included in this transaction and Hauzer will be supplier of consumables to all Cromatipic® users worldwide. Cromatipic® is an environmentally friendly technology that replaces electroplating on varied plastic substrates and

MACHINE TOOLS WORLD FEBRUARY 2016

future aluminium alloys for many applications. The technology uses only two process steps, where electroplating needs many more. With the technology a flexible chrome layer is applied that needs no top coat. The end result passes all common automotive requirements for automotive interior and exterior parts. The technology has already been proven and delivered in combination with the inline production platform the Metalliner®.

IHI Hauzer Techno Coating belongs to the IHI Group, that has headquarters in Japan, and is a leading supplier of Physical Vapour Deposition (PVD) technology and equipment for the tool, tribological and decorative markets worldwide. Cromatipic® is a worthwhile addition to Hauzer’s portfolio that will serve existing and new customers, especially in the automotive market. For the IHI Group as a whole, the acquisition of Cromatipic® is a step

further towards state-of-the-art solutions for global challenges in the automotive industry. Going forward, IHI Hauzer Techno Coating and its sister companies such as IHI Ionbond AG, IMS and VTN will work together to provide a comprehensive portfolio of services in both metal and non-metal applications, furthering IHI’s ambition of becoming a global leader in heat treatment and surface treatment technology markets which are expected to show significant future growth. Website: www.hauzer.nl

BUSINESS NEWS

Atlas Copco Ranked Top Machinery Company for Sustainability by Global 100 Atlas Copco, a leading provider of sustainable productivity solutions, was again recognized as the world’s most sustainable machinery company by the prestigious annual Global 100 list. The list, presented at the World Economic Forum in Davos, Switzerland, ranks companies that prove they are increasing productivity while using less resources. Atlas Copco is ranked 34th overall, and is the only company in the machinery industry included on the list. It is the 10th time that Atlas Copco appears on the list. “Providing customers with the most innovative, energy efficient, safe and ergonomic products is a key part of our business model,” said Mala

Chakraborti, Atlas Copco’s Vice President Corporate Responsibility. “Integrating sustainability in our operations generates great value for both industry and society.” Atlas Copco’s innovative, energy-saving products include its variable-speed compressors, a technology that the Group pioneered in 1994 that enables compressors to run only at

the speed necessary, cutting energy consumption. In 2013, Atlas Copco launched the patented VSD+ technology, which slashes energy use by more than half compared with traditional compressors. This groundbreaking compressor has received an overwhelmingly positive customer response. Atlas Copco is also listed in the Dow Jones Sustainability Europe Index for 2015/2016, and is ranked number 11 globally in the Newsweek Green Rankings, one of the world’s foremost rankings on corporate sustainability.

Group serves customers with innovative compressors, vacuum solutions and air treatment systems, construction and mining equipment, power tools and assembly systems. Atlas Copco develops products and services focused on productivity, energy efficiency, safety and ergonomics. The company was founded in 1873, is based in Stockholm, Sweden, and has a global reach spanning more than 180 countries. In 2014, Atlas Copco had revenues of BSEK 94 (BEUR 10.3) and more than 44 000 employees.

About Atlas Copco Atlas Copco is a worldleading provider of sustainable productivity solutions. The

For more information, Website: www.atlascopco.com

ESPRIT CAD/CAM Software Unveils Innovative New Website & Branding ESPRIT CAD/CAM SOFTWARE enters a new era with the launch of its new brand identity and corporate website, espritcam.com. The website showcases an elegant new 3D-style logo that updates yet honors the company’s original one.

Immediate and Immersive Experience “Our new website immerses visitors in the software - straight from the homepage,” says ESPRIT’s Director of Global Marketing and Communication, Cedric Simard. “Thanks to our

ESPRIT CAD/CAM’s innovative, educational and responsive new website: espritcam.com

MACHINE TOOLS WORLD FEBRUARY 2016

educational videos, machinists can instantly experience ESPRIT software in action and witness its compatibility with machine tool brands from around the globe.”

Intuitive and Responsive Design Built with machinists and ESPRIT customers in mind, the website is available in nine languages and is responsive across multiple platforms and devices. The site features clear navigation for visitors in any manufacturing industry. Whatever their needs, machinists can access relevant information based on their

industry, their machine tool, or the type of machining operation they want to perform.

Educational Content The new website showcases ESPRIT’s capabilities, especially in 5-axis, multitasking, wire EDM, and Swiss-style machining. In addition, product pages highlight ESPRIT’s compatibility with machine tool builders, world-class customer support and factory-certified post processors.

Website: www.espritcam.com

BUSINESS NEWS www.mtwmag.com

Water-Based Bonded Coatings for Improved Workplace Safety When selecting products for coating elastomer profilesand components, workplace safety plays an increasingly important role since the volatile organic solvents enabling application of the bonded coating may cause considerable air pollution. This is why manufacturers and coating companies are increasing their efforts to find alternative products to replace conventional bonded coatings which contain organic solvents. Klüber Lubrication has now launched water-based bonded coatings which are completely free of organic co-solvents. “We succeeded in developing bonded coatings which outperform comparable products and at the same time make a substantial contribution in increasing the operational safety at a customer’s plant”, explains Frank Werner, Head of Business Unit Automotive for Klüber Lubrication. Klüberflex 100-0 N is one such new product which particularly helps in reducingfriction and wear of profiled seals used in the automotive industry. Due to its innovative formulation including a modern binder system, the silicone-hybrid bonded coating hardens quicker than conventional products. The curing time of Klüberflex 100-0 N in the coating chamber at 150 °C is only 5 minutes instead of the usual 15 minutes taken by conventional products. In Klüberflex 100-0 N, cross-linking takes place on the extrusion line at an

object temperature of 220 °C in under 60 s. In addition, customers benefit from a higher flexibility of the coating, even at temperatures down to minus 40 °C.

Another new addition is the Klübertop TP 22, 27, 31-1310 A-B (series). This series of water-miscible, two- component bonded coatings for “automotive body seals” have been specially developed for reducing friction, wear and noise in automotive body seals in contact with glass. Klübertop series offers a one product concept to customers with several solid lubricant variants available. For instance, this product is used in applications for window channel seals and weather strips. It is also suitable for various other applications like door and sunroof seals, folding top seals and front and rear window seals. The product also offers quick quality inspection of the coating after application by integrated UV indicator. Many of the products from this coating range have been approved by OEMs worldwide and are used across application points. To know more on solution for bonded coatings please visit, Klüber Lubrication at the Auto Expo Component Show, 2016, in hall 10, stand no. 10.3

Website: www.klueber.com

FEBRUARY 2016

MACHINE TOOLS WORLD

BUSINESS NEWS

Renishaw Launches New CARTO Software Solution for Calibration Systems Renishaw is launching a new free software suite for Renishaw calibration systems at EMO 2015. The suite includes Capture and Explore, which provide data capture and analysis for the XL-80 laser interferometer system. CARTO release 1.1 supports linear, angular and straightness measurement with a choice of keypress, position and remote (TPin) triggering. CARTO features a new database system which automatically stores and organises data for the user, simplifying operation and allowing users to quickly and easily compare data with historical results. Capture has been introduced to the CARTO suite as an improved and updated data capture application with the following features: • The orientation of machine movement is detected automatically, reducing the

MACHINE TOOLS WORLD FEBRUARY 2016

adding company logos.

User-friendly interface

chance for human error in the process. • The intuitive user interface allows new users to begin capturing data quickly with less requirement for training. • All the core functions are available on one screen for efficient navigation. • ISO-10360 target sequences can be automatically created, simplifying a challenging test set-up. Explore brings the advances of XCal-View data analysis software to the CARTO suite

with the following features: • Tests in the database can be searched by different criteria (such as machine name, operator, and date etc.). This enables users to review historical test data conveniently. • Multiple data sets can be overlaid on the same screen for visual comparison. • Linear error compensation files can be created from test results. • Customisable test reports can be created with choices such as graph line thickness and

The intuitive CARTO user interface allows new users to begin capturing and analysing data quickly, without the need for training or reading lengthy manuals. The capacity for customisation throughout the suite means that both Capture and Explore can be tailored to suit an individual user’s requirements. Further development on CARTO will follow to add more features, including rotary, flatness and dynamic measurement. CARTO release 1.1 will be available to download free of charge from www.renishaw.com/carto.

For more information, Website: www.renishaw.com

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BUSINESS NEWS

BIMH’16 Grows & Confirms the Recovery of the Sector With four months still to go before it opens its doors, BIEMH, International Machine-tool Exhibition, has already exceeded the figure for floorspace attained at its previous editions, with 1.183 exhibiting firms having reserved space in five halls at the exhibition centre. Since the campaign for the event kicked off in June last year significant growth has been maintained over the figures recorded at equivalent times leading up to the previous edition. These are the data presented yesterday at a press conference. The speakers at the press conference were Arantza Tapia, Chair of the Board of Directors of Bilbao Exhibition Centre and Basque Government Minister for Economic Development and Competitiveness, Xabier Basañez, General Manager of BEC, Xabier Ortueta, General Manager of AFM (Spanish Association of Machine-Tool, Accessory, Component and Tool Manufacturers) and Jorge García, Chair of AIMHE (Association of Machine-Tool Importers). After the press conference there was a visit to the facilities of Danobat, Delteco and AIC (Automotive Intelligence Center), as representatives of manufacturers, importers and users. Thus, after a year which saw a consolidation in the recovery of industrial activity, a clear year-on-year increase in output indices and improvements in the main economic indicators, the prospects for this year are positive and the effects on contracting are plain to see.

MACHINE TOOLS WORLD FEBRUARY 2016

Thanks to this situation, the first preliminary information on exhibitor numbers highlights the presence of first-time exhibitors and firms who are returning to the event after the crisis in a display of renewed confidence. Such firms account for more than 20% of the total number registered so far. In terms of sectors, growth is most notable in tools (26%), shaping machine tools (15%), robotics and handling (10%) and product development and manufacturing software (6%), making this a forum for advanced solutions. Other sectors taking part include cutting machine tools, components and accessories, services, metrology and quality control, welding and flame cutting machinery and other machinery. Firms outside Spain value the opportunity offered by the BIEMH against a background of recovery in domestic demand, and the international nature of the event is thus taking shape with confirmations of attendance from exhibitors hailing from 20 countries (Germany, Italy, Switzerland, Portugal, France, the UK, the Czech Republic, Turkey, Taiwan, Denmark, Belgium, Austria, Japan, the USA, Sweden, Finland, Netherlands, China, Poland and Bulgaria).

Between them they will turn the BIEMH into a great “factory of the future” that contains key points for understanding the challenges of Industry 4.0 and the new paradigms associated with it. Predominant among them are concepts concerned with the application of online intelligence to production processes in the form of smart solutions associated with strategic commitment, and commitment at national level, to the Europe 2020 plan for a smart specialisation. The Basque government has approved three programmes worth €5.2 million, aimed at implementing electronics, information and communication technologies (EICTs) in manufacturing industry and supporting technology transfer projects.

A key years for consolidating competitiveness Firms are seeing this year as a key period for consolidating their competitiveness, modernising their production machinery

and developing new technology-related investment projects. In that context, the BIEMH provides a unique opportunity to see at first hand the best solution is for offering smart products manufactured smartly. In an international context, the campaign to attract visitors is gathering strength in those countries highlighted by exhibitors as priority destinations for machine-tool exports, i.e. Germany, France, Italy, the UK, Sweden, Poland and Turkey in Europe, plus China, India, the USA, Mexico and Colombia. The commercial team for the event has already travelled to many of these countries and is currently preparing trips to Germany, the UK and India in the near future. The ultimate aim of these trips by the organisers of the BIEMH is to attract foreign purchases via the programme of hosted delegations. They are backed up in that endeavour by distributors, importers and sectoral associations, their own agents, the offices of SPRI abroad & chambers of commerce. Moreover, in view of the recovery in the domestic market, the organisers are reinforcing actions intended to attract strategic domestic purchasers, also in line with indications provided by exhibitors themselves.

ADDIT3D AIMS to set ADDITIVE Manufacturing In Context Bilbao Exhibition Centre and Addimat (Spanish Association of 3-D and Additive Manufacturing

BUSINESS NEWS www.mtwmag.com

Technologies) are set to take another step forward in their commitment to advanced manufacturing with the staging in May of ADDIT3D, Spain’s first fair of 3-D and additive manufacturing aimed exclusively at the trade. The firms in the sector have welcomed this initiative warmly because, in their own words, it enables them to set 3-D and additive manufacturing in context as regards manufacturing technologies, raises their profiles and gives them a commercial boost. The exhibition area of ADDIT3D is to feature firms working with systems and machinery, raw materials, R&D, industrial applications, consumables, services, software, scanners and training. The event organisers are also designing abroad programme of presentations and activities that will com-

bine educational and technical aspects with the presentation of innovative applications and products, with live demonstrations of the advantages of these technologies.

Workinn, Spain’s Only Industrial Employment Fair The WORKinn employment and training fair will be held concurrently with BIEMH. Aimed at young people, the event’s goal is to bring students into contact with the job market and opportunities in the machine-tool sector with a view to future recruitment at firms in the sector. Universities, vocational training centres, temporary employment agencies, employment and development agencies and firms from sector will be taking part in the only industrial employment fair in Spain, where they will be showing off current job opportunities, seeking to

identify talent and promoting the recruitment of the best qualified individuals. WORKinn will feature presentations, an exhibition area, workshops and private meeting and interview areas.

International Oil&Gas and Maintenance Conferences Finally, also concurrently with BIEMH, Bilbao Exhibition Centre and international event organiser Easyfairs are to organise two international conferences: Oil & Gas and the Maintenance Innovation Conference. These events will provide annual meeting points for the sectors involved, following on from the first editions in 2015 of the Pumps & Valves and Maintenance fairs.

Biemh, a Milestone for Business Tourism BIEMH is set to be one of the

landmark events on the agenda of Bilbao Exhibition Centre 2016, which is expected to be a year of consolidation following the economic recovery of the previous year. In 2015 over 2550 exhibitors and almost 848.000 visitors took part in the 221 events held at the centre, which between them attain the economic impact of more than €73 million. BIEMH is also one of the biggest events in the Basque Country for business tourism, as it is the biggest industrial platform in Spain and attracts thousands of manufacturers and buyers from all over the world. To offer participants an all-round experience that also extends to the local cuisine, culture and landscapes, Bilbao Exhibition Centre works closely with Basquetour, a Basque tourist agency answerable to the Basque Government.

NUM to Demonstrate End-Mill Grinding Software Innovation at GrindTec 2016 NUM will be demonstrating an innovative new development to its renowned NUMROTO tool grinding software at GrindTec 2016. The company is launching a suite of enhancements for the package, including new gash out-X and flute-X facilities that pave the way for next-genera-

tion complex geometry tools. NUM has also further enhanced the flexibility of NUMROTO by adding a number of new facilities for end-mills and drills. These include ‘Quickedit’ pages to simplify parameter selection for re-sharpening standard tools, predefined minimum cycle times to ensure reliable communication between the PC and the CNC even when generating very high precision tool paths with many points, and optimised grinding of rough profile end-mills. First launched in 1987, NUMROTO software has become the preferred choice for many of the world’s leading manufacturers

of machines for the production and re-sharpening of tools such as end-mills, drills, step drills, form cutters and many others. Compared to some competitive products on the market, the software provides a much more direct and efficient path between tool design and manufacture. Featuring an integrated modelling-simulation-interpolation chain, NUMROTO avoids the sequential CAD-to-CAM

and CAM-to-CNC translation phases of conventional software approaches and provides a true WYSIWYG output. This helps users of tool grinding machinery sidestep multiple data format changes and emulations. NUM’s stand at GrindTec 2016 – 7070 in Hall 7 – should be the first port of call for visitors wishing to see the future of CNC machine tool automation. Technical staff, equipped with computer workstations, will be on hand to demonstrate the advantages of NUMROTO software and to answer customers’ questions. Website: www.num.com

FEBRUARY 2016

MACHINE TOOLS WORLD

BUSINESS NEWS

Smart 3D Imager Arrays – A New Class Of Automated Metrology Sensor FARO Technologies, Inc. (NASD AQ: FARO), announces highly adaptable 3D imager arrays that promise to drive automated industrial manufacturing metrology processes to the next level. The new FARO Cobalt 3D Imager is equipped with dedicated on-board processors – an industry first. The smart sensor allows unique multiimager array configurations enabling industrial manufacturers to significantly improve productivity and operations in a way never before possible. An unlimited number of 3D imagers can be placed in array configurations virtually anywhere in a manufacturing process – all scanning simultaneously and controlled by a single computer. Ideal for integration within the production environment, Cobalt can also be installed in

more conventional ways, such as in conjunction with a rotary table, robot, or industrial inspection cell. Combining blue light projection, stereo cameras and powerful onboard processing, Cobalt captures and processes millions of 3D data points in seconds. With high resolution, automatic exposure and high dynamic range, Cobalt expertly handles complex parts with fine details, varying colors, textures and reflectivity. Cobalt delivers fast and consistent measurements, independent of the operator, for quality inspection and reverse engineering applications on parts, assemblies, and tools. “The FARO Cobalt 3D Imager delivers reliable and accurate 3D scan data within an automated workflow. With no restrictions on the number of sensors in an array, the sky is the limit for improving

inspection cycle time, making it an exciting new product that enhances the FARO portfolio for in-process or near-process inspection,” stated Dr. Simon Raab, FARO’s President and CEO. “The price and capabilities of Cobalt make it a cost-effective, versatile, and convenient tool that delivers a rapid return on investment for customers in a variety of metrology and product design applications.” Dr. Raab added, “We are particularly proud of Cobalt’s patent-pending on-board processing feature, which ultimately helps simplify the integration of the sensor into advanced production environments. Coupled with

FARO’s CAM2® Measure 10 software, an unlimited number of Cobalt sensors can simultaneously capture large surface areas or complex assemblies. The configurable field of view, intelligent on-board point cloud processing and resolution can adapt to multiple measurement needs. Our analysis shows that for dedicated inspections of large products or assemblies, a fixed multiple imager array of Cobalt sensors will be faster, more easily integrated, more affordable, more accurate and easier to maintain than purchasing the robot-based imager or laser line systems currently on the market. Yet, Cobalt can also outperform as a robot-based system with its high resolution and data processing speeds in combination with its low profile and light weight.” The FARO Cobalt 3D Imager is designed for quick and easy integration onto the production floor, and seamlessly connects with the full-featured FARO CAM2 Measure 10 metrology software.

For more information, Website: www.faro.com/india

MACHINE TOOLS WORLD FEBRUARY 2016

BUSINESS NEWS

Henkel Appoints Hans Van Bylen to Succeed Kasper Rorstedas CEO

Mr. Kasper Rorsted, Chief Executive Officer, Henkel

Henkel has announced that CEO Kasper Rorsted,who has decided not to renew his current contract beyond 2017, will leave the company at his own request as of April 30, 2016. He served on the Henkel Management Board for 11 years, thereof 8 years as CEO. Effective May 1, 2016, Hans Van Bylenhas been appointed as his successor. His successful career at Henkel started in1984and he serves asmember of the Management Board since 2005, responsible for the Beauty Care business. The appointment to CEOalready in spring will enable him to leading the development of the new strategy which Henkel will announce at the end of this year and driving its successful execution. “With the appointment of Hans Van Bylenas new CEO we have named a strong successor to the CEO position at an early time – as it is common practice at Henkel. Hans Van Bylenis an excellent choice as he has longstanding, international experience in managing brands and markets as well as a Management Board member at Henkel.

MACHINE TOOLS WORLD FEBRUARY 2016

On behalf of our governance committees and employees I wish Hans Van Bylen all the best and much success in his new role“, said Dr. Simone Bagel-Trah, Chairwoman of the Supervisory Board and the Shareholders’ Committee. The successor of Hans Van Bylenas Executive Vice President Beauty Care will be announced in due course. “I am honored by the confidence which is expressed through this appointment. I am looking forward to shape the future of our company together with my colleagues at the Management Board and an excellent global team. We have strong brands and technologies, leading positions in many markets and categories around the world and a strong innovation power. Building on this foundation,together,we will successfully lead Henkel into the future“, said Hans Van Bylen.

Successful company performance under Kasper Rorsted´s leadership “Kasper Rorstedhas achieved a lot for Henkel. Under his leadership since 2008, the company has delivered a successful performance in a challenging market environment.Sales and profitability increased significantly and our top brands have been strengthened. This is also reflected in a significantly increased market

capitalization which has been more than tripled since Kasper Rorsted took the helm. I would like to sincerely thank Kasper Rorstedon behalf of all governance committees, employees and shareholders of Henkel“, Dr. Simone Bagel-Trah further said. Kasper Rorsted (53) joined Henkel as member of the Management Board in 2005. He was appointed as Deputy Chairman of the Management Board in 2007 and has been appointed CEO following the 2008 Annual General Meeting. “I would like to thank all colleagues at Henkel for their commitment and dedication as well as the governance committees for their advice and support over the past years. Together, we have delivered an excellent performance for our company”, said Kasper Rorsted. “I am convinced that Henkel will continue to excel under the leadership of Hans Van Bylen as CEO.”

About Hans Van Bylen Hans Van Bylen (54) joined Henkel in 1984. His successful career at the company has spanned 31 years of management positions with broad geographical scope in two of Henkel´s business units, Laundry & Home Care and Beauty Care. He started in Belgium, his responsibilities expanded to Benelux and then on to France, Western Europe, Middle East Africa, North

Mr. Hans Van Bylen Executive Vice President Beauty Care, Henkel

America, Asia Pacific and Latin America.Since 2005, Hans Van Bylen is member ofthe Management Board, responsible for the Beauty Care business. He was born in Berchem/Belgium in 1961. He is married with three children. Heis a graduate of the University of Antwerp, with both a degree in business management and an MBA.

About Henkel Henkel operates worldwide with leading brands and technologies in three business areas: Laundry & Home Care, Beauty Care and Adhesive Technologies. Founded in 1876, Henkel holds globally leading market positions both in the consumer and industrial businesses with wellknown brands such as Persil®, Schwarzkopf® and Loctite®. Henkel employs about 50,000 people and reported sales of 16.4 billion euros and adjusted operating profit of 2.6 billion euros in fiscal 2014. Henkel’s preferred shares are listed in the German stock index DAX. For more information, Website: www.henkel.com

BUSINESS NEWS

PETRONAS Lubricants International Partners with Tata Motors to Launch Tata Motors Genuine Oil Tata Motors in association with PETRONAS Lubricants International (PLI) launched the Tata Motors Genuine Oil (TMGO) for its passenger vehicles range in the India market. TMGO will be the first range of co-branded lubricants jointly developed by the Companies. The co-branded range of lubricants – Tata Motors Genuine Oil CH-4 15W-40 for diesel vehicles and Tata Motors Genuine Gear Oil 80EP for passenger cars – makes part of a bigger range of nine co-branded products that will be rolled out in a phased approach. According to Mr. Dinesh Bhasin, Head, Customer Support, Passenger Vehicle Business Unit, Tata Motors Ltd., “Tata Motors has always worked with a customer centric approach and providing its customers with the best post-purchase experience. With the new co-branded TMGO range of lubricants now available, we are creating a distinct & differentiated value

proposition in the market. We will continue to provide our customers with the best lubricant technology expertise and support in today’s competitive market place. We are happy to have partnered with PETRONAS in developing this range for our vehicles. With a commitment to deliver better performance, TMGO will offer trusted support to our customers and will further enhance the customer

experience.” According to Mr. M.P.Singh, Chief Executive Officer, PETRONAS Lubricants (India) Pvt Ltd (PLIPL) “PLIPL has recorded steady volume growth at 40% CAGR and is aiming to capture 5% total market share by 2019. PLI in India is now entering the next wave of growth in line with our aspirations and we are confident that the coming together of Tata Motors, a

highly-respected leader in automotive engineering, together with PLI will help us better our position in this market as a leading provider of premium lubricants. We are offering a unique proposition through TMGO to further strengthen our relationship with customers and deliver products for engine care that is built upon a strong legacy in lubricants technology.” This new range of branded lubricants have been formulated from high performance base oils and additives, providing optimum engine performance through excellent deposit control and wear protection. These lubricants have been developed as per the regulations and specifications required for the Indian passenger vehicles market. These products will be available through PETRONAS distributor network of over 3,500 outlets, across India today and will be rolled out progressively in 2016.

About PETRONAS Lubricants International

About Tata Motors

PETRONAS Lubricants International (PLI) is the global lubricants manufacturing and marketing arm of PETRONAS, the national oil corporation of Malaysia. Established in 2008, PETRONAS Lubricants International manufactures and markets a full range of high-quality automotive and industrial lubricants products in over 80 markets globally. Headquartered in Kuala Lumpur, PLI has over 30 marketing offices in 23 countries, managed through regional offices in Kuala Lumpur, Turin, Belo Horizonte, Chicago and Durban. Currently ranked among the top 15, PLI is driving an aggressive business growth agenda to secure its position as a leading global lubricants company.

Tata Motors Limited is India’s largest automobile company, with consolidated revenues of INR 2,62,796 crores (USD 42.04 billion) in 2014-15. Through subsidiaries and associate companies, Tata Motors has operations in the UK, South Korea, Thailand, South Africa and Indonesia. Among them is Jaguar Land Rover, the business comprising the two iconic British brands. It also has an industrial joint venture with Fiat in India. With over 8 million Tata vehicles plying in India, Tata Motors is the country’s market leader in commercial vehicles and among the top in passenger vehicles. Tata cars, buses and trucks are being marketed in several countries in Europe, Africa, the Middle East, South Asia, South East Asia, South America, Australia, CIS and Russia.

For more information, Web: www.pli-petronas.com

For more information, Website: www.tatamotors.com

MACHINE TOOLS WORLD FEBRUARY 2016

COVER STORY

MAKINO: Global Leadership in EDM Technology Arena Mr. Sadananda Koppalkar Head Business Development - EDM, Die & Mold, Makino India Pvt Ltd

Q. Please brief us about recent initiatives undertaken in EDM space? Which are your focus areas? Electric Discharge Machining technology is undergoing a sea change in terms of process capabilities and productivity levels. Several developments in Power Electronics, Adaptive control technologies and innovative process techniques have pushed the limits of EDM capabilities in terms of machining speed, accuracies and achievable surface finishes. EDM Controllers are getting more intelligent and are able to adapt and optimize machining conditions according to machining requirements and reduce human intervention to a great extent.Automation solutions are also becoming more practical and have a

MACHINE TOOLS WORLD FEBRUARY 2016

dramatic impact on productivity. Makino has been focusing on integrating these new technologies into practical features in its new generation machines and making it work for real life challenges.

Q. What are the market opportunities for your products in India? How do you plan to position these products? The Indian Die Mold tool rooms cater to the Automotive Industry predominantly and to some extent the FMCG Industry. In the last few years, requirements in terms of Quality/Cost/Delivery are driven by globally competitive market forces. Hence the Indian tool rooms have an immediate need to upgrade their infrastructure to meet such global

COVER STORY www.mtwmag.com

justified by their capability to meet current demands for high quality and productivity.

Q. According you what are the factors affecting to your business?

levels of productivity and quality. The requirement is not just high quality machines but also a knowledgeable workforce. This is a huge opportunity for Makino, where we focus more on a holistic technology transfer to our customers rather than just supply machines. In the last two decades, many tool rooms have invested on our High Speed Milling machines but the EDM area has always been lagging behind with low cost machines. With growing demand for high quality molds and dies, at greatly reduced manufacturing lead times, tool rooms can no longer survive with age old, low cost/low end EDM machines. We are now seeing a huge opportunity for highly efficient EDM machines whose higher cost are

• Our market is predominantly dependent on the Indian Automotive industry. Both domestic and export trends in the automotive industry have a direct impact on our growth • The quality and complexity levels of the molds and dies manufactured in India is getting more closer to the global levels and coupled with a demand for short lead times, there is a huge opportunity and demand for highly efficient machining technologies. • Demand for short lead times and cost pressures are resulting in long term efforts to establish local infrastructure for producing high quality molds

Q. What are the key technological trends that are driving EDM industry? • The most important trend that is driving CNC EDM business is the usage of Graphite as electrodes. Most of the shops are in rapid conversion mode from Copper electrodes to Graphite electrodes and this switch over demands a good CNC EDM as the technologies in conventional machines are limited to certain quality and speeds and this creates the demand to go for better machines. • Recently many Japanese and European companies have entered

India directly and also procuring the Tools and Molds from local commercial tool rooms which demand high accuracy and faster lead time. This is forcing the customers to go for a high end CNC Machines to meet the commitments of both quality and delivery. • In order to reduce the dependency on skilled manpower, today’s tool rooms demand an easy operator interface modules and easy programming methods to have smoother transitions. The newest controllers focus more on integrating efficient Adaptive Control and intelligent Programming Features which makes EDM operations simple and less dependent on operator skills.

Q. What is your vision for your company? We would like to be a one stop machining solutions provider to Tool rooms by contributing latest technologies, process and manufacturing practices so that the quality and delivery demands by OEMs can be met by our customers. Keeping in mind the requirement of right manpower for the industry, we have established a Technical Training Center, a first of its own kind that provides a 1 year comprehensive training covering the topics of machining, CAD/CAM, quality and best manufacturing practices. These students, upon successful completion of the course, are offered to our customers across the country.

FEBRUARY 2016

MACHINE TOOLS WORLD

COMPANY PROFILE

Effica’s Robotic solutions

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

A customized robot engaged in machine tending 22

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Effica’s state-of-the-art production facility in Coimbatore 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.

with this the existing plant layout need not be disturbed. It also does bag conveying & 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

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

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 & 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.

Taming power quality is now child's play

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

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

Our equipment are approved by major OEMs and exported (up to 2000 KVA) to countries in Europe, Middle East, Africa

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COMPANY PROFILE

Gurutzpe CNC Lathe Machine : Excellence with technology innovation

/s. Tornos Gurutzpe, S.A. Spain one of the leading Manufacturers of CNC Lathe Machines in the world. They have started their production activities way back in 1957 with conventional Lathes and with their dedication and hard work step-by-step they have increased their production range to latest generation and state-of-art CNC Lathe Machines by incorporating latest Technologies and Innovations available in the market from time to time to comply with competitive quality and tailor made solutions required by its clients and they a ISO 9001 / 14001 certified company. Their range of productions includes 2 Guide-Ways and 4 Guide-

MACHINE TOOLS WORLD FEBRUARY 2016

Ways-Lathes, which include the most up-dated technological advances to satisfy the most demanding Machining request of their customers. Gurutzpe complements this broad range of products with teaching services, machine commissioning and preventive maintenance capable of answering special requests of their customers. ORIENTAL MACHINE TOOLS CO., (Prop. Suraj Tools & Equipments Pvt. Ltd) Office No. 517, 5th Floor, Bharat Industrial Estate, T.J. Marg, Sewree (West) Mumbai-400015 (India) Phone No. 91 - 22 - 2416 1991/92 E-mail: omtc@omtc-online.com / omtc@vsnl.com

COMPANY PROFILE www.mtwmag.com

Kinglan Power Press ALP & ALC Series: High Precision, Rigid, Efficient & long life Fully Automatic Power Press

K Mr. Zuber Shaikh, CEO Hamd Machine Tool Solutions

inglan ALP & ALC seriesare single and double crank Power Press. These are most selling product of Kinglan due to its many features and long life performance. Kinglan believes in total solutions so takes full responsibility and provides wide range of automations like coil feeder, robots with dies as total solution.

High Precision :

These series are highlyprecise with high rigidity and Performance. The dynamic Centre deviation is small, vibrations and noiseis less which improves the life of Die and maintains die accuracy. The structure is of highly rigid steel material with minimizes deflections. Also it uses locking type six face guide ways with low synthetic clearance which enhances precision and rigidity.

USER Friendly

Fault Diagnosis is user friendly and easy due to graphical display of alarms and their recovery procedure.Operating of machine is easier due to customized PLC and display screen.

Energy saving

High Level of Safety

Kinglan Power Press are energy efficient and saves 30% of power consumption which reduces the major running cost.

Is provided in the machine to operator as well as to machine. A special double acting hydraulic over load protection valve is provided along with different functional interlocks to avoid running of machine under abnormal conditions and prevent Press and die. Also provided over run safety device &mis feed protection to avoid damage of components. Front side of Press avery sensitive and high response time Photo electric sensor is provided with double push button interlock. Safety keys are provided to safety interlocks and machine parameters.

For more information, Web: www.hamdmachines.in

FEBRUARY 2016

MACHINE TOOLS WORLD

COMPANY PROFILE

Lokesh Machines : Coherent Performance Driven Growth

Mr. M. Lokeswara Rao Managing Director

Mr. M. Srinivas Director

Mr. M. SriKrishna Director (CNC Machine Division)

CNC Turning centres 28

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Horizontal Machining Centres

/s. Lokesh Machines Ltd commenced its operation in 1985, presently operating from Hyderabad & Pune (Total 5 locations). M/s. Lokesh Machines Ltd. has been serving industry with Special Purpose Machines (SPM’s) like Simplex & duplex milling, Multi Drilling, Gun Drilling. Fine boring, Mini Transfer Lines, Semi Automated equipment’, Special applications. Other product range includes general purpose machines like CNC lathes, Vertical Machining Centres, Horizontal Machining Centres. Lokesh Machines Ltd is also into automotive component machining

Vertical Machining Centres with pallet changers

Vertical Machining Centres business. Years of experience of SPM building & experience of component machining has helped to offer highly productive & rigid machines . Lokesh machines have a lot of distinct features to offer extra to customers ; for example Vertical Machining Centres are offered with LM Roller guide ways . More than 3000 installations of GPM’s in Indian & overseas market along with local service & support network, Lokesh Machines Ltd has established itself as a successful manufacturer & a solution provider in the field of machine tools.

For more information, Website: www.lokeshmachines.com

COMPANY PROFILE

Radius Engineering : The extensive application expertise in deep hole drilling

adius Engineering Solutions Private Limited was promoted in the year 2006 essentially as a engineering solutions company and service provider offering turnkey solutions to customer. The company can offer gundrilling machines / Deep hole drilling, BTA machines and also Stator coil making machines. Radius Engineering solutions private limited has extensive application expertise in deep hole drilling and offers subcontract manufacturing / job work for deephole / gundrilling for various components in different sectors like automotive, aerospace, die mold etc. Radius can offer subcontract gundrilling for various diameters ranging from 1mm dia to 30mm diameter The Company has the following area of expertise. The company has the following area of expertise.

1. Gundrilling / deep hole drilling machines 2. BTA machines for diameters ranging from 30mm diameter to 100mm diameter with pressure head and steady supports. 3. Micro Gundrilling machines for diameter less than diameter 2 for fuel injection systems and medical parts like cannulated holes, bone screws etc 4. Subcontract deep hole drilling / Job work for gundrilling for sizes from dia 1mm to dia 30mm 5. Coil curing press, coil spreading machines, coil straightening buffing and cutting machine, taping machines for stator coils and roebel bars. 6. Design Conceptualization. Preparation of detailed design and layout. Integration and Assembly. Tryout and Testing to prove accuracy and reliability. After sales service.

MACHINE TOOLS WORLD FEBRUARY 2016

7. Retrofitment with CNC system and PLC and automation 8. Reconditioning and Refurbishment. The company has the following area of expertise.

1. Design Conceptualization. 2. Preparation of detailed design and layout. 3. Integration and Assembly. 4. Tryout and Testing to prove accuracy and reliability. 5. Best after sales service. 6. Retrofitment with CNC system and PLC and automation. 7. Reconditioning and Refurbishment. Radius Engineering Solutions Private Limited is an emerging unit providing integrated turnkey solutions for the engineering segment through interdisciplinary and integrated approach with blended skills and thorough know how in mechanical, electrical, application & design areas. Radius will capitalize on its expertise by positioning the company to develop products like standard slide assemblies, spindle assemblies, rotary indexing modules & cater to both local and export markets & develop machine tools accessories like lubrication unit, coolant tank, hydraulic power pack etc. The Company intends to partner with key clients in providing sales and service support for their products (High end products which are service and application intensive) and secure and sustain Annual Maintenance Contracts. The Company intends to have strategic tie-ups with local / foreign companies for either manufacturing or sales/services of different products. In machining, the focus will continue to be on components used in semisophisticated equipment where a possibility exists to pursue the next

level of integration by assembling components or prepare part kits for assisted assembly. Focusing on this product-component relationship will facilitate the companyâ&#x20AC;&#x2122;s ability to pursue the vertical integration of the business and pass on the value-added savings to our customers. The Company intends to partner with key clients in providing sales and service support for their products (High end products which are service and application intensive) and secure and sustain Annual Maintenance Contracts. The company intends to have strategic tie-ups with local / foreign companies for either manufacturing or sales/services of different products. In machining, the focus will continue to be on components used in semisophisticated equipment where a possibility exists to pursue the next level of integration by assembling components or prepare part kits for assisted assembly. Focusing on this product-component relationship will facilitate the companyâ&#x20AC;&#x2122;s ability to pursue the vertical integration of the business and pass on the value-added savings to our customers. For more information, Website: www.radius.net.in

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

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

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

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

www.junker.in

TECH UPDATE

Ceramic Coatings from Spraymet for Refurbishing Machine Tool Parts

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

MACHINE TOOLS WORLD FEBRUARY 2016

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. â&#x20AC;&#x201C; P.K. Balasubbramaniian

Waste into wealth: Spraymet harnesses the best of surfacing technologies to reclaim machinery components and parts and conserve resources

TECH UPDATE www.mtwmag.com

Mastercam X9 Mill Brings Speed, Efficiency, & Automation

astercam X9 Mill offers expanded machining flexibility and an increased emphasis on speed and automation. 2D High Speed Toolpaths, 3D enhancements, and Multiaxis features combine with dozens of additional new enhancements in a package intended to improve shop floor productivity. Here are some of the most significant highlights and new functionality in Mastercam X9 Mill:

X9 linking moves are closer to your model, eliminating costly excessive air motion when rest roughing against irregular stock shapes. streamline and simplify workflow, X9 supports Preview Toolpaths for select Mill toolpaths. You can use the new preview button to see your resulting toolpath before closing the parameters dialog.

2D High Speed Toolpaths

3D Enhancements

Mastercam X9 supports generic Radial Chip Thinning in a number of applicable Mill and Mill 3D toolpaths, making it easier to program efficient feeds and speeds while maintaining targeted chip thickness. Mastercam X9 also builds on its already efficient and powerful Dynamic Motion engine, and introduces an optional Conventional cut feed rate, giving you better control of your machining dynamics. In an effort to

Surface High Speed Hybrid now supports dedicated flat processing, making Hybrid even more intelligent and efficient. Mastercam X9 introduces new containment boundary options for better control over your tool tip

and actual tool contact point. Surface High Speed Finishing toolpaths now support two ways to treat your containment boundaries for more control over your motion. The efficiency of the 3D HST Rest Roughing Linking has been improved—

Multiaxis Improvements

Program your multiaxis equipment with confidence and ease using the new Multiaxis Link operation, which ensures reposition moves between 2- through 5-axis operations are safe and collisionfree. Mastercam X9 introduces improved processing logic for advanced multiaxis toolpaths. Select multiaxis toolpaths now process in the Multi-Threading Manager, streamlining your 2- through 5-axis workflow experience. Additional powerful tools in Mastercam X9 Mill include:

• New minimize tilt option for Port Expert to refine the already smooth and efficient Port Expert motion. • 2D High Speed Peel Mill makes a comeback in X9. • Multiaxis toolpaths are displayed as normal tool motion instead of vectors in the graphics window. • Thread Mill and Barrel tool support have been added. • 2D HST Blend includes a new cut order. You can now machine from the outside to the center or from the center to the outside.

For more information, Website: www.mastercam.com

FEBRUARY 2016

MACHINE TOOLS WORLD

TECH UPDATE

Hangsterfer’s Crystal Brite EDM - Dielectric Fluid Low-Viscosity Dielectric Fluid for Spark-Erosion EDM Is Stable under High Amperage Good for Both High and Low Amperage Spark Erosion

he formulation of Crystal Brite EDM cutting oil and dielectric fluid, which is available from Hangsterfer’s Laboratories Inc. and intended for die-sinking EDM, has been proven successful in both high- and low-amperage sparkerosion processes. Its blend of ultrapure hydrocarbons with the latest synthetic technology provides a crystal-clear fluid with high oxidation stability and extremely low viscosity. The fluid is stable under high amperage and offers fast flushing in tight-tolerance finishing

work. Crystal Brite EDM is suitable for both roughing and finishing applications. The extremely low viscosity of this dielectric fluid, combined with its low specific gravity, makes both flushing and filtration fast and efficient. The result is higher metal-removal rates. Filtration efficiency benefits from lower carbon and residue formation. The filter lasts longer, and particulate matter is prevented from returning to the interface between the electrode and the workpiece. With proper filtration, this fluid will last indefinitely. Crystal Brite EDM is safe and operator friendly. The odorless fluid contains no solvent-based hydrocarbons, which helps eliminate skin irritation and reduces oil mist and exposure to solvent vapour. It is not to be mixed with water. Hangsterfer’s Laboratories supplies a full range of metalworking fluids, including coolant concentrates, cutting oils, metal-forming compounds, machine lubricants, dielectric fluids, rust inhibitors, solvent- alternative cleaners, and specialty additives, and also offers a line of complementary equipment. The products work well with aluminium, carbon steel, cast iron, chrome alloys, composites, copper, magnesium, nickel alloys, stainless steel, and titanium alloys. For more information Hangsterfer’s Laboratories, Inc.USA Sanjay Tools & Adhesives, India Mobile : +91 9822028518 +91 9892516810 E-mail: hangsterfers@sanjaytoolsnsk.com Website: www.hangsterfers.com

MACHINE TOOLS WORLD FEBRUARY 2016

TECH UPDATE

Increased productivity & process reliability at MTU Aero Engines due to Safe-Lock Due to the positive form and frictional clamping system made by HAIMER, MTU Aero Engines in Munich was able to increase the reliability in the process of machining difficult-to-cut materials while also decreasing their processing times.

TU Aero Engines is Germany’s leading engine manufacturer and an established global player in the industry. The company engages in the design, development, manufacturing and support of commercial and military aircraft engines in all thrust and power categories and stationary gas turbines. Due to HAIMER‘s patented Safe-Lock™pull out protection system, MTU was able to optimize their machining process regarding the production of structural frames and castings. Jet engines are high-tech products. In their production, innovative technologies and processes are used. To keep current technologically, MTU develops innovative manufacturing strategies, and if necessary obtains additional external expertise. So was the case when they contacted HAIMER, the tool holding specialists from Igenhausen, Germany, to help optimize the demanding machining process of manufacturing frames and castings. Difficult-to-machine materials, highquality components and the high degree of automation at MTU require an absolutely smooth and reliable machining process to maintain the highest levels of quality. In order to ensure this consistency and to control the high axial cutting forces during machining, MTU decided to implement the Safe-Lock™ pull out protection system by HAIMER. In the HAIMER Safe-Lock™ system, special drive keys in the tool holder and grooves in the tool shank prevent the cutting tool from spinning during extreme machining, thus preventing tool pull out from the chuck. In addition to the frictional clamping forces of the selected

MACHINE TOOLS WORLD FEBRUARY 2016

clamping system, the cutting tool is held using positive form locking in the tool holder through the constructive design of the Safe-Lock™ system.Alexander Steurer, Senior Manager NC-Programming Stator Components at MTU Aero Engines AG in Munich, explains the decision for the HAIMER system: “Through the introduction of Safe-Lock™ and the shrinking technology from HAIMER, we can guarantee process reliability even with milling challenging high temperature materials. This is a prerequisite to guarantee smooth processing during manufacturing of frames and castings, given our high degree of automation.“ The combination of pull-out protection and highest concentricity of the SafeLock™ system leads to low vibration and as a result, a very stable machining process. Due to the increased cutting depths and feeds, the metal removal rate can be increased significantly. And thanks to the improved runout accuracy of HAIMER shrink fit chucks, tool life is improved by up to 50%. The benefits of less than 3 µm runout, that the symmetrical Safe-Lock™ design provides, coupled with optimum balance and the possibility for easy length presetting were substantial reasons for

MTU to switch to the HAIMER system instead of continuing to use Whistle Notch or Weldon tooling systems. While these other systems do in fact prevent tool pull out, both are unsymmetrical by design, hence providing insufficient runout and balance accuracy. Through the use of a set screw the cutting tool is wedged against the opposite wall of the clamping bore. The holder pushes the cutting tool off center and thereby leads to excessive amounts of runout. Any such design also allows for significant radial play between the tool shank and the bore itself. That way the aforementioned holders actually push the cutting tool off center, thereby inducing excessive amounts of runout. Hans Drahtmüller, Line Manager Machining Stator Components at MTU in Munich, explains the resulting problems: “Due to the deteriorated runout, the tool life could not be fully realized. As a result, the tools with a Weldon flat had to be exchanged early. With Safe-Lock™ regrinding could be automated due to the cylindrical form of the system, as the cutting tools no longer have to be inserted manually into the grinding machine compared to Weldon flat tooling. This saves tool costs!“

TECH UPDATE www.mtwmag.com Easy and quick tool change

In addition to productivity improvements in the machining process, time is also saved outside of the machine via extremely fast and easy tool changes. HAIMER Power Clamp Premium NG, the high end shrink fit machine MTU is using currently, offers an ergonomic working space, perfect handling and linear guided cooling bodies with temperature monitoring for maximum safety. Presetting the tool length to exactly 0.02 mm (e.g. for sister tools) can optionally be integrated into this machine. The intelligent New Generation (NG) coil is adjustable. With one turn, you can set the coil to the size of the shrink fit chuck both in length and diameter. This new system obsoletes the former interchangeable ferrite stop disks, which were always at risk of breaking during change overs. Thanks to the multiple patented HAIMER technology, the shrink fit chuck is only heated in areas where it is necessary. This way the process of both heating and cooling the tool holders is much faster. During the cooling process different sized cooling bodies shorten the cooling time and create a gentle, even and clean cooling effect. The cooling bodies ride on linear guides, so that the cutting edges are always protected from collision with the cooling body. MTU Aero Engines

MTU Aero Engines AG is Germany’s leading aero engine manufacturer. The company is a technological leader in low-pressure turbines, high-pressure compressors, turbine center frames as well as manufacturing processes and repair

techniques. In the commercial OEM business, the company plays a key role in the development, manufacturing and marketing of high-tech components together with international partners. In the commercial maintenance sector the company ranks among the top 5 service providers for commercial aircraft engines and industrial gas turbines. The activities are combined under the roof of MTU Maintenance. In the military area, MTU Aero Engines is Germany’s leading industrial company for practically all engines operated by the country’s military, the German Bundeswehr. MTU operates a network of locations around the globe; Munich is home to its corporate headquarters. In the fiscal year 2014, the company had a workforce of some 9,000 employees and posted consolidated sales of approximately 3.9 billion Euro. HAIMER shrinking technology

During modern high-end milling operations systems with Weldon shanks reach their limits because of their insufficient runout accuracy. During operations with a high rpm even the smallest differences can lead to poor results, tool and spindle wear and can reduce the surface quality. Here lies the strength of the shrink fit chucks, which offer high runout accuracy thanks to their rotationally symmetric clamping body. HAIMER products offer runout accuracy of less than 3 µm at a length-to-diameter ratio equal to 3x the tools diameter. Website: www.haimer.com

FEBRUARY 2016

MACHINE TOOLS WORLD

TECH UPDATE

Laser calibration at the speed of light - comparatively speaking

he word “laser” implies “light speed” for the casual listener, but witnessing a bi-directional laser calibration run on just one linear axis of a CNC mill conjures up a completely different image – that of something less than the speed of light. A short 1 m axis can typically take 30 to 60 minutes as the machine axis moves in 10 mm increments and stops to pause and settle before the laser interferometer takes a reading. That pause can be as long as 23 seconds during some tests. The downtime it causes for calibration of a large, high value asset can make a machine shop owner bite through nails. Depending on machine crashes and the quality system the shop adheres to, a machine may be out of action for several days each year to perform a laser calibration, so shop owners are always focused on this issue. However, a technique that takes advantage of a feature in Renishaw’s XL-80 laser interferometer reduces settling time to just 250 milliseconds after each incremental axis move, cutting calibration times by 85-95 percent. In addition to reducing downtime on critical production assets, this methodology better reflects axis positioning accuracy under actual

cutting conditions, where moves are fast and there is virtually no settling time before tool engagement with the work. Quality Tech Services in Byron, Georgia, USA, has used the technique and instructed new laser buyers on it as well. “As a new calibration service, the first concern we hear when we walk in the door is downtime on a machine,” said Mike Schraufnagel, company owner. “Customers will do anything to cut downtime on a critical asset, and our customers who own lasers love this capability. For us, the technique has been a boon to our efficiency. What normally would take 30 minutes now takes just three. In one afternoon we were able to complete six laser set ups and three ballbar set ups on a machine in two hours. This would normally have taken at least a day.” M-Code and an open contact relay is all that is required

To use the high speed calibration technique, a machine’s CNC could use an available M-code which, if not available, is usually a purchasable option to close a “normally open” set of relay contacts for between 10 and 20 milliseconds. Closure of the relay contacts, via an auxiliary I/O

cable, will provide a trigger for the laser to record the difference between the laser reading and the target position. M-codes are typically used in CNC for probing cycles, to control coolant and capabilities other than axis positioning moves, so this option is available as standard on many CNC. In others M-Code may be an option that simply needs to be purchased or turned on by the OEM. “We identified spare relays that can be controlled via M-Codes on a Haas CNC machine in our lab. This got us started in thinking of the many ways users could reduce overall machine down time by triggering the laser interferometer via a part program. This type of signalling will more accurately record the moment the machine achieves its commanded position” said Michael Wilm, Calibration Business Manager, Renishaw Inc. “Because mechanical relay contacts can bounce for the first few milliseconds, we have added a bounce rejection feature programmed into the electronics of the laser. The laser simply needs to see the relay close for as little as a microsecond; any chatter within 20 milliseconds gets ignored, the laser takes a reading, and the axis moves to the next measuring position.” High speed data capture can be used to calibrate positioning stages and other equipment where no CNC is involved. “It may take some customising of the machine control with an auxiliary board to trigger the laser, but these boards are readily available and well known by people in the controls business,” Wilm concluded.

For more information, Website: www.renishaw.com

MACHINE TOOLS WORLD FEBRUARY 2016

EDM Special Section

TECH UPDATE

Manufacturing and servicing rotary tools with VOLLMER: Efficient & Precise Erosion technology has led the way for many years when it comes to machining metal-cutting PCD tools. Nowadays top standards are required and achieved in terms of precision and surface finish. For these tasks, VOLLMER - the world market leader in grinding and erosion machine technology - offers a high-tech range of machines with both wire and disk electrodes.

he increasing use of lightweight construction materials and modern composites has led to highly complex machining tasks in all metal cutting processes. Erosion machines provide a highly economic way of machining PCD tools both for production and sharpening purposes. A basic distinction is made between machines with wire and disk electrodes: both are offered by VOLLMER in its extensive “Q series” of machines.

The VOLLMER QWD series

VOLLMER wire erosion machines are equipped with two rotary CNC axes in conjunction with three linear axes and the option of a tail centre for machining tools with centres. All five CNC axes work on the principle of path interpolation. The free tool programming allows complex geometries such as profiles and bell-shaped tools to be machined – a

MACHINE TOOLS WORLD FEBRUARY 2016

key factor in the versatility of these machines. The wire electrode is continually renewed, thus guaranteeing original conditions at all times at the point of erosion leading to maximum precision to the cutting edge geometry. In addition, the combination of VOLLMER wire technology and expert software allows a maximum of variants while ensuring plenty of scope for development of the cutting edge geometries. At present, the majority of PCD tools are finished with VOLLMER wire erosion machines. This removes the need for any refinishing work such as grinding. The combination of automatic measuring and erosion in a single clamping fixture and expert software for individual machining of complex workpiece geometries enables the wire erosion machines QWD 750 and QWD 760 to produce optimal results in terms

Wire erosion machine QWD 760H with 5 CNC-controlled axes. For automatic measurement and erosion of tools with cutting edges made of PCD and other hard materials, with unsupported clamping or clamping between centres. With magazine for up to 36 work pieces

of precision and economy. The automation of the wire erosion machines QWD 750H and QWD 760H with magazines for tools such as milling cutters, multi-stage tools, reamers, etc. allows round-the-clock operation – in three shifts, including weekends – a vital condition for top economic efficiency. The VOLLMER QXD 250

The VOLLMER disc erosion machine QXD250 makes it possible for tool manufacturers to process more than

EDM Special Section

TECH UPDATE www.mtwmag.com

30 percent PCD cutters in the same amount of time as has been the case by previous technology. This milestone in production is made possible by the newly developed generator technology Vpulse EDM, which sets the eroding beat at the heart of the QXD250. Depending on the demands, the Vpulse EDM can increase the speed of the tool production or increase the surface fineness. The Vpulse EDM achieves these advances when processing PCD surfaces by using individually cycled eroding impulses. This corresponds to two-fold improvement and more in comparison to the eroding technology which have been available up to now. The QXD 250 gives greater flexibility and opens up a wide range of new possibilities for PCD tool manufacturers when processing PCD cutters, allowing manufacturers to react in a targeted way to the demands of their customers and markets. The VOLLMER QXD 250 also offers a simultaneous track interpolation in six CNC controlled axes. As a result of the increased tool track distance

and swivel range, PCD tools with diameters of 320 mm and lengths of 250 mm can be precisely processed. In one single clamping fixture, the QXD 250 measures, grinds, erodes and polishes diamond tools in only one combined process. The Vollmer automation technology allows 24-hour production without the need for an operator to be present, during which the loading & unloading of the workpiece reservoir can take place simultaneously by automatic operation. The integrated tool changer for up to six eroding, grinding or polishing discs makes the processing of different work piece variants possible. VOLLMER machines in use worldwide

Swiss company Wirz Diamant AG from Biel/Bienne has been working in partnership with the watchmaking industry, manufacturing tools such as diamond-tipped milling and turning tools for the production of watch movements. For machining PCD-tipped cutting edges, Wirz uses the QWD 750H wire erosion

Tailor-made diamond tools can be produced round the clock in high quality and without manual intervention with the VOLLMER QXD 250 eroding machine

machine from VOLLMER. “We chose the VOLLMER wire erosion machine because it enables us to sharpen even complex tool geometries with a high level of precision,” says Thomas Meyer, Managing Director of Wirz Diamant AG. “In addition, it is important that we are able to produce large quantities of milling and turning tools cost-effectively and uniformly: The QWD 750H allows us to do all that, whilst at the same time being unmanned and fully automated, round the clock.” 9,000 kilometres away from Biel/ Bienne, in Seoul Sinjin Diamond uses the VOLLMER disc erosion machine. Sinjin Diamonds supplies diamond tools with a controlled waviness of less than 50 nanometres. These ultraprecise diamond tools are used to machine contact lenses as well as for the production of cameras, telescopes, and laser printers. The QXD allows them to reach the level of precision that their customers expect from their products and they can fully sharpen a profile cutter with a surface roughness of less than one micrometre in four to five hours. That shows that VOLLMER is a global partner for tool production and sharpening services and, with its service teams, performs on-site servicing and maintenance on machines all over the world. The experience gathered throughout its 100 year history has made VOLLMER a true success. Sharpening tools has transformed the medium-sized company from Germany, into a world-leading sharpening machine specialist with sites in Germany, Austria, Great Britain, France, Italy, Poland, Spain, Sweden, the USA, Brazil, Japan, China and India. 700 workers worldwide ensure customer proximity and consistently high support quality.

For more information, Website: www.vollmer-group.com

FEBRUARY 2016

MACHINE TOOLS WORLD

EDM Special Section

TECH UPDATE

EDM wire specialist with technology excellence

e at Nickunj, are committed to offer quality services to all our customers by providing a superior technological edge, innovative hi-tech industrial products and services backed by trained, agile & responsible staff. Our aim is to emerge as an end-to-end manufacturing solutions provider, drawing inspiration and guidance from our overseas Principals and from the active support of Team NICKUNJ, comprising of over 350 talented professionals. We remain committed to meeting the complex demands of our valued customers by stretching our core competencies, viz. “Innovative Product Sourcing”, “Customized Solutions” and “Impeccable Customer Service”, beyond conventional standards. We strive to maintain a focused approach and ensure the expansion of our scope, far beyond the realms of basic trading activities – delivering only the highest quality products, complete manufacturing solutions, productivity improvement projects and various other services through our in-depth industry knowledge. We are pleased to introduce ourselves as the largest manufacturer of EDM wires in India, with 2 manufacturing units: one at Baddi, Himachal Pradesh and the other at Umbergaon, Gujarat with a combined capacity of 1000 metric Tons per annum. We manufacture Plain Brass Hard wires, Diffused Coated Brass wires and Zinc Coated Diffused Brass wires to suit various machines like Agie. Agie Charmilles, Charmilles Robofil, Mitshubishi, Makino, Sodick, Fanuc. Accutek, Electronica etc. These wires are in the diameter of 0.15mm, 0.20mm. 0.25mm and 0.30mm and in the hardness range between 48kg/sqmm (around 500 Newtons – Soft) to 110kg/sqmm (around

MACHINE TOOLS WORLD FEBRUARY 2016

1050 Newtons-Hard). The percentage elongation would vary between 1% to 20 % respectively depending upon the Tensile Strength (Hardness) viz hard variety to soft variety.

machines

Wire – Plain Brass Wire with high copper content for use on machines with high electrical generators

Wire – Plain Brass Wire for general purpose application machines

NICKUNJ Manufactured Wires

Wire – Zinc Coated Diffused wire fully established for Agie, Volmer, Charmilles machines having Zinc Coated technology stabilized and being successfully sold throughout India on the machines referred above Wire – Developed very recently this Brass Wire has undergone special Treatment to specifically for all Japanese , Taiwanese and Korean machines including Agie Charmilles has been extremely successful against all Imported Plain Brass Wire both in terms of higher cutting speeds and accuracy. Wire – Diffused Coated Wire meant mainly for Charmilles Machine and well established in India on several machines that do not require “ AWT” process

Wire – Zinc Coated Diffused Brass Wire for Application on machines accepting Zinc Coated technologies

Wire – Diffused Coated Wire suited for high speed cutting on all

9. EconoTM Wire - Plain Brass Wire for general purpose application machines

Berkenhoff GmBH

The world’s best manufacture of EDM wires Berkenhoff GmBH have been associated with us for last 30 years and we are their sole agents in India. a. Cobra cut A: - Zinc Coated wire that is synonymous with Agie, Charmilles, Volmer and recommended by the machine manufacturer. b. Broncocut-X:-Suited for Charmilles and Agie Charmilles and recommended by Machine

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TECH UPDATE www.mtwmag.com

manufacturer.

4. Rust Removers and Rust Inhibitors :- Imported from Japan and well accepted in Indian Industries for its specified application

c. Mega cut: - Suited for all Japanese machine, recommended by the machine manufacturer.

d. Micro cut – Extremely fine wire in the range of 60 microns up to 20 microns used specifically for the tightest tolerances and very exceptional fine precision cutting on EDM wire cut.

EDM Consumables

1. Filters : Imported from the largest manufacturer of Filters overseas and well accepted on all Indian EDM and Spark cut machines

2. Nickion Mixed Bed ION Exchange Resin:- For maintaining proper conductivity on EDM Wire Cut machines

5. Mechanical Spares – Imported from Germany and Taiwan. These Spares for all EDM Spark Cut machines have been well accepted In Industry 6. Tungsten Copper Rods and Flats , Brass and Copper Tubes :- Sourced from Taiwan and well accepted by the Industry at large

7. Dielectric Fluid –To be used on Spark cut Application 8. Electrolytic Copper – 99.99% oxygen free copper for manufacture of copper electrode for EDM Spark erosion machine 9. Machine Graphite Electrodes – Imported Graphite Blocks are tailored / machined on VMC’s for use as Electrode in the EDM Spark Erosion process. 10. Fixturing Systems – For repeat-ability and consistency of 2 microns. Sourced from Germany the world best manufacturer Hirschmann GmBH . These products are tailor made and machine specific

3. Polishing Stones – Imported from Boride Engineering Abrasives USA for obtaining exceptional finish on all jobs manufactured on EDM Wire cut and EDM Spark cut machines.

FEBRUARY 2016

MACHINE TOOLS WORLD

TECH UPDATE

EDM Special Section

Industry Expertise & Experience in helping machining customers make what matters

he Makino commitment to customers starts with global leadership in metal-cutting and manufacturing technology, with industry-leading horizontal machining centers, vertical machining centers, wire EDM and Sinker EDM, and graphite machining centers. Makino is the company you can rely on machining parts more accurately, productively and at a lower cost per part. The partner you need to build and sustain a metal-cutting business. Numbers matter. That’s why, with more than 140 patents, Makino is the world leader in EDM technology, providing faster processing times & superior surface finishes for even the most complex and involved part geometries. By combining innovative Makino machine tools and software with game-changing support from Makino Engineering Services, shops of every size are competing and winning the kind of work that matters on the global EDM stage. The flexibility of Makino technology and proven turnkey engineering solutions allows for EDM solutions at all levels to help further reduce operational costs.

Reliable, Flexible and User-Friendly technology that matters to delivering exacting productivity When precision, superb surface finish and low cost per part matter, no job is too big, or too small, for Makino Sinker EDM machines. Machine highlights:

Makino Sinker EDMs feature the revolutionary Hyper-i control system, which is the same interface system used on Makino’s wire EDM products, signifying a standardization of Makino’s EDM machine controls. The unique and modern Hyper-i control system represents a paradigm shift in operational efficiency on the shop floor and provides operators with an identical, powerful, user-friendly interface that boosts

MACHINE TOOLS WORLD FEBRUARY 2016

• ArcFree: This set of safety-focused productivity for both Makino wire and settings virtually eliminates the sinker EDM products. The Hyper-i control possibility of the machine developing system improves machine productivity by destructive DC arcs during the course intelligently streamlining the interface so of a burn. ArcFree technology, coupled that all operator skill levels can achieve the with Makino’s extremely fast servo most efficient results. This modern graphical control response time, enables safe, control makes use of pinch, swipe and spread unattended burning, even when the touch functions similar to smartphones & current applied to an electrode exceeds tablets, & provides effective and natural its maximum current density. While arc operation using a 24” class hi-definition prevention has been a part of all modern touch screen. User-friendliness is further sinker EDMs, ArcFree technology is the enhanced with the integration of on-board next advancement in intelligent adaptive digital manuals, intelligent e-Tech Doctor controls for prevention of DC arcs. help functions & e-learning training system. • Flower pattern: Special conditions were developed to obtain a uniform Ra value Productive solutions: surface finish with a large RSm value to Makino has developed many advanced improve the performance of mold release leading-edge generator technologies that for plastic injection tools. The more open improve productivity and capability. The structure of the surface finish improves development of these adaptive control plastic part mold release and tool life technologies provides enhanced machining while reducing the interval for mold speeds while delivering optimum accuracy, cleaning maintenance. uniform surface finish with superior edge • HQSF™ (High-Quality Surface Finish): and metallurgical quality, destructive DC This optional configuration dramatically arc protection and low electrode wear. improves the produced surface finish • HyperCut: This special generator setting of tool steels using copper or graphite provides improvement to machining electrodes. The technology was speeds without increasing electrode wear specifically designed to eliminate postor required electrode reduction amount. machine polishing and produce superior HyperCut can be used on part details metallurgical results that extend tool life. up to 30 amps, and improves machining Makino’s HQSF process uses a special speeds by up to 30 percent without µSC powder additive that is mixed affecting surface quality. in the dielectric oil that enhances the • SuperSpark™ IV: This family of stability and even disbursement of the technologies utilizes dynamic power machining spark energy. HQSF can also supply adjustments and jump motion provide cycle time reductions when not control during the machining process. machining to ultra-fine surface finishes. It enhances automation and unattended • EDcam™ software: Makino has developeration capabilities by eliminating oped an off-line programming system the need for external flush lines and for Sinker EDM that makes use of the increases the control’s ability to maintain electrode and work piece CAD model higher cutting speeds regardless of the information. The system eliminates the application or operator’s experience level. requirement of having to create paper Reduction in rough machining cycle times process sheets for manual data entry of can be achieved when using SuperSpark™ the programs on the machine control, technology regardless of the shape, size or which invite critical human errors. By depth of cavity.

EDM Special Section

TECH UPDATE www.mtwmag.com

intelligently utilizing available electronic data, the EDcam software brings the Sinker EDM process into the 21st century and provides a means of program simulation and verification without the need for time-consuming, on-machine, dry-run operations. • Remote machine monitoring: As part of efficient unattended machine operation, operators and supervisors alike may wish to monitor the machining progress while away from the machine. Makino offers two software options that provide a means of process updates. The EDM mail option enables the machine to generate e-mail text-based messages on any alarm/stop status or by timed intervals. The EDM viewer option provides direct viewing of the machine control interface on a remote PC.

Versatility, Low Operating Cost and User-Friendliness that matter for Optimum Performance and Efficiency Makino’s new U3 and U3 H.E.A.T. wire EDM machines redefine the expectations of versatility and user-friendliness that matter to the EDM industry. The features and technologies incorporated into the U3 and U3 H.E.A.T. provide optimum EDM machining performance for every application, and further reduce wire consumption and maintenance requirements. The revolutionary Hyper-i control system offers intuitive, interactive and intelligent functions that boost productivity and reduce operator workload. The high-definition, 24” class size touch screen monitor with Smartphone/tablet functionality makes operation extremely easy and straightforward. With on-board electronic manuals, maintenance procedures and video training system, operators have all of the resources they need to be productive right at their fingertips. The U3 and U3 H.E.A.T. feature a new cutting technology called HyperCut, which provides superior part accuracy and surface finish. HyperCut is capable of producing a 3umRz surface finish with three-pass machining, and represents a 20 percent reduction in cycle time and 14 percent sav-

ing in wire consumption when compared to previous technologies. Materials for steel and carbide have been developed and support both sealed and non-sealed flushing applications. The U3 H.E.A.T. also features Makino’s H.E.A.T. (High Energy Applied Technology) technology for unparalleled wire EDM machining speed and accuracy in parts featuring poor or difficult flushing conditions. Makino has been the industry leader in low wire consumption technologies, dramatically reducing one of the single largest expenses in operating a wire EDM machine. There are no special settings or “part-time” buttons required to experience this saving; every cutting condition, including sealed and poor flush applications, is automatically optimized and designed from the ground up on the Makino for low wire consumption. Together, these features deliver optimum EDM machining performance with an ideal mix of speed, accuracy and wire consumption for the highest level of overall efficiency, throughput and cost. Only Makino can provide this level of performance in every condition and application. The U3 and U3 H.E.A.T. contain a diverse cutting condition library with over 2,200 settings for many material types and flushing conditions from 0.1~0.3mmØ Wires. These settings include optimized conditions for standard hard brass wires, high-speed coated wires and high-taper soft wires. The depth and versatility of the entire cutting condition library ensure that all applications can be machined at optimum productive levels. The U3 wire EDM machines use a space-saving and highly rigid design. The dielectric reservoir is built into the base casting of the machine, reducing the footprint while improving thermal stability. Part accuracy is further improved with the stationary worktable design, and the automated front-drop door provides excellent access to the machine and workpiece. A dielectric chiller unit, water quality deionization system, transformer and high-performance filtration system are all standard machine features. Makino has also developed a unique Pro-Tech circuit that provides electronic galvanic protection

to the workpiece in order to prevent or minimize rusting and oxidation. This unique Makino technology is standard on the U3 and U3 H.E.A.T. machines, and it preserves the integrity of the workpiece without the need for chemicals. GS-Cut Technology (Reduce belly/bow)

One of the most difficult challenges faced by wire EDM operators is the machining of vertically straight workpieces to very close tolerances. Inaccuracies are usually at their worst in the center of the vertical span of a workpiece. These inaccuracies are typically defined as a “belly” or “bow” in the workpiece. Such an error occurs 90 percent of the time during the initial rough-cut operation. The advantage of using GS-Cut Wire EDM technology is that it reduces the belly or bow in workpieces during these roughing operations. By reducing the belly or bow in the rough cut, thus cutting closer to the final net shape, this technology reduces or eliminates the need for additional skimpass machining.When skim-pass machining is necessary to achieve finer surface finishes, GS-Cut helps to reduce the total cycle time and consumable costs by reducing the amount of error (belly/bow) and remaining material on the final part, thus leading to faster skimming times. Improved Compensation

GS-Cut technology is built into the E-code, so that parameters change automatically with workpiece height. The technology compensates for changes in the wire caused by eroded wear and wire lag. This compensation is done by automatically machining on a slight taper in the rough cut and through adaptive servo movements. The result is that GS-Cut produces straighter and more accurate parts without increased wire consumption. The improvement in part straightness can be as much as 40 percent over conventional wire EDM technology. This reduction in both total cycle time and production costs makes your shop more profitable.

FEBRUARY 2016

MACHINE TOOLS WORLD

EDM Special Section

TECH UPDATE

CHMER Precision Economical CNC EDM Machine

HMER company was established by a prominent team from the field of EDM. They especially incorporate Japanese EDM technology in their machines. CHMER is the biggest CNC EDM manufacturer in Taiwan.

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Some of the outstanding features of machine are as follows:

• The machine structure is designed by advanced CAD system to ensure deformation-free performance and high accuracy machining. • Table surface is hardened to high hardness by high frequency heat treatment for maximum wear resistance. • Precision ball screws on X, Y, Z-axis provide smooth transmission and high accuracy traverse. • The machine structure is manufactured from high quality cast iron (FC30), seasoning treated and tempered to relieve stress. This assured high rigidity, deformation-

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free and dependable machining accuracy. The spindle feed on linear motion guides to ensure long term accuracy and durability. The machine structure is designed via computer analysis to anti-pull, anti-press and anti-stress, ensure machining accuracy. Dialog programming helps with selecting optimum machining conditions based on electrode size and material, work piece type, depth of erosion and target surface finish. Automatic edge, centre find and Z reference location find. 3-Axis linear, 2-axis arc, 3-axis spiral and 4-axis contouring offset movement. 99 sets of working parameters available from database operator changeable. 1000 sets of working conditions edition and memory storage. Working conditions can be changed

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and saved in memory during processing. Friendly operation and quick start manual to shorten the operator training hours and increase operator efficiency. Friendly conversation window available. Suitable working conditions easily and quickly come up by just input electrode and work piece material, sparking current and desired surface roughness. E-codes (canned cycle) commonly used as: side machining, square, vectoring and circular orbiting, tapering etc, sub staining the complicated G-code programming. Chmer CNC EDM types of machines are available. X, Y traverse ranges from 300 X 200mm to 3000 X 750mm. Erosion data On-Time (TON:0.52400µs) & of-Time (0.5-2400µs) fine tuning (0.5µs, 1µs, 2µs, 5µs, 10 µs) for coping with special alloy machining. Closed-loop linear scales feedback on X, Y & Z axes for precise positioning & cutting accuracy. 15” TFT with graphics, 3 ½” FDD, RS232, Ethernet. S-code function E-code function Auto edit function

More than 150-200 CHMER machines are working in India satisfactorily. The performance of the machine is similar to that of any reputed Japanese Make CNC EDM. Infact it is Japanese Technology at Taiwan Machine Price. For more information, Website: www.sankimachinetools.com Tel. No.: +91-22-26861326 / 65215111 / 5005

MACHINE TOOLS WORLD FEBRUARY 2016

EDM Special Section

TECH UPDATE www.mtwmag.com

CHMER Precision Economical CNC Wirecut EDM Machine G Series

HMER company was established by a prominent team from the field of Wire Cut EDM. They especially incorporate Japanese Wire EDM technology in their machines. CHMER is the biggest CNC wire cut EDM manufacturer in Taiwan.

Some of the outstanding features of machines are as follows:

• C-frame construction was designed by finite element analysis (FEA) along with multi-ribbed structure features high rigidity, large table load, and low mechanical deformation. • Stainless steel 3-sided work table and brushed stainless work tank for long endurance and least maintenance. • Auto wire threading (AWT) can be provided as optional and can use finest brass wire Ø0.1mm for auto threading. • AC power supply.

• Automatic Corner control function. • It has 15” TFT display and water proof PVC film panel for low maintenance. • It has new LCD remote control which have X, Y, Z, U, V positioning display, centre and edge finding, cut and thread function. • Real time monitoring of machine operation without attending to the workshop, you see what the operator sees on the CNC controller from anywhere on your home PC or laptop by just installing the software on your computer and get immediate access via existing network. • Computerised power supply system provides efficient and stable machining technology for excellent cutting speed and consistent spark energy, consistent speed and surface finishes. • Lower arm is water cooled to avoid thermal expansion. • Machine is compact in size & therefore space saving. • More Taper angle ±14.5 degree over 80 mm • Chiller unit for Dielectric Fluid is provided as standard • PCD cutting circuit is standard. • In G series both Submerged and Flushing type machines are available. X, Y traverse ranges from 360x250mm to 900x600mm. More than 150-200 CHMER machines are working in India satisfactorily. The performance of the machine is similar to that of any reputed Japanese Make CNC Wire CUT EDM. Infact it is Japanese Technology at Taiwan Machine Price.

For more information, Website: www.sankimachinetools.com Tel. No.: +91-22-26861326 / 65215111 / 5005

FEBRUARY 2016

MACHINE TOOLS WORLD

EDM Special Section

TECH UPDATE

CHMER Precision Economical ZNC EDM Machine

HMER company was established by a prominent team from the field of EDM. They especially incorporate Japanese EDM technology in their machines. CHMER is the biggest CNC EDM manufacturer in Taiwan. Some of the outstanding features of

rapidly reaction for better flushing in precision process. • These types of machines are available. X, Y traverse ranges from 300x200mm to 600x500mm. More than 150-200 CHMER machines are working in India satisfactorily. The performance of the machine is superior.

machine are as follows:

• Adopted AC servo motor design in Z-axis free of confusion about motor brush replacement. • 15” TFT LCD monitor. • Three axis DRO (Direct Read Out) display. • Programmable CNC control; an average power output circuit design as well as traditional machine, it brings a steady, low electrode wear and fine finish processing on the job and more. • Built in Anti-Arc protection. • Z-axis Ball screw backlash error calibration to travel. • Adjustable Z-axis servo (up/down time and reciprocation distance for higher processing efficiency) • Multi preset positions on Z-axis for optimum roughing to finishing setting. • 1000 built in machining parameters that can be manually edited during processing. • Dialogue programming editor to help users to process a quickly job. • Friendly operations interface and attached clearly manuals to shorten the training time of any operator. • CHMER unique E-code function to simplify NC programming instead of G, M code; to reach 3 axes synchronise action for the same. • Friendly conversion window available. Anti-arc circuitry and

MACHINE TOOLS WORLD FEBRUARY 2016

For more information, Website: www.sankimachinetools.com Tel. No.: +91-22-26861326 / 65215111 / 5005

TECH UPDATE www.mtwmag.com

Automation in machine tools By: Rajan Goyal Chief manager Motion Control Systems, Drive Technologies, Siemens Ltd.

ndia a leading manufacturer of machine tools, ranked 17th in production and 12th in the consumption of machine tools in the world (source IBEF). The country is all geared up to establish a firm foothold in the global machine tools industry and is likely to see substantial high-end machine tool manufacturing. With the current trend of â&#x20AC;&#x2DC;Make in Indiaâ&#x20AC;&#x2122; giving the much-needed push to the manufacturing sector, the country is on its way to become a major manufacturing giant. The machine tools users in the industry are now moving towards increasingly sophisticated computerized numerical control

(CNC) machines imbibing the latest technology. The growing demands and transition of technology in segments such as Automobiles, Aerospace, Power and Medical, etc., have ensured an improvement in performance and productivity. With the current scenario of supply and demand, investment in this sector is said to guarantee a sustainably higher ROI in the long run. Machine tool manufacturers hence need to step up their game in order to fully exploit these opportunities. As a first step towards this advancement, CNCs are being utilized to their maximum to achieve the best

FEBRUARY 2016

MACHINE TOOLS WORLD

TECH UPDATE

quality and finish of the product in the shortest possible time. When the right manufacturing software is matched with the latest CNC controllers and machine tools, it allows the user to implement a process chain that delivers maximum performance for their business. This significantly reduces the chances of errors as well as the general downtime of the machine, minimizing the need of manual labour and production. Siemens has been a major player and an established leader in the automation and machine tool market for well over 50 years with its wide range of SINUMERIK CNC controllers. Our combination of software and manufacturing equipment expertise enables us to develop part manufacturing solutions that provide our users with unique and powerful advantages. Robots lead the way

Today, manufacturing companies are searching for even leaner solutions and they have found alternatives in the vast arena of Robotics. An industrial robot has come into existence and its use is expanding into a wide range of applications. While the human body experiences fatigue, a robot is capable of performing repetitive tasks with the highest amount of accuracy. This not only eliminates errors, but also ensures higher productivity. Higher productivity equals higher profits. Industrial robots are credited for faster production as opposed to traditionally existing manufacturing methods, by decreasing the cycle times. The very essence of the robot is its ability to create a leaner and more efficient manufacturing cycle. Industrial robots can be used for diverse operations including robotic handling applications like machine tending, plastic moulding etc. In the

MACHINE TOOLS WORLD FEBRUARY 2016

automotive industry, these robots are mostly used on machining lines. In a machining line or cell, the robots are typically used for loading/unloading operations. Robots are electrically interfaced to the machine tool controller via typical hard-wired information exchange, or using industrial communication bus protocols, the most widely used being PROFINET & PROFIBUS. Gantry type robots are controlled by a general motion controller, whereas the articulated arm robots require a special motion controller that can handle nonCartesian motion. This creates another seamless opportunity for integrating the two controllers, the CNC controller and the robot controller. Grasping this exact opportunity, Siemens introduced SINUMERIK Integrate Run MyRobot - A flexible solution that allows the robot to be operated from the same user interface as that of the CNC machine. This technology package facilitates high-speed workpiece and tool handling. Diagnostics, retraction and operation can all be executed from the CNC operator panel. The robot can be easily operated from the SINUMERIK Operate interface resulting in simple production automation and minimizing the loading and unloading time. The technology from Siemens does not just end with the controllers as the Company realises the manufacturing sectorâ&#x20AC;&#x2122;s need for software to guide and take the complete manufacturing process to fruition. The Product Life Cycle Management (PLM) software from Siemens works collaboratively with companies to deliver open solutions that help them turn ideas into successful products. The combination of software and manufacturing equipment expertise provided by Siemens products support a CAD-CAM-CNC process chain that

maximizes the value for customers using latest machine tool investments. It provides a complete package for its users in the manufacturing industry with its versatile range of CNC controllers, ability to integrate with Robotics and its wide variety of software solutions. Of these, NX provides a complete set of NC programming capabilities in a single CAM system as well as an integrated set of manufacturing software applications. These applications facilitate part modeling, tool design and inspection programming â&#x20AC;&#x201C; all based on proven NX technology. NX CAM delivers differences through key capabilities such as its advanced programming, postprocessing and simulation functionality. It provides advanced programming to match the powerful capabilities of SINUMERIK controllers. NX combines both automatic and user-selected options to ensure that the postprocessor provides optimized output for SINUMERIK controllers in areas such as high-speed cutting and 5-Axis machining. It imparts advanced CAD tools that can be used by the NC programmer for everything from modeling new parts to creating setup drawings directly from 3D model data. Multiple-axis machining in NX enables users to produce precision complex parts with fewer operations and setups â&#x20AC;&#x201C; reducing cost and delivery times. The Indian machine tools sector offers several opportunities for investment. Players who look to succeed in the sector in the long term, need to focus on key success factors, such as, developing capacity and scale, design capability, acquiring the latest technology etc and therefore Automation & Digitalization will play a key role for its success in the manufacturing sector.

CASE STUDY

Solid stamp of trust and reliability of Godrej Locks reflects in Haas machines

ince its beginning in 1897, the Godrej Locking Solutions and Systems, a unit of Godrej & Boyce Manufacturing Company Ltd, has set several benchmarks in the locks industry – from the first spring-less lock in 1907 to the iconic ‘NavTal’ in 1954 to the Ultra range in 1995 to the revolutionary 3KS in 2007. From a state-of-the-art manufacturing facility in a suburb of Mumbai, the company provides locking solutions that reach homes, offices, industries and the hearts of millions of people in India and around the world for whom ‘locks’ means Godrej. A symbol of trust and security for 118 years, lock on almost every Indian home’s front door is of Godrej. It goes to show how the customers have placed their trust and confidence in the company. Since the first lock was manufactured in 1897, it has been Godrej’s endeavor to constantly evolve and design products and services that exceed the expectations of individual and institutional customers. Over the years, the locks have changed in form, function and scope of application, but one thing remains constant – the solid stamp

MACHINE TOOLS WORLD FEBRUARY 2016

of trust and reliability. The company adheres to global quality norms and hold ISO 9001, ISO 14001 and OHSAS 18001 certifications. “Initially, we were carrying out manufacturing process on conventional lathe and special purpose machines (SPMs). Since our style of manufacturing is quite flexible, we designed some special fixtures also that matched our machining process. However, later we shifted to

vertical machining centres (VMCs) and turning centres as they give us opportunity to machine various designs of locks on a single machine,” the Associate General Manager (Manufacturing) of the company, Mr. MHM Shaikh said. “We serve all typesof customers and customize locks as per demands of the consumer. This is the reason why one can see Godrej lock on almost every Indian door. This trust of customers on us has transformed us into a company that provides locking solutions,” Mr.Shaikh

CASE STUDY www.mtwmag.com

said. Explaining the manufacturing process, the official said they carry out forming, die casting, plating and then machining (that includes milling, drilling, turning, boring etc.) of the products. “In fact we do all the processes that a VMC has been designed to do,” he added. As on today, the company has over 50 machines of which 20 are Haas machines. “We carry out machining on VMCs, turning centres and turnmillcentres. We purchased first Haas machine in 2006 and by 2010 we had 6 Haas machines. After that, we are adding one machine in our kitty almost every year,” the Senior Manager (Manufacturing) of the company, Mr. DN Kharat said. The methodology adopted by Godrej for selecting any machine tool is that they first prepare an exhaustive list of parameters and features as per the end application. After preliminary round of discussions with various vendors, a comparative analysis is done and 5-7 vendors are selected who match at least 80% of their requirement. Explaining the rationale behind selecting Haas machines, the officials said that when the company decided to go for CNC machines, itcategorizedthe supplier on the basis of power required to run the machine, operational safety, environmentfriendliness,end application and above all whether it gives the best productivity in terms of optimized cycle time. “We found everything in Haas and decided to go with them. Besides this,

we were satisfied with the maintenance aspect of Haas machines as it involves minimum wear and tear that reduces operational cost. Also, the service support from Haas is excellent and their engineers respond to your call within no time. This adds value to our trust on Haas and its machines,” the officials said. “The installation of ST10Y turnmill centre from Haas did magic for us. It reduced the cycle time beyond our expectations as it gives us advantage of two machines in one. We plan to add many more from this series,” Mr. Shaikh quipped. “Ever since we installed first Haas machine, the company has helped us a lot in the process that included service and application support. We were able to lessen the machine downtime and increase our productivity. Our end component accuracies are in the range of 20 microns and we are able to meet the same with Haas machines,” Mr. Shaikh said and added that Haas machines are true value for money. “And with continual improvement in terms of precision deliverables and responsiveness to their customers, Haas is worth recommending to the industry. I am sure that with Haas’ support, Godrej Locking Solutions will continue to reap rich dividends in the years to come. It’s a partnership built on trust, support and continual engagement which will certainly go very far,” Mr. Shaikh concluded. Website: www.haasCNC.com

FEBRUARY 2016

MACHINE TOOLS WORLD

CASE STUDY

SPRINT 50 for more flexible productivity For several months now three new SPRINT 50 automatic lathes have been fortifying the range of services at Flühs Drehtechnik GmbH in the areas of system technology and precision-part manufacture Flühs Drehtechnik GmbH has been active consistently and exclusively in the fittings sector since 1926. And for the entire 88 years from its site in Lüdenscheid. Initially it operated solely as a toll manufacturer of precision turned parts made of brass, but gradually moved into complete machining and later even started with the development of complete modules and systems. With around 450 employees Flühs today ranks as a leader in all its fields of activity – and with its system developments even as a quality trademark in the international sanitary industry.

etal cutting always was, is and will always remain the basis of the success of Flühs Drehtechnik GmbH in Lüdenscheid. Every day Flühs machines around 75 tons of brass to produce over a million turned parts. There are countless multi-spindle machines in the production halls used in three-shift operation to accomplish its high-volume business. These are supplemented by any number of single and doublespindle production turning centres used for more flexible manufacturing orders with volumes ranging from between 10,000 and 20,000 parts. And this is exactly where the three SPRINT 50 machines from DMG MORI have

For almost 90 years Flühs has ranked as an expert in turning technology. Its product portfolio today includes valves and system technology for the sanitary industry.

MACHINE TOOLS WORLD FEBRUARY 2016

An extensive high-bay warehouse with 1,400 tons of brass raw material ensures both a high degree of availability and flexibility. Flühs processes 75 tons of the metal a day. been in operation since the end of last year – each in the version with a main and counter-spindle, TWIN concept, two turrets each with 12 driven tool stations and the TRIFIX® tool clamping system plus two Y-axes for optimising milling options. One of the key arguments mentioned at Flühs for investing in the SPRINTs is first and foremost the TWIN concept with the cross stroke of the counterspindle / tailstock combination. After all, this version offers virtually two separate work areas on the main and counter-spindle, which enables collision-free parallel machining even of longer workpieces. Another machining alternative offered by the SPRINT 50

CASE STUDY www.mtwmag.com

is 4-axis machining using the top and bottom turrets which, claim the people in Lüdenscheid, in interaction with the two Y-axes enables a multitude of complex turn/mill operations. The stability of the machine is another important aspect. Where Flühs was previously limited to the use of smaller tools with their correspondingly longer processing times, wide sectional steels can now be used with the SPRINT 50 thus giving productivity an extra boost. An attribute which of course applies equally to the TRIFIX® quick change tool holders of the two turrets as these come as standard equipment with the SPRINT

The TWIN concept of the SPRINT 50 enables collision-free parallel machining on the main and counter-spindle.

The degree of accuracy and complexity of brass workpieces is often very high – an ideal range of parts for the SPRINT 50.

In 2013 Flühs invested not in one, but in three SPRINT 50s in order to give a significant boost to flexibility in the manufacture of precision parts with a high level of productivity.

The stability of the SPRINT 50 allows the uncompromised use of wide sectional steels for more productivity. 50, they allow tools to be clamped with maximum precision and a repeat accuracy of just a few µm. So the timeconsuming procedure of re-adjusting every tool, i.e. having to measure the tool holders with a dial gauge every time and optimising them where necessary, is now a thing of the past for many standard operations thanks to TRIFIX®. Where the demand for precision machining is concerned, here, too, the three SPRINT 50 machines fulfil all expectations, one reason, of course, being their already mentioned stability. In addition the processes benefit from the optimised thermal management of the machines. Both the motor and the spindles are cooled keeping thermallyinduced changes to a minimum. In view of the above-mentioned features, functions and machining results, it is little wonder that the three new SPRINT 50 machines received positive acclaim after their first few months in operation. The more so as Flühs claims the question of flexibility will be given higher priority in the long term, particularly where toll manufacturing is concerned. Because even in the sanitary fittings sector the trend towards individuality is on the rise, with the result that more diversity is being called for and batch sizes are on the decline. For more information, Website: www.dmgmori.com

FEBRUARY 2016

MACHINE TOOLS WORLD

MACHINE TOOLS WORLD FEBRUARY 2016

CASE STUDY

Renishaw – cranking down cycle time for Hope Technology Renishaw produced the world’s first 3D printed metal bicycle frame for UK company, Empire Cycles. The pedal cranks and other components used to create the fully built bike were produced using more conventional machining processes, at Barnoldswick based Hope Technology. In its high-tech, high-volume production factory, the company employs Renishaw’s non-contact tool setting and breakage detection technology, CMM contact scanning probes and modular fixturing to maximise machine up-time and to ensure consistent component precision.

Lindley Pate, Hope Technology’s works and production manager with a finished crank arm

he production of the world’s first 3D printed metal bike frame at the end of 2013 was unquestionably a landmark for the cycle industry which has always embraced the latest technology and innovations in its quest for greater speed, lightness and strength. However, additive manufacturing processes do not necessarily lend themselves well to the creation of all bike components. At least, not yet. A number of the drivetrain components mounted on the Empire Cycles frame were produced using conventional, prismatic machining techniques. The pedal cranks, for example, were made by world-renowned Hope Technology Ltd. The Lancashire-based company was founded by cycling enthusiasts and time-served tool makers 25 years ago. Its 24-7 factory has around 55 of the latest CNC machine tools, employs around 100 people and exports 50% of its production to 40 countries. Mr. Lindley Pate, Hope Technology’s

investment requirements. As soon as we could bring it in-house, we did so.” Since those early days of in-house metal cutting, Hope Technology’s CNC machines have been equipped with Renishaw NC4 non-contact tool setting and breakage detection systems. Recently, the company has also invested in a new co-ordinate measuring machine (CMM), equipped with a Renishaw PH10

MACHINE TOOLS WORLD FEBRUARY 2016

Taking touch points using the Renishaw PH10 motorised head works and production manager, was the first employee at the company. As an ex-Rolls-Royce machinist, it’s no surprise he brought with him some very high standards, not least when it comes to controlling precision and quality. “We’ve always believed in making everything in-house, right here in the UK,” he says. “In the very early days we sent a few parts out, but only because of

CASE STUDY www.mtwmag.com

Renishaw PH10/SP25 and modular fixturing contribute to Hope’s quality control process articulating head, SP25 contact scanning probe and Renishaw modular fixturing. “We bought the new CMM with the Renishaw probe to improve our inspection function and also to give us the ability to reverse engineer,” says Mr. Pate. “It gives us the option to benchmark our competitors and helps with compatibility, which is a big issue with bicycles.” The Renishaw tool breakage detection systems and the contact scanning probe were both used during the production of the pedal cranks for the Empire Cycles project. Although the model of cranks used is a relatively new product, they are a standard design rather than custom made, which means they are produced and shipped in quantities totalling tens of thousands per year. As well as pedal cranks, Hope is famous for innovative, lightweight anodised wheel hubs, brakes, headsets, stems, chain rings and bottom brackets. Each different component is machined in high volumes to serve a growing, global customer base, and are finished in a wide variety of eye-catching colours. The factory has a prodigious output: 70,000 wheel hubs a year, for example. Needless to say, productivity and machine up-time are extremely important. Minutes shaved off a cycle time can add up to savings of thousands of pounds a year. Dominating Hope Technology’s factory floor is a line of high-specification, Japanese-built Matsuura horizontal

Renishaw NC4 system helping to reduce downtime on Hope Technology’s Matsuura machine machining centres. “The Renishaw NC4 system is deployed on all of our Matsuura machines,” states Mr Pate. “They run 24-7 unmanned. If a tool breakage alarm sounds, the machine stops to prevent producing parts using a damaged cutter. As a result, the Renishaw NC4 system serves many purposes: it ensures product integrity, eliminates costly scrap, and also the possibility of a broken spindle, which would be hugely expensive to replace in such high-end machines. We do everything we can to avoid downtime. The consequences could be severe. After all, to keep inventory costs down, we only hold an hour’s worth

of stock at any one time!” The NC4 is a flexible laser-based system with ultra-compact laser tool setting transmitter and receiver units that can be mounted on separate brackets, or as a single fixed unit. Dependent on the system, separation distances and mounting, tools as small as 0.03 mm diameter can be measured at any selected point along the beam. The company’s latest Matsuura, an H.Plus-300 3-axis horizontal, has two 15-station pallets, with each pallet fixture featuring a tombstone-style configuration with four parts mounted on four faces - thus 16 components per fixture. Hope Technology uses its pallet pool to fixture different sets of parts on different pallets, all waiting their turn on the machine, including cranks. The cranks are forged in Italy then transported to Barnoldswick, where they are machined in two set-ups (one for each side) before the spline is added. The company produces a range of different cranks to suit frame length and axle requirements. The Hope factory also houses a line of five other Matsuura machines: MAM72 models with smaller, twin pallets, each of which also employs a Renishaw NC4 system. A single Hope Technology operative oversees all five machines, which also run 24-7. “It’s a high-volume production environment, which means it is critical that we maintain production flows,” reiterates Mr Pate. “Renishaw technology is vital to the process and also to part inspection. We take components off the line on a regular basis for sample measurement on the CMM, using the Renishaw PH10/SP25 head and probe. We also check the first-off from each run, to make sure nothing has changed since we last made the part. If we know the part is good, that’s great. If the CMM showsup errors we change the program or the tools, press cycle-start and walk away. The Renishaw products give us the confidence we need.” For more information, Website: www.renishaw.com

FEBRUARY 2016

MACHINE TOOLS WORLD

EVENT PROFILE

TAGMA-INDIA is organising the next DIEMOULD INDIA 2016 in April

AGMA-INDIA the apex association for Tooling Industry is organising the next DIEMOULD INDIA 2016 (DMI 2016), the 10th Biennial Die & Mould International Exhibition from April 6-9, 2016 at Bangalore International Exhibition Centre (BIEC), Bangalore, Karnataka. The series of DIEMOULD exhibitions “A Trend Setter” organized by TAGMA since 1998 has build growing awareness and reputation as a unique trade fair in India for the Die & Mould Industry and very large by international standards of similar Die Mould Exhibitions held globally. The 9th Die & Mould India International exhibition achieved a milestone success, inspite of an overall downturn in the economy globally with the formal inauguration by Dr. APJ Abdul Kalam, the 11th President of India, with his aptly chosen keynote address titled ‘A Vibrant Die and Mould Industry for an Economically Developed Nation’. His Excellency, highlighted the importance and necessity to grow this vital mother industry, which largely contributes to a successful manufacturing economy of a country. In view of the overwhelming response for DMI 2016, Hall 1 & Hall 2 offered are now fully booked, hence additional space is being made available in Hall 3A to accommodate further demand.

MACHINE TOOLS WORLD FEBRUARY 2016

Further DMI 2016 will have an expanded product range and focus on various initiatives like:

• New Product Range – 3D Additive Manufacturing Technology solutions, Precision Machining, Aerospace, Injection Moulding Machine & related solutions. • Buyers Pavilion • B2B Meetings • Country Pavilions • Special Overseas Delegations, etc. The DMI exhibitors will have Unique opportunities like -

• Special Overseas Delegations, etc. • Free emailer promotion service to exhibitors, by sending their product/ service specific email to over 80 Lacs engineering database TAGMA has access to.

10th Die & Mould India International Exhibition April 6-9, 2016 Bangalore International Exhibition (BIEC), Bangalore, Karntaka, India.

We take this opportunity to invite the entire tooling fraternity to visit the exhibition. Come…… let us experience this excellent opportunity and be part of the growth of Indian Die & Mould Industry

For more information, Email: mumbai@tagmaindia.org

www.tagmaindia.org

EVENT PROFILE

IMTEX FORMING 2016 & Tooltech 2016 Paves Way for “Making in India” 1. 485 exhibitors 2. Over 500 live machines 3. Business orders worth about Rs. 450 crores generated 4. Business enquiries worth about Rs. 4300 crores obtained 5. Footfall of around 40,000 visitors 6. Participation from 23 countries including India 7. Group participation from China, Germany, Japan and Taiwan

MTEX FORMING 2016, an international show on forming technology and Tooltech 2016, a concurrent event of machine accessories concluded on 26 January 2016 on a positive note. The exhibition had around 485 exhibitors displaying over 500 live machines in 3 exhibition halls covering a gross area of around 30,000 sq.mts. Four countries – China, Germany, Japan and Taiwan formed country pavilions. The participation other than India came from 22 countries. Organised by the Indian Machine Tool Manufacturers’ Association the twin exhibitions held at the

MACHINE TOOLS WORLD FEBRUARY 2016

Bangalore International Exhibition Centre in Bangalore attracted a footfall of around 40,000 visitors. Over 100 trade delegations from various industry sectors such as aerospace, auto components, automobiles, capital goods, defence, electrical and electronics, oil and gas equipment, railways, plastic machinery sector, white and brown goods, and many more visited the show. Key public sector undertakings such as Bharat Heavy Electricals, Hindustan Aeronautics Limited, Indian Space Research Organisation, National Aeronautics Limited, Railways, Ordnance Factory Board, etc. visited as part of trade delegations. Many private companies such as Bajaj Auto, Fiat India Automobiles, Larsen & Toubro, Robert Bosch Automotive Electronics India, Volvo Construction Equipment, Hawkins Cookers, Toyota, Maruti Suzuki, Caterpillar, PRICOL, Infosys, UTC Aerospace, Honda Cars, TVS and Kalyani Technoforge also visited the show. Exhibitors who attended the show felt that there is a demand base for metal forming machines in India. The interactions have been fruitful and the exhibitors were keen to take the established relationships to the next level. Overall

the exhibition recorded business orders worth about Rs. 450 crores and generated potential business enquiries to the tune of about Rs. 4300 crores. Parallel events organized during IMTEX FORMING also had good turnouts. The International Seminar on Forming Technology organized a day prior to IMTEX FORMING had around 250 delegates participating in concurrent sessions on Design & Software, Equipment and Tools, and Process. For the first time 40 academic institutions participated in the i2 Academia Pavilion. Twelve institutions including IITs made presentations to the industry as part of the IMTMA Industry Institution Collaboration (IIIC) intiative. The best research presentations were awarded prizes. Around 300 students participated for ‘CONNECT’ – an awareness programme for imparting knowledge on the machine tool industry for young engineers. Students from both mechanical and electrical engineering streams availed of this opportunity to gain more knowledge on machine tool and manufacturing sector and to pursue their career in these industries. By interacting with industry experts they were able to understand how machine tool industry helps in industry growth. Close to 40 students participated in the “JAGRUTI” – a programmeto familiarize engineering students with the machine tool industry and the technological happenings in this industry segment. IMTMA organizes JAGRUTI with the help of UDAAN members. To conclude, IMTEX FORMING 2016 & Tooltech 2016 was a grand success. The strong presence of business visitors and policymakers from India and overseas made it a truly pan global event and pave way for further growth of the Indian manufacturing industry. IMTEX FORMING will return in the year 2018 after a gap in 2017 when IMTEX (Metal Cutting) will take the centre stage.

PROJECTS www.mtwmag.com

Automotive Components Amara Raja Group

Pipes & Pipe Fittings

The Group has committed an investment of Rs 5,000 crore across business verticals such as auto, IT, energy, electronics, and infrastructure in the state of Andhra Pradesh. MOU was signed recently the group with the state government.

Petrochemical

Place: Andhra Pradesh

Automotive Components Aviation Biodiesel

PROJECT

Manufacturing

Ports & Shipping Power Transport

UPDATE

Tyres

Contact: Satya Sunita Menda, Head Marketing Services (ASB Unit), Terminal A 1-18/1/AMR/NR, Nanakramguda, Gachibowli, Hyderabad-500032, Telangana. T: 040-23139000 Pricol Ltd Auto components manufacturer plans to expand its production capacity. The company is setting up a new plant at Pune. The commercial operations is likely to start by May 2016.

Place: Pune Maharashtra Contact: Sundar Raman, President, No 109, Race Course, Coimbatore-641018, Tamil Nadu. T: 0422-4336000, F: 4336299, E: sundararaman.g@pricol. co.in, vikram@pricol.co.in

runway into the sea so that it can handle A320 and ATR turbo planes. RITES is advising AAI on this project.

Place: Mumbai Maharashtra Contact: J Rakshikar, Assistant GM, ATC, Porta Cabins, New Airport Colony, Vile Parle (East), Mumbai-400099, Maharashtra. T: 022-26613721, 26616738, E: r.jitendra@aai.aero GMR Hyderabad International Airport Ltd. 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

Aviation Airports Authority of India Plans to extend Juhu airport

Contact: “L N Tatwani, Gm Engineering, Chennai International Airport, FEBRUARY 2016

MACHINE TOOLS WORLD

PROJECTS

Chennai - 600027, Tamil Nadu. T: 044-22564027, 22561122, F: 22560512 E: apdchennai@aai.aero

Biodiesel Southern Online Bio Technologies Ltd (SBT) Bagged order to supply biodiesel in Andhra Pradesh and construct a biodiesel plant at Raipur in Chhattisgarh. The order involves the supply of biodiesel (B-100) towards annual requirement for 10 percent blend from Andhra Pradesh State Road Transport Corporation (APSRTC) for its 78 depots.

Place: Chhattisgarh Contact: Y V Shankar, Project Manager, H.No 8-3-833/173, Kamalapuri Colony, Phase-II, Hyderabad-500073, Telangana. T: 040-49221999, F: 49221998, E: info@sol.net.in, yvshankar@sol.net.in Southern Online Bio Technologies Ltd (SBT) SBT has got letter of acceptance from Indian Railways Organisation for Alternate Fuels (IRAOF), Ministry of Railways, for the execution of balance work of setting up automated 30 tonne per day (TPD) biodiesel plant on turnkey basis at Raipur. The order invoves subsequent operation, maintenance and supply of biodiesel to Indian

MACHINE TOOLS WORLD FEBRUARY 2016

Railways.

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: 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

Pipes and Pipe Fittings Finolex Industries Leading rigid PVC pipes and fittings manufacturer plans investment to add 1,00,000 tonne of pipes capacity over the next three years. Funding is planned through internal accruals. The manufacturing

facilities are located at Urse and Ratnagiri in Maharashtra and Masar in Gujarat.

Place: Gujarat Contact: Anil Whavi, CFO, D-1/10, MIDC, Chinchwad, Pune - 411019, Maharashtra, T: 020-27408200, E: aw@finolexind.com

Petrochemical HPCL-Gail HPCL-Gail combine plans to set up a greenfield petrochemical complex in the state of Andhra Pradesh.

Place: Andhra Pradesh Contact: Rajeev Goel, Dy. General ManagerPR&CC, Petroleum House, 17, Jamshedji Tata Road, Mumbai , Mumbai-400020, Maharashtra. T: 022-22845158, 22863315, rajeevgoel@hpcl.in

Ports & Shipping Plans to assign construction of cargo handling facilities at outer terminal-ll near 2nd Oil Jetty on the river Hoogly for handling mini bulk carriers. The scope of work includs construction of hardstand, road network and railway network as well as supply, operation & maintenance of required cargo handling equipment and conveyor system for shore handling at Haldia Dock complex, Kolkata Port Trust.

Place: Kolkata West Bengal Contact: U.K.Kundu, Manager, Haldia Dock Complex, Kolkata, West Bengal. T: 3224-252110, F: 252740, M: 9434052110, E: ukkundu@kopt.in New Mangalore Port Trust (NMPT) The port trust is building Liquified Natural Gas (LNG) terminal. The completion is targeted by next year.

Place: Kolkata West Bengal Contact: M.R. Hedaoo, Chief Engineer (Civil), A.O. Building, Panambur, Mangalore - 575010. T: 0824-2407493/62, F: 2407493/62, mrhedaoo@yahoo.co.in SKIL Ports & Logistics Ltd. The company is currently developing a modern port and logistics facility at Karanja Creek in the Raigad District. The facility will be developed over 200 acre of land with a sea frontage of approximately 1,000 meter. The work is in progress.

Place: Maharashtra Contact: Jay Mehta, CEO, 411, 4th Floor, A wing, Hermes Atrium, Plot 57, Sector 11, CBD Belapur - 400614, Navi Mumbai, Maharashtra. T: 022-61929000, E: jay.mehta@skilpl.com,

PROJECTS www.mtwmag.com

W: www.skilpl.com

gautam.jain@kalpataru.com

Place: Maharashtra

Place: Mumbai Maharashtra

Hiranandani Energy

Tata Power Ltd

Energy arm of the Hiranandani Group is building two LNG terminals in India. These terminals are coming up in Jaigarh and a floating LNG import terminal off Haldia, West Bengal.

The company is coming up with 660 MW Naraj Marthapur project in the state of Odisha. All major clearances including environmental clearance is obtained. The plant is expected to be commissioned within three years of the completion of the land acquisition. The land acquisition will be completed during the year. Mandakini coal block in Angul is allocated to Tata Power along with Monnet Ispat and Energy Limited, and Jindal Photo Ltd.

Contact: Shalini Singh, Chief Corporate Communications, Bombay House, 24, Homi Mody Street, Mumbai-400001, Maharashtra. T: 022-66658748, 66658282 , E: shalinis@tatapower.com, BD@tatapower.com

Contact: Yatin Sakhalkar, Executive Engineer, Bandra-Kurla Complex, MMRDA, Office Building, Bandra-Kurla Complex, C-14 & 15, E Block, Bandra (East), Mumbai - 400051. T: 022-26591239, 26590001, 4000, F: 26591264, M: 9969022244

Place: West Bengal Contact: Prashanto Banerjee, Head-Business Development, 12th Floor, Knowledge Park, Hiranandani Business Park, Powai, Mumbai - 400076, Maharashtra. T: 022-25715100, 5299, F: 25763777, E: pbanerjee@henergy.com

Place: Odisha

Power Kalpataru Power Transmission Ltd Bagged an order for a 400 KV transmission line project strengthening the transfer of power from new hydroelectric power projects in Bhutan to India. The transmission line project is to be constructed in West Bengal and Bihar.

Place: West Bengal Contact: Gautam Jain, AGM Investor Relation, 101, Kalpataru synergy, Opp. Grand Hyatt, Vakola, Santacruz (E), Mumbai-400055, Maharashtra. T: 022-30642100, 30642317, M: 9930253089,

Contact: Shalini Singh, Chief, Corporate Communications, Bombay House, 24, Homi Mody Street, Mumbai-400001, Maharashtra. T: 022-66658748, 66658282 , E: shalinis@tatapower.com, BD@tatapower.com

Tata Power Ltd The company is coming up with 1600 MW Coastal Maharashtra Project. The Rehabilitation and Resettlement (R &R) Authority of the Maharashtra Government has approved the R & R proposal made by Tata Power. Land acquisition has commenced. The plant is expected to be commissioned within four years of land acquisition.

Transport Delhi Metro Rail Corporation (DMRC) DMRC has prepared a plan for the required flyovers at important busy junctions along the proposed 21.82km Technocity-Karamana elevated light metro corridor in Thiruvanan- thapuram.

Place: Thiruvananthapuram Kerala Contact: Sushma Gaur, Sr. DGM (Corp Comm), Metro Bhawan, Fire Brigade Lane, Barakhamba Road, New Delhi - 110001. T: 011-23416079, 23417910, 12, 23418415 Mumbai Metropoli- tan Region Development Authority (MMRDA) Mumbai Trans Harbour Link (MTHL) project also known as Sewri-Nhava Sheva Trans Harbour Link, is a proposed 22 km, freeway grade road bridge connecting Mumbai with Navi Mumbai. The Centre has recently issued the coastal regulation zone (CRZ) clearance for the project.

Chennai Metro Rail Corporation The corporation is likely to conduct trial runs on the six-kilometre stretch between Alandur to Chennai Airport next month.

Place: Chennai Tamil Nadu Contact: R.Ramanathan, Director (Projects), Poonamallee High Road, Koyambedu, Chennai 600107, TamilNadu, T: 044-23792000, 23792202, F: 044-23792200, E: dproj.cmrl@tn.gov.in

Tyres MRF Ltd The company is considering plans to set up a new plant outside South India most likely in Gujarat.

Place: Gujarat Contact: Koshy K Varghese, Executive Vice-President (Marketing), 114, Greams Road, Chennai-600006, Tamil Nadu. T: 044-28292777 FEBRUARY 2016

MACHINE TOOLS WORLD

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

MACHINE TOOLS WORLD FEBRUARY 2016

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

PRODUCTS www.mtwmag.com

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

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

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

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

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

Following are some of its unique features:

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

• • • • • • •

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

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

FEBRUARY 2016

MACHINE TOOLS WORLD

PRODUCTS

SB 2000 Portable Grinding Wheel Balancer

For Product Enquiry Contact SBS Precision Systems (India) Pvt. Ltd. 24, Ram Swarup Khettry Road First Floor, New Alipore, Kolkata 700 053 Tel: 033-32920078. Mobile: 093311-40202. E-mail: enquiries@sbsindia.in

Single or Dual Plane Manual Balancing at an Economical Price. The SB-2000 is an easyto-use, compact manual balancing system offering both one and two plane manual balancing capabilities. It comes in a dedicated machine installation version (SB-2000) and a portable version (SB-2000-P), both at a very low price. In both versions this control provides exceptional balancing accuracy. It displays up to four digits for vibration and six digits for RPM, and supports a spindle speed range of 30 to 100,000 RPM. With its digital design and intuitive icondriven user interface, the SB-2000 is simple to set up and easy to use. Five balancing modes are supported (single position, 2-weight, 3-weight, fixed position and circumferential arc) with storage capacity for up to 30 balancing profiles for different machines or setups. The unit also allows spectrum vibration plots to be generated andstored. The portableSB-2000-P version attaches magnetically to anylocation for easy setup and use.

Ha-VIS RFID antenna adapts to every customer application

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

HARTING is presenting the all-new, innovative Ha-VIS LOCFIELD® RFID antenna. It adapts to every customer application. An additional benefit for the customer: the compact antenna is ideal where space is at a premium. Every package can be followed in real time. Here, RFID technology offers a multitude of options for increasing process security and ensuring optimal transparency. However, there is generally very little space available at belt conveyors. In addition, classical RFID antennas cannot map curved tracks. But today, traceability is the decisive criterion for customer satisfaction. Customers want to be able to track and trace production history. With the new Ha-VIS LOCFIELD® RFID antenna, HARTING is offering the ideal solution. The new antenna requires a minimum of space. The antenna itself consists only of an industrial-grade coaxial line. The antenna cable is mechanically flexible and can therefore be installed and laid in any given shape. Consequently, the antenna can also be laid around the curves of conveyor belts, precisely according to the requirements of specific customer applications.

Industrial Lubricant segment India is Fifth largest lubricant market in world after China, US, Russia & Japan. The lubricants usage can be divided in two key segments – Automotive and Industrial. The demand for automotive lubricants in India is driven by growth in vehicle population and the consumption of industrial lubricants is highly correlated with Index of Industrial Production (IIP). Automotive lubricants typically are higher margin products compared to industrial lubricants. Majority of automotive lubricants demand is derived from commercial vehicles (CVs) and tractors, largely dominated by diesel engines. Industrial lubricants is the largest market segment in India, with more than 54 percent of the total market. Power generation, chemicals, automotive and other manufacturing, railways, marine, and metals are the leading end-user industries, accounting for nearly 80 percent of industrial lubricant consumption. India is a huge market for process oils as well, with 53 percent of the overall industrial lubricant demand. Rapid expansion of the power generation and distribution infrastructure has also created a strong demand for

MACHINE TOOLS WORLD FEBRUARY 2016

PRODUCTS www.mtwmag.com

For Product Enquiry Contact See Lube Technologies (P) Ltd. (An ISO 9001:2008 and ISO 14001 : 2004 Certified Company) corp Off : 30, Guru Nanak Market,Focal Point, Ludhiana 141010 Ph no +91 161 4641296. 2675525, 5051296 Email : info@seelube.com Web Site: www.oilandlubricant.com

transformer oils in India. Industrial engine oils (including marine and railroad), metalworking fluids and hydraulic fluids are other important product categories. See Lube Technologies (P) Limited is fast growing brand in Industrial Lubricant segment. See Lube with its brand ST KOOL is aiming to grow with dream project of H’ble Prime Minister MAKE IN INDIA. See Lube is determined to take India on International map of Industrial Lubricants. ST KOOL is banked upon its capabilities of research & Development. See Lube is probably the first company in Small scale to put up huge investments in instruments for laboratory to conduct tests in house. Fully equipped laboratory in house ensures the consistency of quality products. See Lube is also thinking ahead in terms of environment protection & conservation too. It has pledged for NOT to use any of the chemicals which are hazardous to planet. See Lube is also producing products, which are replacement to hazardous products. “ Your Partner in Increasing Profits by Value Engineering” is the principle of ST KOOL Industrial Lubricants. Value engineering (VE) is systematic method to improve the “value” of goods or products and services by using an examination of function. Value, as defined, is the ratio of function to cost. Value can therefore be increased by either improving the function or reducing the cost. It is a primary tenet of value engineering that basic functions be preserved and not be reduced as a consequence of pursuing value improvements. See Lube is providing its customers in reduction in cost through continual improvement in quality of products. In a single case study of Tapping Operation, where industries are using Neat oil where cost of the oil is more, post operation cost is more, ST KOOL introduced a highly innovative product ST KOOL 15T, which is water soluble. Without sacrificing on finish & tool life, cost of machining is reduced to half. Even post operation cleaning too vanished. So as per its motto See Lube reduced the over all cost through Value Engineering. See Lube Technologies are full line supplier. Where Metal Working Lubricants, Rust Preventive Oils, Hydraulic Oils, Gear Oil, General & speciality Greases, EDM oil, Metal Cleaners, Hot Forging Lubricants, Rust Converters, Rust Cleaners, Stamping oil, High Temperature chain oil & Maintenance aerosols are major products, which are available off the shelf.

SMC closes the gap in the market with new digital gap checker

For Product Enquiry Contact SMC Pneumatics (India) Pvt. Ltd. A-4, Sector - 88, Noida - 201 305 (U.P) Ph: 91-120-4780222, Email: info@smcindia.in Website: www.smcin.com

SMC, the world’s leading provider of pneumatics, has closed the ‘gap’ in the market place by launching a new durable and highly effective digital gap checker. The ISA3 has been created to meet customer demand for an energy efficient, easy to maintain, quiet and robust gap checker. Subsequently, SMC’s ISA3 has been designed with a two-colour digital display so checks can be made at glance. This has been combined with an easy three-step setting, delivering enhanced labour cost savings. It’s also very simple to maintain as the ISA3 design only has one, but much larger internal orifice reducing the risk of clogging. And it can withstand three times the pressure of its sister product, the ISA2, giving it a longer operating life. Energy and environmental efficiencies are driven by the fact the ISA3 is 55% lighter and consumes up to 60% less air than the ISA2. And because it doesn’t exhaust air from its body, the ISA3 is almost noise-free and, therefore, suitable for quiet environments. Operators can also have peace of mind that the digital gap checker won’t be prone to unintentional changes to the set values with the introduction of a Keylock Function. Suitable across general automation and car production, the ISA3 is ideal for various applications including machining pieces, control positioning installation components, checking for good and bad pieces, quality control or inspection parts for machines and air leakage control.

FEBRUARY 2016

MACHINE TOOLS WORLD

ADVERTISERS INDEX COMPANY NAME

PG. NO.

COMPANY NAME ERWIN JUNKER MASCHINENFABRIK GMBH

A ACCURATE INDUSTRIES

ACMEE - 2016

FATTY TUNA INDIA PVT. LTD.

ADOR WELDING LIMITED

AMTEX - 2016

C 61

CNC SERVICING & SOLUTIONS (I) PVT. LTD.

CNC SOFTWARE, INC.

BACK PAGE

HARTING (INDIA) PVT. LTD.

J JYOTI CNC AUTOMATION LTD.

LAPP INDIA PVT. LTD.

INSIDE BACK COVER

24-25

N 39

NICKUNJ EXIMP ENTP P LTD

COMPANY NAME

PG. NO.

R RENISHAW INDIA (PUNE)

E EFFICA AUTOMATION LIMITED

CHHANIARA ENGINEERS PVT. LTD.

DOWEL ENGINEERING WORKS

GUJARAT LATHE MANUFACTURING CO. PVT. LTD.

PG. NO.

INSIDE FRONT COVER

S SANJAY TOOLS & ADHESIVES

9 & 37

SANKI MACHINE TOOLS (INDIA) PVT. LTD.

SPRAYMET SURFACE TECHNOLOGIES PVT. LTD.

U UNITY CONTROLS PVT. LTD.

V VOLLMER TECHNOLOGIES INDIA PVT. LTD.

For advertising contact: 7

shekhar@divyamediaonline.com or call: 09820551279

FEBRUARY 2016

MACHINE TOOLS WORLD

Mr.

Sadananda

Inside Story

Koppalkar

Head Business Development - EDM, Die & Mold, Makino India Pvt. Ltd.

My Lifeâ&#x20AC;&#x2122;s Goals Aim & Ambition: I believe in living my life to the fullest. Be it the business or family. I want to give my best in whatever I do and the destiny will take me in a right way. Setting in mind something as best and trying to achieve it may undermine the capability. Sky is the limit and only thing we can do is to treat every day as a gift and perform to the fullest of our capability.

Vision: To serve the community where humans understand nature and coexist peacefully with lesser frustration, anxiety and greediness. Live a balanced life, and apply ethical principles to make a significant difference.

Social Goal: We all have evolved from nature and breathe from it every day. I would like to work towards conservation of nature and expanding the green cover so that the future generations live a healthier life.

Business Goal: Makino has been a pioneer in the Die & Mold segment for last many decades. Indian Market is trying to move up on the value chain. I believe Makino has tremendous oppurtunities to work closely with customers to meet this objective. Hence as a business goal, I would like to get into critical applications where accuracy and productivity is the key. This I believe will ensure our market leadership in the years to come.

My Leisure Choices Favourite Tourist Spot: Kashmir and Forests of Madhya Pradesh.

Music I Like: Anything and everything which sounds good, especially Hindustani classical vocal and Bollywood.

Sports I Love: Cricket & Table Tennis

Ask my Taste Buds Favourite Food: Indian food especially authentic south Indian served on banana leaf.

Favourite Drink: Mojito.

In Awe of I Admire: I love and admire the talks of OSHO.

MACHINE TOOLS WORLD FEBRUARY 2016

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