Improve Your Gear ‘Apps’
Learn how Gleason’s latest gear production, inspection and service technologies are taking India’s gear applications to the next level.
www.gleason.com/GWI
Booth # P1
Bombay Exhibition Centre Mumbai, India March 3-5, 2016
Precision. Flying is considered the safest way to travel. Also thanks to the precision of Hermle machines.
Hermle machining centres are the durable masters of micro precision engineering. Simultaneous 5-axis machining of workpieces weighing up to 2,500 kg – with an accuracy of a few microns. For the perfect results.
Open House in Gosheim 20 – 23 April 2016
Email: epd.sales@phillipscorp.com
www.mtwmag.com
Publisher
Contents
Vol 1 Issue 10 | MARCH 2016
Shirish D.
IN FOCUSE
CEO Shekhar D.
Editor Shilpa Dongre
26
Marketing Team Ladoji Pendurkar, Amol Powle, Bhavin Shah, Bharat Shah, A.Purohit, Vinod Surve, Kavita Chaudhari
Indian Gear Industry is now more matured & can compete with any global players: Debashis Chattopadhyay
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
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MACHINE TOOLS WORLD MARCH 2016
COVER STORY
32
20
ADOR: The pioneer & trendsetter in welding technology
Gleason: Adoring Excellence Through Performance
TECH UPDATE
46
Mr. Pardeep Aggarwal General Manager, Gleason Works India Pvt. Ltd.
BUSINESS NEWS
8
COMPANY PROFILE
RHEINTACHO introduced new series of plastic sensors for detecting rotational speed
12
16
Effica’s Robotic solutions
18
Zenith Industrial Products: The industrial fastner expert
JUNKER Group exhibits new technologies at the GrindTec 2016
10
Next Generation of Mastercam Released for Global Public Testing
50
Manufacturing Accuracy Regardless of Circumstances
Ziehl-Abegg SE turnover increased by 6% to 448 million euros
10
Magnetic Encoders Contribute to Reliable Wafer Transfer Robots
52
An Old Invention Making New Impressions
CASE STUDY
60
HAAS : Dürkopp Adler Case Study
64 23
Production as a unified whole
73
PROJECTS
Mounting box production directly from the sheet metal storage system
76
PRODUCTS
Editorial Board
Editorial Index A
L
Ador Welding
32, 76
B 55
C
Heidenhain Optics & Electronics India Pvt. Ltd
Walchandnagar Industries Ltd.
Mrs. Mohini Kelkar Managing Director Grind Master Machines Pvt. Ltd
Mastercam
14
N
Concept Laser Mr. GK Pillai Managing Director & CEO
79
M
BFL CO.
Mr. A.P. Jayanthram Managing Director
Lakshmi Machine Works
62
D
NEMADE ENGINEERS
23
P
DMG MORI Dormer Pramet
66 52, 78
E
Portescap
54
PREMO
56
R
Effica Automation
16
Renishaw
46
RHEINTACHO
10
G Gleason Works
20, 82
H
Mr. Arjun Prakash Managing Director Effica Automation Ltd.
Ms.Samina Khalid Marketing Manager
Renishaw Metrology Systems Ltd.
Mr. MIHIR Baxi President – Global Sales
S Shanthi Gears
26
Spraymet
42
Haas Automation
60
Hangsterfer
77
T
HARTING India
78
Timmer GmbH
Heidenhain
50
58
U
Jyoti CNC Automation LTD
J
Unity Controls
JUNKER Group
79
12, 13 Z
K
Zenith Industrial Products 18, 77
KASTO
48, 64
ZIEHL-ABEGG SE
8
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
MARCH 2016
MACHINE TOOLS WORLD
5
BUSINESS NEWS
MachAutoExpo 2016 concluded with overwhelming response from 300+ exhibitors MachAutoExpo has grown from strength to strength every passing year and is rated one of the largest Machine Tool and Automation Technology Exhibition in the northern region. Due to rapid change in technology, it has become imperative to keep pace with the global Market. The basic aim of this event was to develop and promote the small scale industrial units of Punjab so as to make them globally competent. In this mega event the main thrust was on showcasing the latest technology in every segment of Industry. Udan Media and Communications Pvt. Ltd. a premier company has been instrumental in organizing this event for the past four years. Organizers have very successfully planned and customized such Trade Fairs and Exhibitions to cater the need of the entire Industry particularly MSME units for the past many years. All the events organized by the company have been Grand Mega Success. Our vision is to see the Indian Industry at Number One position on International Industrial map.Machautoexpo-2016 presented 300 plus participants and 40,000 visitors attended this event from all over the country. The Exhibition was organsed in eight Pavilions covering 20,000 sq. meters. Major companies manufacturing latest CNC Machines, complete range of Machine Tools, Engineering Machinery, Auto Parts, Automobiles, Automation Technology, Cutting Tools, Welding Equipments, Laser Technology,
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MACHINE TOOLS WORLD MARCH 2016
Handling Equipments, robotics and related products showcased their products in this Event. This event proved to be a biggest ever SME gathering and a grand mega success. Main attraction of this event was that many big stalwarts of leading Machine Tool manufacturers participated. Live demo of machinery and precision manufacturing was another attraction. The main emphasis was to become self reliant in every field of manufacturing and keep pace with the latest technology. Our vision was to show the developed nations that we are second to none. We are optimistic to achieve our objective. Ludhiana city known as “Manchester of the East” is once again on the upper slot in the Industrial Map of the Globe. The stage was set to host a confluence of exciting business opportunities, world-class technologies and enthusiastic participants across the globe, to converge on a single platform. The five days MachAutoExpo-2016 Exhibition was undoubtedly a gateway to the world of opportunities. Let’s get gear for the growth! Entrepreneurs and successful Industrial Pioneers have accepted that Innovation and
350 plus participants and over 45000 visitors, 2000 products across the country and overseas. The vision of Organizers was to see that objective “Make in India” is achieved in true letter and spirit. Main highlights of this Exhibition was Seminar on “Smart Manufacturing and multiply Productivity” conducted by renowned premier companies from India, Germany and Japan and “Vendor Development Programme” for the benefit of MSMEs by NSIC. This fifth edition of Machautoexpo-2016 was another milestone for the Industry of Ludhiana in particular, Northern Region in General and overall the entire Industry of our country.
technological advancement are key factors to success. Innovation draws inspiration which leads to competitiveness. Entrepreneurs have an opportunity to showcase their Innovations and it is perfect launching pad to explore new ideas, conductive environment for forging joint ventures and collaborations to enhance their business. MachAutoExpo-2016 featured
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1. Place of publication
FORM - IV SEE RULE 8 : 303/304, Harmony Tower, N.S.Road, Court Naka, Thane West, Thane -400601
2. Periodicity of its publication
:
Monthly
3. Printer's Name Whether citizen of India Address
: : :
Shirish Dongre Yes 29/30, Anitha Art Printers Oasis, Next to Vakola Market, Santacruz(E), Mumbai-400055
4. Publisher's Name Whether citizen of India Address
: : :
Shirish Dongre Yes A3/604, Chavandal Tower, Parsik Nagar, Kalwa West Thane -400605
5. Editor's Name Whether citizen of India Address
: : :
Shilpa Dongre Yes A2/603, Chavandal Tower, Parsik Nagar, Kalwa West Thane -400605
6. Name and Address of individual who own the
:
Shirish Dongre A3/604, Chavandai Tower, Old Thane - Mumbai Road, Parsik Nagar, Thane -400605
I, Shirish Dongre, hereby declare that the particulars given above are true to the best of my knowledge and belief. Date: 1-03-2016
Sd / Shirish Dongre Publisher
MEET THE GEAR EXPERTS TURNING
GEAR CUTTING
SURFACE GRINDING
I.D. & O.D. GRINDING
GEAR HONING
TOOLING
COMPLETE MACHINING
COMBINED MACHINING
SERVICE
WWW.DVS-TECHNOLOGY.COM
ENGINEERS PRIVATE LIMITED
IPTEX 2016, BOOTH P6
Official representative of the DVS TECHNOLOGY GROUP www.nemade.in
BUSINESS NEWS
Ziehl-Abegg SE turnover increased by 6% to 448 million euros
The inspection process in the manufacture of printed circuit boards at Ziehl-Abegg is fully automated but if the machine identifies any anomalies then employees like Vitalij Fofonov check the boards. “We have achieved another significant increase in turnover last year in difficult conditions”, says Peter Fenkl, CEO of the Ziehl-Abegg SE. Even though the economic development in the BRIC countries (Brazil, Russia, India and China) is slowing down, Ziehl-Abegg has succeeded in increasing turnover worldwide by six percent to 448 million euros (previous year 423 million). Business in Europe was also well above expectations, as it was in America. “We have grown at a disproportionate rate despite the slow overall economic development”, says Fenkl, making reference to Ukraine and Russia. During the course of business, the general economic situation was also reflected at Ziehl-Abegg Brazil, with turnover falling just below the previous year’s level. Even turnover in Germany is increasingly shaped by the global influ-
8
MACHINE TOOLS WORLD MARCH 2016
ences coming from Russia and the slower growth in Asia. “In spite of the numerous military conflicts and the economic crisis regions, the bottom line is that we can report a clear increase”, says the Chairman. A large proportion of the turnover is being achieved with products that have not yet been on the market for five years. “The praise for this goes direct to our developers and engineers,” says Fenkl. Regulatory targets for energy savings are prompting customers to take a closer look at performance and power consumption. We are also seeing this in China. “If you use quiet, efficient fans, fitted with modern drives, then Ziehl-Abegg is a must” emphasises Fenkl. The high quality represented by ‘Made by Ziehl-Abegg’ also scores highly in medical equipment and elevator drives. The same applies to the area of electro-mobility in public
Ziehl-Abegg distinguishes itself not only from the engineering aspect but with Blue is also setting a visual highlight. In 2015 the Künzelsau-based fan and drive manufacturer grew its global turnover by approx. six percent to 488 million euros. transport. The gearless in wheel hub motor ZAwheel produced by Ziehl-Abegg is the world’s most efficient drive system for city buses. Whilst lesser importance is attached to efficiency in many communities, noise pollution and emissions caused by diesel buses are seen as the greater problems. “First it was Peking, then New Delhi and now Stuttgart” says Fenkl, listing three major cities as an example of fine particle pollution alarm. “We are getting to the point at which bus manufacturers, local transport operators and politicians are urgently demanding the introduction of electric buses in city centres.” For example, the Hamburg and Berlin Senates have decided that by the year 2020 they will only purchase zero emission buses. London has taken the same decision and five years after that date Paris wants all buses to be purely electric driven.
In spring 2015 the city of Münster in Germany made the start for quiet and pollutionfree transport by ordering five electric buses; the engines came from Ziehl-Abegg in Hohenlohe. The purely electric drive sits directly in the wheel hub so it does not require either any transmission or differential, both of which only consume unnecessary energy. The current year in Europe will see a significant increase of clean and quiet electric buses fitted with ZAwheel. The number of employees at Ziehl-Abegg rose to 3450 (previous year 3400); between them the five Hohenlohe sites employ a total of 1950 people (previous year 1900). The company traditionally does not give out any information on profits.
Website: www.ziehl-abegg.com
BUSINESS NEWS
RHEINTACHO introduced new series of plastic sensors for detecting rotational speed With its high IP69K protection class, RHEINTACHO is set to introduce a complete new series of plastic sensors for detecting rotational speed and direction from the second quarter of 2016. Thanks to different sensor lengths, cable outlet directions and connector options, this product line offers users a high degree of flexibility, enabling adaptation to entirely individual requirements. And even if none of the available models is suitable, RHEINTACHO will be pleased to draw on its recognised expertise in customised solutions to develop the right solution for you. Why IP69K? RHEINTACHO Sales Manager Wolfgang Sexauer: “There are two main reasons why we were motivated to develop this new series. Firstly, we see a tendency to specify higher IP
10
MACHINE TOOLS WORLD MARCH 2016
classes in many applications for safety reasons, than was the case a few years ago. Secondly, the IP69K protection class enables technical potentials to be realised even more efficiently today. This applies to both available materials and, of course, to intelligent constructions.” The FQ product line is consequently a further development of the current FK product line, which fulfils protection class IP65. In recent years the FK sensors have developed into a genuine success model. Numerous electromotor applications would be inconceivable without these rotational speed sensors. The basic geometrical data for the RHEINTACHO FK has meanwhile been adopted by significantly larger competitors too. The electronic design of the FQ product line is successively
complemented with different variants in order to fulfil different requirements. In detail: Frequency range, detection distance, EMC and temperature stability. According to the current development plan, all versions will be designed as a twochannel sensor, enabling the detection of rotational speed and direction of rotation. RHEINTACHO wholeheartedly welcomes higher specifications from users in regard to its sensors. “Our experience has shown that specifying too low an IP class and putting the onus on users via operating or maintenance instructions, is not practical. This simply doesn’t work”, continues Wolfgang Sexauer. “When a machine is to be cleaned with a steam jet for practical reasons, it is difficult to convince the operators otherwise – regardless of
what is found in the operating manuals. Subsequent problems “in the field” are then inevitable. Whether in consideration of all actual costs a more cost-effective, lower-specified component is then the means of choice is at least doubtful. And just for this reason we are expanding the proven FK product line to include the FQ series with its higher protection class. We always strive to offer the best technical and economic solution, tailored to the specific application.”
For more information, Website: www.rheintacho.com
BUSINESS NEWS
JUNKER Group exhibits new technologies at the GrindTec 2016
The grinding technology world comes together at the GrindTec in Augsburg, Germany from March 16 - 19, 2016. The JUNKER Group will be exhibiting a wide range of new technologies under its JUNKER, ZEMA and LTA brands at booth 5003 in Hall 5: JUNKER will be demonstrating grinding operations on tool blanks, ZEMA will be presenting a cylindrical grinding machine for shaft grinding and LTA will complete the Group’s presentation with a vast array of innovative filtration solutions.
Consistent quality during the cylindrical grinding of tool blanks The JUNKER Lean Selection speed is able to realize several grinding operations on tool blanks in a single clamping set-up. One or two highperformance grinding spindles, mounted at the swivel-action wheelhead (B axis), work using the QUICKPOINT grinding method. An integrated loading system ensures short loading times.
12
MACHINE TOOLS WORLD MARCH 2016
First-class shaft grinding At this year’s GrindTec, ZEMA will showcase its NUMERIKA GH 1000 live in action. This durable cylindrical grinding machine, with its hydrostatic X and Z axis and hydrostatically mounted grinding spindle, is ideally suited for a wide workpiece spectrum in the automotive industry such as crank, rotor or transmission shafts. In addition, the operating element of the GH 1000 is extremely simple and convenient to use.
Filtration technology to the highest standard Filtration solution specialist LTA Lufttechnik GmbH will be on the booth demonstrating the separation of oil/emulsion
mist and fume particles using electrostatic and mechanical filter models, and also explaining the possible application of safety / fire protection components and the associated pipe systems.
The JUNKER Group The companies which make up the JUNKER Group develop, produce and sell precision grinding machines for the metalworking industry, as well as air filters for industrial air purification. A workforce totaling 1400 employees is active the world over working to secure the success of the JUNKER, ZEMA and LTA brands. JUNKER has been instrumental in shaping today’s grinding
industry with high-speed grinding machines and groundbreaking inventions since 1962. Today, JUNKER is the world market leader in the manufacture of CBN grinding machines. Another focus will be corundum grinding. The application scope of JUNKER grinding machines ranges from crankshafts to twist drills. The Group’s customers are located wherever ultra-precise metal grinding is vital – currently predominantly in the automotive engineering and tool industries. ZEMA was founded as long ago as 1953, employs a team of over 80, and produces CNC grinding machines with corundum grinding wheels. The traditional Brazilian company has sophisticated solutions for grinding with corundum, e.g. for machining the flange and journal on crankshafts or transmission, turbocharger and cardan shafts. Customers can primarily be found in the vehicle and tool construction sectors. ZEMA has been part of the JUNKER Group since February 2015 and uses the Group’s worldwide sales and service network accordingly. LTA Lufttechnik GmbH is a technological leader in filtration solutions. The air flow specialists research, develop and manufacture filtration systems for industrial air purification.
For more information, Website: www.junker.in
BUSINESS NEWS www.mtwmag.com
JUNKER Group awarded prestigious SGM technology prize for second time
The JUNKER Group is the ultimate partner worldwide in all questions of grinding and air filtration technology - and its innovative solutions are trusted by acclaimed automotive manufacturers. The grinding machine manufacturer was once again the proud recipient of the “Leading Technology Award” from SAIC General Motors Co., Ltd. (SGM). SGM presents this prestigious award to its best suppliers from around the world in a number of categories. The JUNKER
Group is the only European machine builder amongst the winners to have received this award not only in 2014, but again in 2015. Roger Kleffmann, subsidiary director in China, collected the award at the end of January 2016 in Boao, China, against the backdrop of a major event the presentation of GM’s latest models. “This is confirmation of the expertise, know-how and efficiency of the JUNKER Group”, said Rochus Mayer, CEO, delighted at having received this award for the second time. In order to achieve this degree of success both now and in the future, JUNKER invests both capital and capacity into the research and development of new technologies and processes. “We are number one and we aim to maintain our pole position in the field of grinding”, confirmed Rochus Mayer. For more information, Website: www.junker.in
MARCH 2016
MACHINE TOOLS WORLD
13
BUSINESS NEWS
Next Generation of Mastercam Released for Global Public Testing as the new Align Solid Body which simplifies the process of aligning solid models for turning. Chip Break has a new option and a dialog box has been added to the Lathe Rough and Lathe Contour Rough toolpaths to establish when chip breaks occur. • Overall streamlined workflow with improved plane management, level and geometry control, viewsheets, chaining and more. The new Analyze Toolpath feature further improves workflow by displaying useful information when you hover over a toolpath section.
About Mastercam
The next generation of Mastercam, named Mastercam 2017, has a Public Beta now open to all currently maintained Mastercam customers. Shops all over the world, from small job shops to Fortune 100, get a chance to test Mastercam 2017 before it is released and provide valuable feedback that helps shape the final product. Participants in the Public Beta get an early look at the new streamlined workflow and optimized interface that Mastercam 2017 delivers, along with dozens of powerful new tools for simple to complex jobs.
Here are a few things you’ll see in Mastercam 2017 Beta: • New Optimized Interface
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MACHINE TOOLS WORLD MARCH 2016
organizes and streamlines your programming. Based on the successful “Ribbon” interface, Mastercam 2017 capitalizes on your experience with other Windows software, making it easier to find the functions you need to complete your tasks. • Dynamic Motion advances bring new options to our groundbreaking technique, delivering toolpaths that are more efficient, less complex, travel a shorter distance, and improve cycle time. • Expanded CAD for CAM delivers more practical design tools for shop-floor programmers. Mastercam 2017 speeds design for items such as molds and electrode tools, offers auto-
repair on imported solids, and improves current tools such as Solid Disassemble. • New Maximum Stock Engagement option for 3D HST Finishing toolpaths allows you to select a previously made stock model and set the maximum amount of depth so that you can limit how deeply the cutter engages uncut material. • Powerful Multiaxis enhancements include optimized Multiaxis Drill, with stock model recognition for depth and top of stock purposes. Additionally, the various ways of selecting stock have been updated to have consistent workflow and selection methods. • Lathe enhancements such
Developed by CNC Software, Inc., Mastercam is Windows®based CAD/CAM software for 2- through 5-axis routing, milling and turning, 2- and 4-axis wire EDM, 2D and 3D design, surface and solid modeling, and Swiss machining. Privately owned and founded in 1983, CNC Software provides CAD/CAM solutions to more than 211,000 installations in 75 countries in industries including moldmaking, prototyping, automotive, medical, aerospace, consumer products, and much more.
For more information, Website: www.mastercam.com
PRODUCTIVITY ACROSS THE BOARD
CENTERLESS CYLINDRICAL GRINDING The centerless grinding machines of the JUPITER series offer significant production benefits: The patented CNC height adjustment of the support rail minimizes tooling times, automatic adjustment of the grinding gap geometry optimizes the grinding process, and the inclined bed guarantees outstanding dimensional accuracy.
Erwin Junker Maschinenfabrik GmbH India Branch Office Office No. 104, City Square 29-2, K.M. Gandhi Path Bhamburda, Shivaji Nagar Pune 411 005, India +91 20 255 33 896 info@junker.in
www.junker.in JUNKER PREMIUM-SERVICE: • Guaranteed servicing • Fast and competent • 24 hours a day, 7 days a week • Worldwide servicing network
COMPANY PROFILE
Effica’s Robotic solutions
C
oimbatore-based Effica Automation, incorporated in 2005, is today in the focal business of materials handling automation encompassing machine tending, palletizing and conveying, making the most of robots. Under the stewardship of Mr. Arjun Prakash, President, who is the grandson of late Dr. G.R. Damodaran – a statesman, educationist, humanitarian and founder of the legendary PSG Tech, Effica is eminently poised to take industrial automation in India to subliminal heights. A mechanical engineer from PSG, Mr. Arjun pursued an internship and intensive training and experience in the field of mechatronics. The education and insights he received in mechanical engineering, electronics, robotics, computers and software applications helped him build a strong foundation for Effica Automation
which is today in the forefront of integrating robotic systems to enhance operational efficiency, productivity & profitability in Indian industry which is poised to join the big league using robots for automation and manufacturing excellence. Effica started off in 2005 designing and manufacturing special purpose machines (SPMs) for a plethora of applications. It even developed robotized special plasma cutting systems for marking and precision cutting power transmission poles of 60 ft long. Way back in 2009 it executed a project worth Rs. 2 crores in Houston. This was a complex job involving different disciplines – mechanical, electrical, electronics, robotics, machine vision and so on. It involved handling, rotating, holding and cutting of poles where cost of error was very high and forbidden. Present focus
A customized robot engaged in machine tending
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
Effica’s state-of-the-art production facility in Coimbatore 16
MACHINE TOOLS WORLD MARCH 2016
loading and unloading, secondary packing and palletizing systems; and machine vision based picking and intelligent gripping solutions for packing and inspection. It also offers gantry machine tending to replace articulated machine tending projects for payloads from 40 grams to 100 kg. This is an economical solution, and with this the existing plant layout need not be disturbed. It also does bag conveying & 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 userfriendly so that in the event of a failure, the user can also fix it. This way we have removed the fear of breakdown and consequent downtime from the mind of the end-user,” reveals Mr. Arun Prakash. Modern facilities
Effica has a sprawling manufacturing facility housed in a land of 10,000 sq. mtrs. It has an in-house Machine shop, Assembly shop, Design & Dev. Dept., Quality Control section and so on. The Controls Dept. has multiple robots and PLCs. The company has a dedicated workforce of 35 people. Marketing is done directly. However, it has channel partners in strategic locations like Coimbatore, Chennai and Bangalore to extend its reach to the customer. Automobile industry & 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.
Accuracy in Continuing Development For years, absolute linear and angle encoders from HEIDENHAIN have been setting standards for accuracy in machine tools.This will also apply to the latest generation of our encoders.Today these products are diagnosable, feature more interface variants, and are provided with functional safety including mechanical fault exclusion. This is how we continuously develop our proven products to be optimally prepared for the demands of modern machine manufacture.
HEIDENHAIN OPTICS & ELECTRONICS INDIA PRIVATE LIMITED
Angle Encoders
Linear Encoders
Chennai 600031, India
Contouring Controls
phone +91 44 3023 4000
Position Displays
Length Gauges
www.heidenhain.in
Rotary Encoders
COMPANY PROFILE
Zenith Industrial Products: The industrial fastner expert
Z
enith Industrial Products (ZIP) is a leading manufacturer & supplier of industrial fasteners in India. It was established in July 2000 by Mr. Deepesh R Sheth. He got trained under his Father Mr. Rajnikant P Sheth who has got experience of more than 40 years in this field. He owned companies named as, Precision Industrial Components and Forged & Turned Components from 1967 till 1999 which were a substitute to quality fasteners. Following the principles set by his father and keeping up the same goodwill amongst the customers Mr. Deepesh started his Company aiming to provide Quality fasteners at a competitive price in the shortest possible time. At present ZIP is engaged in mfg & supply of Standard & Non Standard Fasteners for all types of Industries. The product range of ZIP includes
Bolt, Nut, Stud & Socket Screws
Any type of Bolt, Hex, Round, Sq head, Rectangular hd, Sq neck Carriage bolt, N/B Bolt, Coach Bolt, Eye Bolt. Hex Socket head Allen Bolt, Hex Socket & Slotted type Grub Sc., Plunger sc., BSP, BSPT, NPT, NPTF, Hex Socket type, Hex hd., Sq. hd., Tapper plug, Hex hd. Plug, Collar / Washers Faced & Allen plug stud, Steeped, Full thread, Tie road & Spindle. Hex nut, Lock, Dome, Nylock, Weld, Flanged Nut, Sq nut, T – nut, Slotted nut, Wing nut, Eye nut, Clinch nut, Rivet nut, Long nut, etc. Screws, Rivet & Sheet Metal Washers & Other Components & Pins
Philips Star punch & Slotted type machine screws, Pan hd., CSK, Round, Truss, Mashrum hd., Washers Faced Flanged type, Hex hd., small hd., Cheese sc., Captive sc., Long size sc., Partly threaded sc., Shim sc., Terminal sc., Self
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MACHINE TOOLS WORLD MARCH 2016
Tapping sc (type B – AB – BT cut and drill point), Rivet round hd, CSK hd, Flat hd solid & Hollow type, & Steel rivets. Plain punched flat washers, Machine washers, Tapper washers, Sq & Flat Spring washers, Star washers, Disk Fan washers, Wave washers, Push on Washers, Bearing washers, Disk Spring washers, Spring Dowel pin, Tapper pin, Solid Dowel pin, Grooved pin, Ext & Int Threaded pin, Cotter pin, etc. Standard Reference
These fasteners are available as per latest standards like ISO, IS, BS, DIN, JIS, ASTM, GOST, etc & non standard items as per drawing or samples of customers. Threads
Metric std MM threads in Coarse & Fine Pitch, British Std BSW & BSF type, American Std UNC & UNF type, Pipe threads BSP, BSPT, NPT & NPTF type, BA Threads, No. 4 to No. 12 UNC & UNF threads, Self Tapping threads No. 2 to No. 14 type. Material & Grade
Mild Steel – 4.6 Grade / Case Hardened, EN 8, EN 8D, 8.8 Grade, EN 19, 10.9 Grade / 12.9 Grade, EN 24, 12.9 Gr, Stainless Steel (SS) 410, 202, 302, 303, 304, 310, 316, 304L & 316L, Brass, Copper, Aluminum, Phosphor Bronze, Spring Steel, Titanium, etc. Finishing
Zinc Platted with Silver, Blue, Yellow or Olive Green Passivation, Copper Zinc, Trivalent Zinc, Cadmium, Nickel, Nickel Chrome, Blackodising, Phosphating, Natural Finish or Self Colour. For SS items Electro Polishing or Buffing, etc Application
All these Fasteners are used for various
Mr. Deepesh R Sheth applications for general purpose, maintenance work or as a specific engineering part. Generally these are used in Machine Tools, Light, Medium & Heavy Engineering Industries, Material Handling Equipments, Automobiles, Textile Machineries, Pharmaceutical Machineries, Home Appliances, Hydraulic & Pneumatic Parts, Pumps & Valves, Electrical, Electronics, Computers, Instrumentation, Automation, Switchgear & Telecom Products, Mono Blocks, Motors, Gears, Plastic Injection Moulding Machineries, Dies & Tools, Roofing, Aluminum Section Framing & Fixing, Scaffoldings, Earth Moving & Agriculture Machineries, Crain, Rubber Industries, Cement, Chemical, Fertilizers & Sugar Machinery Plants, etc. Quality product at a competitive price in a shortest possible time is a key factor for any successful Business. At ZIP above rule is of prime importance and hence there is NO COMPROMISE in quality of any product supplied to customers by ZIP. With such a vast product range & adherence to global quality standards have made ZIP more popular amongst the OEM’s as a ONE STOP SHOP for most of their fastener requirement.
For more information, Website: www.zip-india.com
COVER STORY
Adoring Excellence Through Performance Mr. Pardeep Aggarwal General Manager, Gleason Works India Pvt. Ltd.
Q. Please brief us about company’s global reach & latest initiatives in Industrial gears & motors space. Gleason Corporation’s mission is to be The Total Gear Solutions Provider™ to its global customer base covering more than sixty countries. Gleason’s focus is on manufacturing equipment for gears, including machinery, work holding, tools and related services. Gleason has manufacturing operations in the United States, Brazil, Germany, Switzerland, India, China and Japan, and has sales and service offices in all important market regions.
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automotive, truck, aircraft, agriculture, mining, energy, construction, power tool and marine industries and various industrial equipment markets. From small transmission gears to the largest mining gear, Gleason does offer a manufacturing solution including hobbing, milling, chamfering/deburring, Power Skiving, shaping, shaving, profile grinding, threaded wheel grinding and honing for cylindrical gears as well as cutting, grinding, lapping and auxiliary equipment for bevel gears. With its own automation and inspection solutions, Gleason is also able to provide customers complete gear manufacturing systems.
Q. What are the applications of your products in various? How do you plan to position these products?
Q. What is the current scenario of gears & motors industry?
Gleason gear solutions are employed in
In general the market is quite soft. India
MACHINE TOOLS WORLD MARCH 2016
still remains behind it’s possibilities. Automotive investment programs have been somewhat sluggish in the beginning of 2016 and other industries have not yet taken over to drive major growth. Manufacturers are maximizing their current capacities and working to reduce production costs to remain competitive in the current environment.
Q. What are the future opportunities for industrial gears & motors sector? We see growth opportunities with the automotive, construction, rail transport and small truck industries developing their offerings to new standards while other industries like mining could rebound once oil prices return to higher levels. The energy sector bears interesting opportunities for potential investments.
COVER STORY www.mtwmag.com
Especially the wind power industry has started to improve after struggling with overcapacities for the last years. We are working with customers to be ready with the required expansions. Also, the policy statement of “Make in India” made by the Government of India should be getting into practical application in short-term and we expect that the new budget plans of the government will include incentives to promote this concept. While the markets improve we see opportunities in the optimization of current production equipment with software upgrades, advanced tooling applications such as Quik-Flex® Plus and preventive maintenance programs, tailored to customer’s immediate needs.
Q. As per your opinion, what are the technology transformations in industrial gears & motors industry over the years? Industrial gears show a huge variety of applications. In the last few years,
we have seen a rise in planetary gear boxes to keep designs more compact and save installation space and weight. Such transformations have already taken place in the core industries such as with cement, sugar, mining and construction equipment. We also expect to see more helical gear designs as time progresses.
Q. What are the distinguishing factors in comparison of Indian against the global gears & motors industry? In the past India has positioned itself very competitively as a supplier for low-cost transmissions and gear supply. With the before-mentioned design changes and top-level engineering capabilities the Indian gear industry will compete increasingly with Asian low-cost and Western high-tech transmission manufacturers. Especially the excellent engineering capabilities will become a major differentiator to global competitors. As the gear industry moves along, we will
certainly see more compact and higher efficiency transmissions made in India.
Q. Please comment on how can the Indian gears & motors industry become globally competitive? Indian manufacturers need to practice top technologies, not only in the design of gearboxes and transmissions but also in manufacturing efficiency and quality. Cost-pressure and quality go hand-inhand on today’s markets and suppliers that cannot live up to these demands will have a hard time competing in the international field. We see the key success factor in installing an efficient process chain including the right finishing processes that allow competing on higher quality levels.
Q. Could you brief us about your topline product range? What are value added services you provide to your customers? As “The Total Gear Solutions Provider”, Gleason’s product line covers practically all required equipment and processes to produce a gear, starting from the blank to the finished gear. The benefit to the customer is the profound knowhow in each manufacturing step which allows us to supply complete gear manufacturing systems but also specific solutions tailored to the customer’s application. These include cutting and soft finishing processes, hard finishing equipment, measuring machines as well as work holding and cutting tools. At Gleason, we
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COVER STORY
“
Gleason’s global exposure provides the advantage to employ solutions that have been successful in other parts of the world, so we can
“
exploit the best of all worlds.
do not just sell a product, we provide a solution which includes a process and - if requested - the work holding and tools that fit to the customer’s application. All Gleason products are supported by a global service team. At Gleason Works India we manufacture high-speed gear hobbing machines for transmissions gears employing advanced cutting tools. The company is working closely with other Gleason operations to add more products for the manufacture in India. Gleason Works India provides technical consultation services and partners with customers to find new manufacturing processes. Gleason’s global exposure provides the advantage to employ solutions that have been successful in other parts of the world, so we can exploit the best of all worlds. We also provide spare parts for existing installations and re manufacture older Gleason, Pfauter or Hurth machines.
Q. What are your future plans to maintain substantial market positioning in industrial gears & motors space? We will continue the “Total Gear
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Solutions” approach. Innovative new products like Power Skiving Equipment, modular Quik-Flex®Plus Work holding, the latest 300GMS®P Analytical Gear Inspection Machine for shop floor measuring are proof of our innovation strategy. At the same time, we have been adding Plastic Gears to our product portfolio, expanding into this very special market with a very unique manufacturing approach. Lately we have also concluded the integration of our new division Gleason Automation Systems into our operations. We are now able to supply complete gear manufacturing systems including integrated automation, for a worryfree gear production solution from one single source. With Gleason 4.0 we are researching ways to exploit digital manufacturing solutions for the gear manufacturing world. There are still so many things we can do and we are very excited about the gear industry’s future.
For more information, Website: www.gleason.com
COMPANY PROFILE www.mtwmag.com
Production as a unified whole The DVS TECHNOLOGY GROUP as an integrated system supplier
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mmense competitive pressure and ever shorter lead times for new models are significantly increasing the demands made by the automotive industry on machine tool manufacturers. Maximum flexibility in the layout of the production process, a constant decrease in life cycle costs and a reduction in internal coordination efforts for the planning, procurement and implementation of new production lines are top priority issues for vehicle manufacturers. In the segment of power train component manufacturing, the companies within the DVS TECHNOLOGY GROUP offer holistic manufacturing solutions based on their own mass production experience and the wide range of DVS technologies available. Whereas a machine manufacturer closes the project file following a successful final acceptance procedure, the challenge for the mass producer starts with initial machine operation and continued optimization of the production workflows, with the aim of achieving amortization of the investment costs as quickly as possible. This is a difficult task, because the more machine and tool manufacturers are involved in the project, the greater the coordination efforts must be to optimize the process workflows. The already heavy workload within planning departments due to the increasing number of models being introduced with shorter and shorter life times means that opportunities for saving potentials and more efficient processes in day-to-day production are being missed. Against this background, the DVS TECHNOLOGY GROUP is treading a different path. A coordinated range of systems comprising machine tool, automation and technology solutions
coupled with experience gained in the company’s own production facilities with automotive certification allow the company group to take an integrated approach to new customer projects. DVS can map the whole process workflow for stock-removing technologies from soft to hard finishing with all the in-line automation solutions. Tools, measuring instruments and clamping devices tailormade to the machining process in the group’s own production plants round off the range. The introduction of the DVS ModuLine machine platform was the first milestone set by the DVS TECHNOLOGY GROUP companies as system partners for mass producers of precise metal parts. With this technology-spanning machine and automation solution, almost all the machining technologies of the DVSTECHNOLOGY GROUP can be implemented on one single machine platform and linked in a standard way. Thanks to the modular machine concept suggested by the very name of the
platform, many machining processes are combined in an extremely compact space and executed simultaneously in some cases, with reclamping kept to a minimum. This “integrated solution approach” from the DVS TECHNOLOGY GROUP can be illustrated using the example of the production of planetary gears (pinions) for a passenger car gearbox. It should be noted here that other alternative production concepts are also available. The task of this concept is the production of planetary gears for passenger car gearboxes from the raw part through to the ready-to-install component, taking the following aspects into consideration: • Reduction of the total investment costs • Keeping the machine footprint required to a minimum • Shorter cycle times while observing cycle time synchronism • Increase in manufacturing quality • Less capital commitment thanks to optimised material flow At the start of the production line there is a PITTLER ModuLine supplied by bulk forged parts. Within the context of green turning, the machine turns both the face, the internal bore and the outer
Production flow for DVS pinion production MARCH 2016
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COMPANY PROFILE
OP10 to OP30 Turning & Gear cutting
OP50 to OP70 Bore Grinding & Honing, Face Grinding
OP80 Power Honing on a PRÄWEMA SynchroFine 24
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diameter simultaneously. Simultaneous machining is made possible by a twin work piece and tool spindle design (TWIN concept) which also allows the use of sister tools. All the clamping agents used in the manufacturing chain described are designed on the basis of a diaphragm clamping system from SWS Spannwerkzeuge GmbH, a company associated with the DVS TECHNOLOGY GROUP, which makes them fast and easy to change thanks to a standard DVS interface. Following post-process measurement in the automation cell, the work pieces are conveyed by linear shuttle for further gearing processing to a PRÄWEMA ModuLine equipped with either a skiving moduleor peel skiving technology. Once the gear cutting process and subsequent deburring has been completed, the component is fed by the SCARA robot in the ModuLine automation cell to a rotary magazine which is also part of the DVS ModuLine automation and has proved its worth repeatedly in DVS production operations. 10 work pieces are “skewered” on each of the 16 flaretype metal carriers which are arranged in a circle on a work piece magazine. The carrier scan be removed individually so that the soft-machined work pieces can be placed quickly and easily in precast deep drawing inserts in which they are then sent for hardening. Following hardening, the work pieces are replaced on the flare rods and supplied to the ModuLine rotary magazine. Directly afterwards, the components enter a ModuLine from BUDERUS SCHLEIFTECHNIK, which is also equipped with two tool and work piece spindles in accordance with the DVS TWIN concept. To begin with, the internal bore is ground and honed in a high-precision process using CBN-coated grinding wheels at this station. A further linear shuttle conveys the parts to a ModuLine from DISKUS WERKE SCHLEIFTECHNIK, which grinds both faces to the required final dimension while clamped on the inside in a precise bore.
COMPANY PROFILE www.mtwmag.com Custom-made grind wheels by Naxos-Diskus
In the concrete application case described, grinding wheels specially designed by the DVS company NAXOS-DISKUS SCHLEIFMITTELWERKE are used for the machining process on both grinding machines. The innovative bonding systems from NAXOS-DISKUS are the basis for the long service lives of the grinding wheels. The last machining step in the process is power honing, which is carried out on a PRÄWEMA Synchro Fine machine with at win spindle design. This is also supplied with work pieces via the space-saving and surface-protecting DVS rotary magazine. There is a pre-process measuring station inside the automation cell which guarantees efficient machining. The outstanding features of the “PRÄWEMA Original” honing tool developed by DVS TOOLING are a long service life and durability as well as high dressing cycles. The VarioSpeedDresser® dressing tool, which can also be purchased through DVS TOOLING, permits the microgeometry of the gear teeth to be adapted within the course of the honing process through straightforward changes in the control software without influencing the machining cycle time. The user can thus fine-tune the production process after it has started and effectively combat any noise which
may occur in the gearbox. This makes the complex and expensive production of dressing tools with adapted geometry unnecessary. Easy to maintain
An identical machine platform also means the maintenance concept is identical, which makes servicing of the DVS ModuLine series manageable in terms of personnel, thus increasing machine availability. As described in the production workflow, the end user reaps the benefits of cooperation in technology and tool development as well. The grinding machine manufacturers BUDERUS SCHLEIFTECHNIK and DISKUSWERKE SCHLEIFTECHNIK collaborate closely with NAXOS-DISKUS, the grinding tool producer within the DVS TECHNOLOGY GROUP. Joint configuration of the tool parameters, physical proximity and a constant exchange of experience guarantee the user flexible and prompt implementation of new developments. This also takes place in equal measure at DVS TOOLING, the supplier of original tools and technology support for PRÄWEMA power honing. In close cooperation with PRÄWEMA, tool components such as the honing tool or dresser are continually developed and improved. In both cases the objective is to achieve a significant reduction in tool costs for the mass producer. The potential
DVS ModuLine
Work piece pinion of DVS planetary gear production: • High output with 80% capacity utilisation in three-shift operation: approx. 1.08 million parts per year. • Production area required: approx. 120 m², thus reduced building investment. • Personnel required per shift: 3 workers. Considerable reduction in purchasing costs compared to standalone solutions. • Manageable servicing work. • Consistent machine utilisation with synchronized process times. • Reduced capital commitment thanks to improved material flow. For more information, Website: www.dvs-technology.com www.nemade.in
Mr. Bernd Rothenberger, Managing Board & Chief Sales Officer DVS TECHNOLOGY GROUP c/o DISKUS WERKE AG MARCH 2016
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IN FOCUS
Indian Gear Industry is now more matured & can compete with any global players: Debashis Chattopadhyay Coimbatore-based Shanthi Gears is today a part of the Rs.27,500 Crore Murugappa Group, one of the leading industrial houses in India. The company with a long history of manufacturing high quality, high precision gears, gearboxes, geared motors and gear assemblies, has come out with a whole range of innovative gearboxes for main hoist applications for capacities beyond 350T. Recently it has developed an Accurate Missile Positioning Gearbox with zero back lash, capable of operating at temperatures ranging from -40 degree to 140 degree Celsius. The company’s products designed for arduous applications are also used in traction motors in high speed trains, cement mills, gas turbines, thermal power projects, battle tanks, mining drills and such other critical areas. Mr. P.K. Balasubbramaniian speaks to Mr. Debashis Chattopadhyay, Head-Sales & Marketing, Shanthi Gears Ltd. to discover the strengths, capabilities and new thrusts of this homegrown manufacturer poised to spread its wings and reach out to the world with complete drive solutions in mechanical power transmission. Excerpts:
“Import substitution of gears and gearboxes to cater to niche markets is our prime focus today.” – Debashis Chattopadhyay, Head-Sales & Marketing, Shanthi Gears Ltd.
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Q. What are the new trends in Mechanical Power Transmission? There are various devices being used for transmitting Power from Motor to Machine, like Belt Drives, Chain Drives, Gearbox, etc. depending on the type of application, shaft locations and amount of Power required to transmit at what rpm. Major challenge involved while transmitting power is that how efficiently you are doing so i.e the efficiency of the drive. That’s why the entire world is now working towards energy efficient, compact drives. For Gear Industry, the trend is to go in for more and more planetary drives so that high torque can be transmitted with minimum space. Conventional
gearboxes like standard worm Gearboxes which become less efficient as you want to have more reduction ratio, are being designed with special double envelop profile which can be as efficient as 98%. Gear accuracy in terms of Lead, Profile and Pitch are also an important factor and we can observe that even for general applications Customers are now insisting on ground gears with improved DIN class of accuracy. Straight bevel gears are now being re-designed with Spiral Bevel profile with DIN Class 3 or less for more area of contact and higher efficiency. The Customers today are more knowledgeable and looking for technically advanced products.
IN FOCUS www.mtwmag.com
Q. How does your organization keep in step with them? We, at Shanthi Gears, are always oriented towards delivering “Quality” to our Customers. We have a strong team of 12 Engineers at our R&D center who are constantly working for product innovation and providing support to our Engineering Department. Our Design Engineering department is also equally strong, managed by more than 45 Design Engineers, who are designing gearboxes as per application requirements and life expectancy. Almost 70% of our production is Custom-built and special application based products, designed to suit Customer requirements. We are the only Indian Company, who have designed and supplied with our own capability a VRM Gearbox for Roller press application and it is working even better than overseas OEM supplier for more than 2 years. We are constantly investing on latest machinery which can deliver best quality gears with lowest production cycle time. Equipped with the latest machinery with skilled and experienced workforce coupled with our in-house Design and R&D facility, we are able to take up newer challenges and emerging as the most potential Indian manufacturer to replace import substitute products and develop new products for critical applications.
requires zero backlash operations and should be capable of operating at extreme temperatures ranging from minus 40 degree to 140 degree Celsius. We have also developed gears for High speed trains which are mounted on Axle with traction motors and are supplying gears to various Global players in Germany, Australia and also in India. In addition to the above, we have developed gearboxes for Cement Mill applications for both Roller press and Ball press grinders, High speed turbine gears for Gas turbine applications, Airpreheater gearbox for Thermal power projects, Ring gear and Planetary gears for 4500 HP and 5000 HP Turbo charger applications along with very critical gears required for Battle tanks, Mining drill and a host of other applications. Shanthi Gears have recently ventured into product development for Marine main propulsion gearbox which can be used for both Defense marine applications such as Aircraft carrier, Amphibious transport Dock, large offshore patrol vessel as well as submarine applications. Our R&D team is already working on this project and we are in an advanced stage of developing such products with timebound delivery.
Q. Quality, precision and reliability are the major attributes end-users look for in transmission products. How do you instill these in your products? Today, Customer feels that Quality is a term, which is given. We should ensure the same. Unfortunately, because of price competition, some of the Indian manufacturers are forced to dilute the same, which bears a negative impact on product performance and reliability. A few manufacturers are also engaged in importing substandard products from China and other countries and selling to Indian market by putting their own brand as a short term goal. These may dilute our year long struggle for developing quality products with the tireless efforts of our Indian engineers for so many years. We, at Shanthi Gears are inspired by the values of Murugappa Group, which are Integrity, Passion, Quality, Respect and Responsibility. These are the driving forces for us and we are constantly enriching ourselves with these. For the basic raw materials like Steel, Forgings, etc. we have restricted our source to hardly 3 to 4 most respected manufacturers in India. Most of our Forgings are sourced from Companies
Q. What’s your niche and what are your product innovations? We have developed a lot many products in recent times. Major application involved for Ladle tilting operation, where the product is extremely critical from the application point of view. Apart from this, we have developed Gearboxes for Main Hoist applications for capacities of 350T and above. Currently, we are designing Gearboxes for 450T cranes. These are some of the biggest in the Indian market. We have a large population of such gearboxes in the Indian market. Recently we have developed and supplied an Accurate Missile Positioning gearbox which
Shanthi Gears has an integrated gear manufacturing facility – one of the largest in India MARCH 2016
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IN FOCUS like Bharat Forge, Western India Forge, Kalyani Carpenter, etc. For Bearings, we do buy the same directly from the manufacturer from their various Global Manufacturing units and restricted to world’s best brands such as SKF, FAG, INA, TIMKEN, etc. We have 9 quality centers within our factory at various work stations apart from one main Quality Centre. We do maintain 100% quality checks at each stage of operation and our rejection rate is even below 0.03% at the time of final assembly and delivery. We ensure that only a correct and best component goes inside the Gearbox. We are very proud of our products and we know, what we are delivering to our Customers are the best-in-class. We never compromise on our product quality standards and we are committed to deliver the best. That is our value proposition to our Customers.
Q. Please throw some light on your manufacturing capabilities and wherewithal. We are having probably the largest manufacturing capability in India with latest machineries available in the world. Apart from that, we are the only Indian company having an integrated Gear manufacturing facility with Inhouse Foundry, Forging facility, Gear manufacturing including the latest Heat
Treatment facility and also In-house hob making facility. With more than 4 decades of expertise, equipped with ultra-modern and well backward integrated facility, we manufacture gears weighing from a few grams to more than 40 tonnes, from Textile loom gears to Aviation gears, from simple Worm gearboxes to complex planetary helical / bevel helical gearboxes from standard gears to custom-made gears for all applications. Our Engineering department is well equipped with the latest hardware and software for 3D Modelling and 2D Drafting, Analysis (FEA), Assembly and Animation, Reverse Engineering, Tooling (Mould & Pattern) design & Manufacturing, Generation of NC codes and simulation, etc. These enable us for shorter delivery and quick developments. We undertake Re-Engineering of existing gears and gearboxes for any Plant and Machinery to enhance their capacity, in order to withstand higher speed, feed and load within the available space. The key strength lies with our Huge manufacturing facility supposed to be the biggest in India which includes our state-of-the-art Heat treatment facility. It is a very vital and critical process to increase the surface hardness in order to reduce wear and keeping the core tougher for withstanding higher loads and longstanding performance of gears.
Armed with sophisticated production & QC equipment, Shanthi Gears comes out with products of unmatched quality and reliability 28
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Our heat treatment shop is the most modern and the biggest in India. It is equipped with the latest computer controlled equipment like pit type carburizing furnaces (max. 2500mm dia. ), tempering furnaces, oil quenching tanks and also a VACUUM carburizing furnace from SECO / WARWIK. We also have electrically heated pit type vertical sealed retort furnace for gas nitriding and gas nitro-carburizing with washing, shot blasting and shot peening facilities. We have the very latest CNC testing equipment for hardness checking and raw material microstructure analysis in our heat treatment laboratory. The Gear Cutting and Gear Grinding Machineries are the current generation and latest imported CNC of superior quality from reputed manufacturers from Germany & USA. The gear measuring equipment we have are the most sophisticated and from the best brands like Klingelnberg / Wenzel / Leitz . Further, we are the only company, perhaps in the whole world to have a fullsledged facility to make its own cutter tools. The accuracy of products mainly depends on the machines on which they are produced. To ensure the reliability of the measured dimensions, the inspection instruments are calibrated periodically. We have set up our own full-fledged Calibration facilities in-house in order to check any instrument as and when required. Our Lab with controlled temperature and humidity is equipped with Trimas Lab concept - 0.3-micron accuracy and 0.1-micron repeatability (Traceability with NABL), 50X Nikon computerized profile projector and Zeiss contour checking, Zeiss surface roughness testers. We are equipped with our own latest Renishaw Laser ML 10 Gold, Ball Bar QC 10 including rotary axis, with auto error compensation compatible to CNC systems like Siemens, Fanuc, Heidenhain, etc. With this equipment we are able to carry out Calibration of machine tools, Calibration of Co-ordinate Measuring Machines, and even the performance evaluation of machine tools. Shanthi Gears is backed by Rs.27,500 Cr
IN FOCUS
Shanthi Gears makes gigantic gearboxes for high precision and arduous applications such as aerospace, traction, steel mills, artillery, mining and so on. Murugappa group, one of the leading Industrial houses in India. We have our in-house support for corporate strategy Group, Corporate Strategy sourcing, In-house Technology Centre and Training centre to mentor and develop our key strengths in related areas.
Q. What’s the difference you make as a solutions provider? Our major strength lies on providing most advanced and technical solution to our Customers considering Cost and efficiency of the drive. All our Sales Engineers are trained to handle any Gearbox issues. Our engineers can reach any Customer’s place within 48 hours, to redress his issues. We have the capability to develop internals of other make Gear boxes or provide a Gear solution from any Imported Gearboxes or other gear related problems. We have more than 12 dedicated Service Engineers and over 33 Sales and Service Engineers spread across India through our 10 Branch offices in most prominent locations. Apart from them, we have a dedicated Mobile team available at our works at Coimbatore,
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which comprises members from Engineering, Manufacturing, R&D and Production, who attend to the most critical calls related to new Gearbox designs or tackling critical Gear problems. All our service engineers are typically trained to handle any type of problems and are equipped with most modern instruments for providing on-site service.
Q. What are your comments on ‘Indian engineering’ and how are you geared to make a significant contribution from your domain in its pursuit of excellence? Indian Gear Industry is now more matured and can compete with any Global players in terms of Designing, Delivery of quality products and also provide on time service. Further, Indian market is having its own demand and is growing very fast. Considering the above facts, almost all Global players are looking for a foothold in the Indian market through any existing manufacturer or by way of taking support from its manufacturing base in nearby country. We, at Shanthi Gears, are planning to
focus more on niche segment of products to develop Critical Gears and Gearboxes, which are so far getting imported from various European countries. We are also planning to invest more on modern machinery apart from strengthening our R&D and Engineering team. We do also have an aggressive plan to reach our Customers through modern IT systems, where Customers can not only place orders on-line, they can get basic information on Drive efficiency, Power calculations as well as on-line PD drawings for checking their design layouts. We have already started working partially for Textile Gears with the above concept and started getting encouraging response from the market. We have also planned to expand our Service network across India and conduct more training sessions to our Customers by way of sharing knowledge on various Gear related issues and Case Studies in terms of Real Life Situations. We want to establish ourselves as the only manufacturer in India to provide Complete Drive Solutions in the field of Mechanical Power Transmission Engineering.
IN FOCUS
The pioneer and trendsetter in welding technology Mr. Satish Bhat, Managing Director, Ador Welding Ltd.
Ador Welding Ltd., formerly known as Advani-Oerlikon Ltd., is the pioneer & trendsetter in welding in India. The company has been spearheading technological innovations in the field for the past six decades. All the major welded structures of modern India stand testimony to the quality and reliability of its innovative processes, products and systems. Chiseling out over 9000 welding equipment, standard and customized, and over 35,000 MT of welding consumables annually for all welding processes, Ador caters to the requirements of metal joining solutions in every segment of the industry. The company is also in the vanguard of welding education and skill development in the field. It has the distinction of having churned out over 1,00,000 welding professionals in the past 40 years. Mr. P.K. Balasubbramaniian speaks to Mr. Satish Bhat, Managing Director, Ador Welding Ltd., to get a ringside view of the latest developments in the welding field and Ador’s initiatives to provide contemporary and enduring solutions to the fabricating industry. Excerpts: 32
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Q. What’s exciting in the welding world today? The Welding Industry is moving towards more and more automation to ensure quality and repeatability as well as flexibility in set-up changes. The target is to achieve higher productivity, enhanced quality at PPM level, de-skilling of welders as well as reduction of manual intervention and re-work. Several new advanced single-process and hybrid welding processes have come in vogue, including Keyhole Plasma, Keyhole TIG, Hot wire TIG, HNG MIG and HNG SAW, Electro-Slag welding with various new concepts, Laser & Laser-MIG Hybrid welding, Cold Metal Transfer, Synergic TIG, etc.
Q. As a leader, what’s Ador’s contribution to enhance the quality and ease of welding? Quality of welding is determined by the use of process, quality of consumables, power source, automation and skilled
IN FOCUS www.mtwmag.com
manpower. Ador is committed to offer complete solution for improving the quality and ease of welding. We can proudly say that we are the only Indian company which invests heavily in R&D (recognized by DSIR, GOI) for improving offerings of existing consumables, equipment and automation solutions and develop new technologies for enhancing value offered by our customers. We have about 50 research chemists & engineers in R&D. Our R&D facilities (separate for Consumables & Equipment) are state-of-the-art and comparable to any facility with leading global player. Our quality systems are of global standard to deliver quality products to the customers. Ador welding Academy provides solutions on establishing welding processes and enhancement of welder’s skills to improve quality of weld. We have offered solutions to the strategic customers in indigenizing the consumables and establishing new welding processes with local consumables and still get the desired welding specifications. Our automation solutions are used by key customers in infrastructure projects such as Railway
bridges (also one in J&K) for improving productivity and quality. Customers expect Ador to deliver / offer solutions to their problems. This is always a proud feeling to us.
Q. Automation is the key to productivity. How do you lend yourselves to enhance productivity both on the shop floor as well as at site? Automation is the key to the success of massive infrastructure development plans of GOI. Due to less availability of skills, automation is going to play a pivotal role in the future. We at Ador have hence decided to focus on offering automation solutions and created the business as one of our SBU’s. We have created organization for supporting the business in Welding Automation Products and Systems (WAPS) for designing, manufacturing, marketing and providing after-sales support to deliver customized solutions in shortest time possible. The SBU is headed by a senior manager who is responsible for growth of the business.
Our WAPS Division has provided several customized Automation Solutions to different types of Industries on a pan-India basis as well as to customers in the Gulf countries. A few examples are: • Square Axles Welding System • System for Longitudinal Welding of Girders • System for Internal Longitudinal Welding of Pipes that are 12m long & 350 mm in diameter • Manipulator for Welding of Assembled Railway Bogie • L- Seam Welding System with FCAW • Automated TIG Welding set-up with cold wire feeding for pipe - to - flange welding • Dedicated MIG Welding set-up for LPG Cylinder manufacturing
Q. What are your offerings for cryogenic welding? Consumables are available for all welding processes – In SMAW / TIG / MIG – solid wire + FCW / SAW. The most important criterion for service at cryogenic temperatures is normally toughness, and it is important that
Ador’s sprawling consumables manufacturing plant in Silvassa
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IN FOCUS the weld metals used are capable of achieving good toughness. Large land based storage tanks are normally fabricated from 9% nickel steel with pipe work for distribution, etc. It is often made from austenitic stainless steel. The 9% nickel steels and 304 / 316 austenitic stainless steel consumables are tested down to -196°C. For applications down to -269°C, 304/316 austenitic stainless steel (welded with fully austenitic stainless steel consumables) or aluminum are used.We have also supplied total welding systems to the manufacturers of cryogenic vessels like Cryolar, Chennai and BPCL, Nasik.
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Q. What are the product innovations in the recent past that caught the eye of the end user? Some of the advanced process innovations inbuilt in the welding products in recent days are : • Improved Accu-Pulse technique providing fewer spatters, better arc control and less heat input – very forgiving to changes in stick-out. • RMD – designed for thin materials and gap filling with very low spatter. • Versa-Pulse is a fast, low-heat, low-spatter process resulting in faster travel speeds and increased productivity for semi-automated and
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automated welding. Typically used on thin materials up to 1/4 inch, great for gap filling on sheet metal and tube applications. Weld cells – equipped with customized multi-axis robots , and equipment adaptable to a variety of Weld Cell Configurations Flexible user interface location (power source, feeder, remote operator interface) Welding Intelligence software, for equipment ‘with a power to think and adapt’ Auto-Line™ Power Management Technology allows for any input voltage hookup (230–575 V) with no manual linking. It also eliminates weld defects caused by unstable or unreliable power. Welding of 9% Ni steels using Ni-CrFe alloys for storing & transporting LNG.
Q. What’s the head count of consumables and equipment you manufacture? Any new products in the anvil? We make 9000 plus Welding and Plasma Equipment per annum and about 35,000 M.T of welding consumables for all welding processes. New Products in the anvil are advanced PULSED MIG
Ador’s equipment plant in Chinchwad, Pune
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Equipment with Synergic Pulsing and Double-pulse welding features, Multi– station Data Acquisition and control system, Adaptive Control for Root Welding in pipes, etc.
Q. You are known for your customized welding solutions. Could you recount one recent development work done for a critical application? As explained earlier, customers expect Ador to provide solutions to their problems. They have faith in Ador and we are proud of it. Some of the customized solutions provided are: 1. High speed fillet welding of heat exchanger panels, in boiler manufacturing of power sector, using Flux-Cored Wire instead of solid wire using submerged arc welding. 2. Critical stainless steel cladding onto C-Mn steel using SAW process to meet very critical corrosion requirements.
Q. Could you enlighten us on your wherewithal, capabilities, talent and knowledge base? Ador is truly an Indian MNC. We have four manufacturing plants. We manufacture almost all welding consumables and equipment required by customers. We have modern manufacturing facilities which are unmatched by any Indian manufacturer. Our labs and quality systems are world-class to ensure delivery of quality products. We are approved by most of the critical / stringent authorities including PDO, QP, KOC, KNPC, etc. and world renowned approving agencies. This proves that we have world-class quality systems. Our R&D facility and talent are again world-class. That is the reason why we are able to develop and manufacture products to meet stringent requirements. We do not import and supply products as done by most of the welding companies in India. Over the last six decades, Ador has
IN FOCUS developed a vast knowledge base on the art and science of welding. Our HR practices include Organisation Development and Talent Management. We encourage young and fresh talent to make career in welding and offer them exciting opportunities and freedom to experiment. This has enabled us nurture new talent under the guidance of seasoned adorians.
Q. What is your contribution to welding education, especially when there is a dearth of qualified welding personnel in the country? For over six decades, we have trained over a lakh welders / supervisors / engineers in welding. Hence it will not be an exaggeration if we claim that there are no sectors / segments of industry in our country where people trained by us have not contributed. We were the pioneers in welding training and we started it when the knowledge of welding was in the infancy. Even today, when welding is an advanced technology, we have an Academy which imparts training in all welding processes and for all levels. We also certify the persons who have been
trained by us. We continue to be the leading and trusted welding training Institute.
Q. What makes you to deserve the sobriquet, ‘Welders to the Nation’? We made commercial availability of arc welding electrodes in India as early as in 1951. Every project that helped India to grow had our footprint – Hydro electric, Fertilizer, Railways, Nuclear power plants, Oil & Gas Refineries, Automobiles, Mining, Shipbuilding, Steel plants and Infrastructure included. We popularized MIG / MAG and submerged arc welding (SAW) processes by introducing the welding consumables and equipment for these processes and helped in improving the productivity of the end-users. Starting from Bhakra Nangal hydro electric power plant and dam, Neyveli Lignite thermal power plant, Trombay nuclear power plant, Integral Coach Factory of Railways at Chennai, Hindustan Shipyard at Vizag to the present day Reliance Oil refinery at Jamnagar, Suzlon wind towers, and all those projects that shaped industrial India stand as eloquent testimonies to our significant contribution.
Q. What are the challenges ahead for you? Meeting the new technical requirements of welding consumables for a) super critical power plants b) high tensile steels used in submarines; & Meeting the higher productivity requirements of automobile, shipping & Infrastructure industries are some of the challenges for us.
Q. What are the positive vibes in the industrial climate/economic horizon and what are the prospects of the welding business? The GOI, under the dynamic leadership of our PM, Shri. Narendra Modi, is creating a conducive atmosphere for the manufacturing sector. GOI has launched the ‘Make in India’ campaign which has started showing some improvements especially in the Railways and Defense sectors. We have started receiving some good enquiries from the major manufacturers representing these two industries. With GDP growth expected to be at 7.5% and likely to go up in the next FY, we envisage huge investments in other sectors such as oil & gas, shipbuilding, power plants, etc. and hence we can expect good demand for our welding products and automation systems. We have also started getting indications of finalization of new projects and issuing of LOI by public sector companies from O&G and Steel sectors. In general if we see the GST and Land bill through in the Budget session, we can expect substantial investments which will culminate in good business opportunities for us in the years to come.
Q. What’s your vision for Ador?
Ador’s consumables plant in Raipur. The company makes a comprehensive range of welding consumables
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Ador’s Vision is “To become the ‘best-in-class’ enterprise with a turnover of Rs.600 Crores by FY 2017-18 by providing Complete Welding Solutions to the World of Manufacturing for enhancing their operational efficiency and productivity”.
Taming power quality is now child's play
When you use DigiVolt Stabilizers, Tranquil Ultra Isolation Transformers and Powercon Power Conditioners from Unity Controls, power quality is under total control and would no more hamper your production and product quality. These silent sentinels protect your sophisticated, high precision production equipment from the ill-effects of voltage, spikes, surges, transients, sags, noise and harmonics affecting AC power lines. Thus ensuring continuous uptime and enhanced productivity and consistent quality.
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EVENT GLIMPSES
MTW Magazine Participation @ MACHAUTO EXPO 2016, Ludhiana, Punjab 11th-15th February, 2016
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EVENT GLIMPSES www.mtwmag.com
MARCH 2016
MACHINE TOOLS WORLD
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INDUSTRY FOCUS
World Gasket & Seal Market: Report & forecasts
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his report presents historical demand data (2004, 2009 and 2014) plus forecasts (2019 and 2024) by market, application and product for six world regions and 15 major countries. Total demand is given for an additional 10 countries. The study also considers key market environment factors, evaluates company market share, and profiles 32 global industry players.
Worldwide demand to rise 5.3% yearly through 2019 The world market for gaskets and seals is forecast to expand 5.3 percent per annum to $70.8 billion in 2019. Demand in many parts of the world will return to a more moderate pace of growth after recovering from 2009 recessionary lows through 2014. Healthy increases in motor vehicle production, machinery output, and electrical and electronic equipment production will bolster demand for gaskets and seals. In addition, growing fixed investment levels will lead to purchases of gasket and seal-containing vehicles and equipment. Furthermore, expanding demand for more expensive sealing products made from advanced
materials will boost market value. However, greater utilization of better performing, longer lasting gaskets and seals will have a mixed effect on demand as initial value gains will be somewhat offset by decreased aftermarket sales opportunities.
Africa/Mideast, Asia/Pacific regions to grow fastest The Africa/Mideast and Asia/Pacific regions will record the strongest growth in percentage terms through 2019. The Asia/Pacific region will be led by some of the fastest growing national markets in the world, such as India, Thailand, China, Indonesia, and Malaysia, all of which are expected to post motor vehicle production increases well above the global average through 2019. China surpassed the US to become the world’s largest gasket and seal market in 2009, and by 2019 China is expected to represent over one-fourth of the world market. Gains in the Africa/ Mideast region, on the other hand, will be bolstered by relatively small, fast growing markets in countries that are attempting to diversify away from resource extraction toward higher value manufactured goods.
More mature markets to also post demand increases The more mature manufacturing economies of North America and Western Europe are also forecast to post gasket and seal demand increases through 2019, although growth will not be as strong as that expected in less developed regions. Gains in North America will be bolstered by strong growth in Mexico, where suppliers will benefit from healthy output growth in motor vehicle manufacturing. However, the US will continue to account for the majority of North American demand for the foreseeable future. Gasket and seal shipment growth will outpace demand in Western Europe through 2019. This region is home to several of the world’s leading producers, and many of the countries in the region maintain sizable trade surpluses.
Electrical/electronic market to grow fastest Every major market for gaskets and seals is expected to register healthy gains through 2019. Motor vehicle applications will continue to account for the largest share of product demand, bolstered by 3.9 percent yearly increases forecast in global automotive production. Increased fixed investment spending will stimulate growing machinery output, which will in turn lead to advances in associated sealing product sales. Electrical and electronic equipment production is forecast to rise 5.2 percent per year through 2019, which will benefit sealing product demand in this market. However, sales in this market will be held back to some degree by intense price competition as the gaskets and seals utilized here are largely low value, commodity products.
For more information, Website: www.reportlinker.com
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MGM-Pubblicità(210x297)_Layout 1 08/04/13 10.33 Pagina 1
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• RS-RT worm gearboxes: 28 to 150 mm centres. One stage worm, helical/worm and double worm. • RD helical gearboxes: 50 to 2300 Nm. Two and three stages. • RN parallel shaft gearboxes: 180 to 3300 Nm. Two and three stages. • RO-RV bevel/helical gearboxes: 180 to 3300 Nm. Three stages. • RG precision planetary gearboxes: 10 to 230 Nm. One and two stages. • VR dry friction speed variators: IEC63 to IEC90 1 to 5 stepless speed range, 300 to 1500 rpm. • VS planetary speed variators: IEC71 to IEC112 1 to 5 stepless speed range, 200 to 1000 rpm.
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TECH UPDATE
Ceramic Coatings from Spraymet for Refurbishing Machine Tool Parts
Waste into wealth: Spraymet harnesses the best of surfacing technologies to reclaim machinery components and parts and conserve resources
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achine Tool Industry has undergone major developments in providing enhanced service life to spindles, arbors, bearings, etc. Ceramic Coatings by Plasma Spray have been in use in many industries since 1960. Since last decade, this process and ceramic coatings are being used to provide surfaces to seal areas of spindles, contact faces of arbors and electrical and heat insulation to bearings. Apart from OEM level coatings, many user industries are using ceramic coating for refurbishing of spindles and other machine tool parts.
Typical Spray Materials used with Plasma Spray
Metals and its alloys: Steels, Ni alloys, Co alloys, Moy, bronze, copper, Babbit, etc. Ceramics: Chromium Oxide, Aluminium Oxide, Al Oxide + TiO2, ZrO2, etc. Carbides: Tungsten carbide, Cromium carbide, TiC
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Hardness range of coatings: From SOFT 60Rb (Bronze) to HARD 70 Rc (ungsten carbide) Benefits of Plasma Sprayed Ceramic over Hard Chrome
Environmental: Less hazardous as there is no Hexavalent chrome involved dust disposal; easier than bath liquid. Performance: 3-4 Times more wear resistant than Hard-chrome; Micro porosity holds lubrication; Selective area coating is possible; Higher thickness up to 300 microns per side is possible. Limitations: Ceramics are brittle and are to be handled carefully. The process is not as widely available as hard-chrome. Spraymet Surface Technologies
Bangalore-based Spraymet Surface Technologies Pvt. Ltd., headed by Mr. P.T. Bindagi, Technical Director and a veteran metallurgist, is engaged in thermal spray, ENP plating and weld surfacing. While their main plant is in Bangalore, the second plant is located in Pune, to stay closer to its customers
especially from the automobile sector which is demanding technical excellence, proximity and service all at the same time. Spraymet has the distinction of having pioneered the carbide coatings in the steel mills and galvanizing line roll coating. Spraymet owns a few proprietary coatings like Moly bend (Spraymet MoB) for metal-to-metal wear, and Ductile matrix carbide (Spraymet DMC) for plastic process feed screws. Mr. Bindagi is working towards expanding applications in turbine industry, medical implants, and other frontiers. In his quest to spread knowledge, Mr. Bindagi also picks students from universities for project work related to tribology and wear metallurgy. Spraymet has helped the industry save a lot of money and helped conserve its scarce resources. – P.K. Balasubbramaniian
TECH UPDATE
Magnetic Encoders Contribute to Reliable Wafer Transfer Robots
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wafer ultimately becomes multiple IC-units in a series of complicated processes, where wafers rely on a wafer transfer robot to perform fast and accurate transfers between process stations. Wafers are valuable and break easily, meaning that stability and reliability are critical for the robot’s effectiveness. A Korea-based robot manufacturer Robot and Design (RND) uses a RLS LM10 series incremental magnetic encoder system to optimize the performance of its wafer transfer robots. RLS is a Slovenian associate company of Renishaw. Working principle of wafer transfer robots
After silicon, a commonly used material for semiconductors, passes through a number of upstream processes, such as
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cutting lithography and etching exposure deposition, it becomes a disc-shaped wafer with a ‘printed circuit’ on the surface. The wafer then passes through a number of downstream processes including bonding, wiring, packaging and testing, to finally become multiple units of powerful miniature ICs. In fact, modern technology is capable of manufacturing wafers with thicknesses down to the nanometre level. However, such thinness of wafers easily causes
damage during the transfers and also necessitates the wafer surface to be dirtfree throughout the whole process. Most manufacturers are now using robots instead of humans for wafer transfer, one of the important operations in semiconductor manufacturing. RND’s general manager Mr. HyunGug Jung says, “Most wafer transfer robots are used in upstream processes. Robots typically feature multiple axes, responsible for transferring wafers to containers at each process station, and involving a large amount of linear and rotary motion controls.” He continues, “There are a variety of wafer transfer robot designs in the market to satisfy the needs in the field, such as Vacuum, SCARA, WET and Cartesian coordinate. To take our Cartesian coordinate robot as an example; it adopts
TECH UPDATE www.mtwmag.com
a dual arm design which makes it possible to handle two wafers at the same time. The entire robot body is fitted on a carriage, travelling linearly between wafer containers at high speed. The robot features five axes, including: R1 / R2 axis, responsible for controlling the arms to load and unload the wafers to containers; Z axis – driven by a ball screw system and controlling the robot’s vertical movement; T axis – controlling the robot’s rotation, and X-axis – controlling the robot’s linear movement between containers. The R, Z and T axes are all equipped with Japanese servo motors with built-in absolute encoders, while the X-axis is equipped with a LM10 series linear magnetic encoder with a travel range of 1.5 m.” The importance of a feedback system
RND’s wafer transfer robot operates at velocities up to 1.8 m/s. It relies heavily on a highly responsive, reliable and stable position feedback system. Any small position errors can cause wafers to crash, resulting in a very costly economic loss. Mr. Jung explains, “Generally speaking, compared to other semiconductor equipment, the accuracy requirement for the encoder on a wafer transfer robot is relatively low. The accuracy is important, but stability is our top priority. To imagine the robot moving back and
forth continuously at high velocities every day, making sure the operation will be stable is one of our challenges during the development. When researching the market for encoders as one of the robot’s core components, repeatability is always a primary concern. LM10 series magnetic encoder offers repeatability up to the unit of resolution. Its performance has been very stable over the years, so we will definitely keep using it now and in the future.” The LM10 series is a magnetic encoder designed for high speed applications in harsh environments. It offers resolutions down to 0.244 µm and maximum speed of 7m/s at 1 µm resolution, with a sealing rating of IP68. Inheriting the ergonomic design of RLS’ encoder family, LM10’s readhead features a setup LED and wide installation tolerances to remove the need for complex setup equipment and provide a truly simple and efficient installation. Moreover, LM10 utilises an adhesivebacked magnetic scale equipped with bi-directional reference. The maximum scale length is up to 100 m, allowing a ride height of 1 mm.
industry with a fast pace of technology updates. All production equipment must have the ability and flexibility to cope with the updates and satisfy the market needs. We therefore always take account of suppliers’ reputation, as well as their potential for long term development. RLS aims to develop innovative products and is keen to provide custom solutions to customers sharing the same goals. Furthermore, compared to other brands, LM series offers a higher price-toperformance ratio and excellent after-sales service which enables us to use it without any worries.” RND is a well-known Korean robot manufacturer, offering a wide range of robots for a variety of industries, including semiconductors, photovoltaic panels, LED, biotechnology and other high-end industries. It is the largest wafer transfer robot manufacturer in Korea, annually shipping more than 500 units and supplying high-quality wafer transfer solutions to many well-known companies such as Samsung and SK Hynix. Many new projects are currently being developed at RND, including a high-speed wafer transfer robot.
Reputation / high price-to-performance ratio / excellent after-sales service
Reputation was one of the main reasons RND chose Renishaw as a business partner. Mr Jung says, ”There are a lot of manufacturers supplying competitive encoder products in the market. We chose RLS because we trust their product quality. Semiconductors is a high-tech
For more information, Website: www.renishaw.com
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TECH UPDATE
Efficient storage in the smallest possible space
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he system is available in three different designs: as UNITOWER for the storage of bar materials, UNITOWER B for sheet metal, flat products and containers, and as a compact universal store UNITOWER C for bars and sheets. The tower storage systems are designed as modular systems with individual modules. As a result, individual solutions can also be implemented with ease. UNITOWER is available as a single or double tower, optionally freestanding in a workshop or as a separate storage building outside with ceiling and wall elements. Any number of input and output stations can be positioned at the front or on the long side of the storage tower and at different levels, depending on the customer’s requirements. Cassettes, pallets or supporting frames are used as the load carriers. Depending on the design, each storage space can carry loads of up to five tonnes. The towers effortlessly accept bar stock from 3,400 to 14,600 mm in length, thus giving users recourse to different standard lengths as well as workpiece or production-optimised special lengths.
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The basic version of the UNITOWER has a usable width between 600 and 1,240 mm. This enables the storage system to be ideally matched to the available space. The UNITOWER B model for storing sheet metal and flat products enables lengths between 2,000 and 8,000 mm to be stored. The usable width is between 1,000 and 2,000 mm. The loading height and therefore the number of storage spaces can be determined at will, thus also enabling pallets, boxes or containers to be accommodated. System heights up to 25 m can be easily achieved with the UNITOWER and UNITOWER B designs. With their variable loading height, tower storage systems provide a flexible solution which saves significantly more space and is therefore more economical compared with conventional floor and cantilever arm storage systems. The KASTO range also includes a cost-effective, standardised compact storage system for different bar and sheet formats in the form of the UNITOWER C. With a maximum height of 7,200 mm and flexible compartment distribution, it is ideal for small businesses, workshops, maintenance shops and as a buffer store between production areas. Two versions are available: as a storage system for flat goods with a usable width and length of 1,524 x 3,048 mm and loads between one and three tonnes, or as a storage system for bar stock accommodating cassettes with dimensions 840 x 6,500 mm and loads between 0.8 and 2.5 tonnes. Along with the low space requirement, UNITOWER storage systems are distinguished by their high efficiency. A storage and retrieval machine (SRM) with spreader beam handles the load carriers. Compared with paternoster systems, for example, this has the advantage that it is not necessary to move the entire stock, but only the relevant cassette. This
ensures rapid access times and – thanks to efficient drives – saves energy. Input and output stations can also be connected to other conveyor equipment or processing machines to optimise the internal material flow. Depending on the model, the tower storage system is controlled by KASTO’s own semi-automatic or fully automatic EasyControl and BasicControl controllers. These can be operated easily and intuitively by means of a graphical interface. The user can call up and control various functions such as storage compartment and cassette management, order expediting and system diagnostics using the touch screen. High availability is ensured by KASTO’s sophisticated service concept. This not only includes roundthe-clock telephone advice, a rapid supply of spare parts and competent on-site support, but also remote monitoring via the Internet. This enables KASTO experts to find and rectify faults at an early stage before they lead to costly system failures.
For more information, Websie: www.kasto.com
TECH UPDATE
Manufacturing Accuracy Regardless of Circumstances Closed loop position measurement provides high accuracy in any situation with small series By Abhilash Tripathi, GM(Sales & Service) Heidenhain Optics & Electronics India Pvt. Ltd.
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ccuracy often suffers in small series production with constantly changing tasks and processing procedures. In many cases the reason for this are the permanently fluctuating and unforeseeable temperature changes in the machines and drives, which lead to the thermal expansion of the ball screw drives. Closed loop position measurement with HEIDENHAIN linear encoders eliminates these fluctuations in the drive train. It determines the exact position of the machine table at all times. This results in consistently accurate workpieces and strict adherence to tolerances. Flexible small series continue to demand a lot of even the most upto-date enterprises if they are to run economically and accurately. The organization and logistics, in particular, devour time and personnel. After all, the preparations as well as the production and further processing steps all have to be synchronized with the greatest of accuracy. If the actual machining is much faster than the setting up of the machines and plant, then delays have serious consequences. The calculation is torpedoed just as much as the time-consuming and intricate planning of subsequent machine occupation. No wonder that with all this organization and fine-toothed planning, the topic of accuracy is prominent in flexible small series production. In fact, modern machines usually do have an acceptable intrinsic accuracy. However, the devil is often in the details and in
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Unaffected by the temperature development on the ball screw drive: Closed loop position measurement with a linear encoder
this case he is thermal expansion due to internal heat sources in the machine and therefore from the machining itself. Thermal expansion has surprising effects
We all know that materials expand when heated. In the case of the linear axes it is mainly the ball screw drive
which is affected. Due to the initial stress and associated friction between the ball screw and the nut, it heats up each time the machine table traverses during machining. The so-called fixed/ floating bearings of the ball screw drive allow for the associated expansion so as to prevent damage to the bearing. The expansion for a steel ball screw
Ball screw drive in action: The ball screw reaches temperatures of up to 45 °C.
TECH UPDATE www.mtwmag.com
Clearly visible after the second machining: The deviation of 70 µm due to the thermal expansion of the ball screw drive
Invisible second drilling with closed loop control: A twice machined part with no corners and edges
drive can be easily calculated taking the thermal expansion coefficient of steel of 10 µm per meter length and degree of temperature difference. In the case of a ball screw drive 1 m long, a rise in temperature of 1 °C causes a deviation of 10 µm. Since temperatures of 45 °C are quite common on the ball screw drive—an increase in temperature of 25 °C above the ideal temperature of 20 °C—it is easy to imagine the actual dimensions of the deviation.
continuously during machining. After the 25th part the heat increase had reached the critical point when the thermal expansion of the ball screw drive causes the tolerance of ±0.02 mm to be exceeded. The deviation on the last part was even70 µm. You can clearly demonstrate this deviation with a simple trick: After machining of the 40th part, the first part is put back on the machine and the feed setting in Z direction is halved. The second holes made in this way in the finished part leave a clearly visible edge in the existing holes, likewise the second milling operation on the contour. This is the result of the 70 µm deviation due the thermal expansion of the ball screw drive.
Scrap due to overheating
On Monday morning the machine is at its ideal temperature of 20 °C after a weekend of standing idle. Now setup and preparation begin for a small series production run of 40 parts. It involves machining of average difficulty without any particularly high traversing speeds for the machine table. The maximum feed is 3.5 m/min. Two holes 350 mm apart are to be drilled in the parts and the contour milled. The machining takes five and a half minutes, the tolerance for the distance between the holes is ±0.02 mm. The subsequent quality control shows that of the 40 parts to be produced only the first 25 are within the specified tolerance. About 40 percent of the production is scrap—what a catastrophic result! What happened? The ball screw drive heated up
again to 20 °C during the switchover or is there still residual heat in the ball screw drive? Nobody knows, and with every subsequent small series production the conditions will become increasingly inestimable. There is no way that you can derive values for future machining runs. The same machining run could produce more or less rejects the next time round depending on the initial temperature of the ball screw drive at the start of machining and how the temperature develops. Everything under control with precise position measurement
Constant switching makes expansion unpredictable
However, the problem in small series production is not the linear expansion, which is easy enough to calculate. The problem is caused by the permanently changing requirements and conditions, which makes the temperature development unpredictable. For the first small series production on Monday morning is followed in the afternoon by a quick change of settings for the next machining run. But what are the temperature conditions in the machine now? Has everything cooled down
On the other hand, position measurement with a linear encoder is independent of the thermal expansion of the ball screw drive—and any other influences. This so-called closed loop control always determines the precise position of the machine table. The result is stable production with a constantly high level of workpiece quality. A comparative machining run demonstrates the example described above. There is no scrap from a machine with closed loop control; all the parts are within the specified tolerance. A second machining run with the first part after machining of the 40th part with half the feed setting in Z direction leaves no visible edge. In particular for companies who specialize in small series productions, the implementation of a machine with closed loop position measurement with a linear encoder is a profitable investment.
For more information, Website: www.heidenhain.in
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TECH UPDATE
An Old Invention Making New Impressions
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ccording to the International Stainless Steel Forum (ISSF) the global demand for stainless steel products has nearly doubled in the last 20 years, and continues to grow five per cent each year. In 2014, almost 42 million metric tons of stainless steel was produced worldwide - a 70 per cent increase from 2005 (24 million metric tons). This growth is predominantly achieved by an increase in China, where production has grown from a 13 per cent share of global output in 2005 to more than 52 per cent in 2014. This rapid development is not only to meet worldwide demand, but also to support increased use within China, where stainless steel is consumed in household metal products, building materials and machinery. Stainless steels’ anti-corrosive qualities make it perfect for use in a huge range of environments and components, such as aerospace, general engineering, consumer, oil and gas, medical and marine industries. Its versatility is reflected by the fact that there are more than 150 different grades. Common stainless steels include ferritic, martensitic, austenitic, super-austenitic
and duplex. More details of which are covered below. The main alloying element is Chromium, which forms an ultra-thin oxide film on the surface. As a general rule, resistance to corrosion and oxidation increases in line with Chromium content. Other alloying elements, such as Nickel and Molybdenum, can be added to change the structure, increase corrosion resistance and improve strength. This increase in production and consumption has coincided with advancements and new developments within the cutting tool industry. Due to the difficult process of machining stainless steel, manufacturers have invested a huge amount of time and resources in finding new ways to try to combat the numerous application challenges. Recent introductions include changes to the cutting tool design, new geometries, improved coolant and developing stronger coatings to improve performance and tool life. Drills with thin margins for example, reduces the contact with the hole surface, minimising friction between the cylindrical land and the hole walls, decreasing work hardening and
Pramet OEHT octagonal inserts for milling stainless steel.
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temperatures generated. Positive point geometries ensure excellent chip breaking and evacuation, while a specially designed web combines the benefits of maximum rigidity with space for efficient chip removal, reducing machine downtime. Coatings and coolant
Significant heat is generated during machining of stainless steel, resulting in plastic deformation and severe crater wear. Therefore, a generous flow of cutting fluid removes heat from the cutting edge, helps chip breaking and improves dimensional stability of the component. When using flood coolant, it is important to ensure a plentiful supply as any period of coolant starvation can cause temperature fluctuations. This can cause thermal cracking, resulting in reduced tool life. Cutting tools with through coolant also provide an instant reduction in temperature and supports chip evacuation. Meanwhile, a Titanium Aluminium Nitride (TiAlN) coating is ideally suited for machining stainless steel as it holds its hardness at higher temperatures due to a layer of aluminium oxide, helping to
The Pramet OEHT face milling range is ideal for machining stainless steel
TECH UPDATE www.mtwmag.com
transfer the heat away from the cutting tool. The high strength of stainless steels combined with their high ductility makes chip breaking more difficult. This increases the risk of vibration, which can affect surface finish quality and reduce the service life of the tool or insert. To address this, always make sure tooling and work pieces are stable and well clamped. Always keep tool overhang to a minimum, especially when drilling or internal turning. To help reduce vibration, use sharp tools or inserts with a small nose or corner radius. Ferritic & Martensitic
The machinability of ferritic and martensitic stainless steels shows a resemblance to that of ISO P: Steel. Normal chromium content is 12-18 per cent, with only small additions of other alloying elements. Ferritic materials are used in shafts for pumps, steam and water turbines, nuts, bolts, hot water heaters, and in the pulp and food processing industries. Martensitic steels can be hardened and are, as a result, used for edges in cutlery steel, razor blades and surgical instruments. Machinability of ferritic and matensitic stainless steels is good and very similar to low alloyed steels. Austenitic & Super-Austenitic
Austenitic stainless steels are the most commonly used ISO M material, accounting for 70 per cent of all stainless steel machined. This is due primarily to their very good resistance to corrosion. The most common composition is 18 per cent chromium and 8 per cent nickel. Steel with greater corrosion resistance is created by adding two to three per cent molybdenum, often called “acidproof steel” or type 316. Super-austenitic stainless steels have a nickel content of more than 20 per cent. Austenitic and super-austenitic stainless steels are used where good resistance against corrosion is required. Typical industry sectors include the chemical, pulp and food processing industries. It is also used in aircraft exhaust manifolds. Austenite stainless steel produces
Duplex
Ricky Payling, application specialist at Dormer Pramet
Stainless steel is a vitally important material for many industries around the world. Even though it was created more than 100 years ago, use of the material has increased significantly since the turn of the 21st century. Ricky Payling, application specialist at Dormer Pramet, outlines the growth of stainless steel, how the cutting tool industry has evolved to machine the material, as well as providing a summary of some of its most common grades. tough, long, continuous chips that are difficult to break. It is prone to work hardening during machining, producing hard surfaces and chips which lead to notch wear. It also creates adhesion and produces built-up edge, resulting in poor surface finish and reducing tool life. To minimize this, avoid using tools with worn edges which could accelerate tool wear and cause breakage. Make regular checks for signs of wear and change tools or inserts regularly. Also, try to avoid any dwells or pauses in the cutting process as this will cause heat build-up and increase work hardening. A high rake angle reduces heat generated during milling, minimising work hardening.
Adding nickel to a ferritic chromium based steel will form a mixed base structure containing both ferrite and austenite. This is known as a duplex stainless steel. Duplex materials have a high tensile strength and maintain very high corrosion resistance. Super-duplex and hyper-duplex indicate higher content of alloying elements and even higher corrosion resistance. Chromium content between 18-24 per cent and nickel content between 4-7 per cent are common in duplex steels, producing a ferritic share of 25-80 per cent. Duplex stainless steels are used in the chemical, food, construction, medical, cellulose and paper making industries, and in processes that include acids or chlorine. They are often used in equipment related to off-shore oil and gas applications. Machinability of Duplex is generally poor due to high yield point and high tensile strength. Higher content of ferrite – above 60 per cent - improves machinability. Dormer Pramet has developed a comprehensive assortment of indexable and rotary cutting tools to support machining of stainless steel. Its solid carbide drill for applications up to 8xD has been specifically developed to overcome problems typically associated with deep-hole drilling of stainless steel. Created within the Dormer product portfolio, the R459 broadens the existing MP-X range which already consists of 3xD and 5xD solid carbide multi-material drills. Meanwhile, a versatile range of OEHT octagonal inserts for cutting depths 4 – 10 mm, alongside REHT (round) and XEHT (wiper) inserts, is suitable for stainless steel. By utilising eight cutting edges – the highest number available for positive inserts – the new range provides an economical offer for customers, while the wiper insert option boosts feed rate capabilities and surface finish quality.
For more information Website: www.dormerpramet.com
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TECH UPDATE
Sterilizable Brushless DC Slotted Mini Motors Provide High Speed, High Torque for Surgical Power Hand Tools Portescap is excited to announce the launch of application specific motors for surgical powered hand tools - arthroscopic shavers, ENT microdebriders and large bone drills. Prototypes will be available to ship within 3 weeks of order placement.
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ased on 20 years of experience in surgical motor design, application specific motors are designed to precise performance requirements of surgical hand tools. Products are designed using Portescap’s standard autoclavable motor design and have the robustness to withstand sterilization. Portescap motor technology has demonstrated autoclavability up to 1000 cycles. Arthroscopic shaver brushless dc mini motor solutions have been designed to drive powered surgical hand tools used in minimally invasive joint surgery; surgical procedures that are responsible for repairing joints such as hip, knee, and shoulder joints. Noload speed of our arthroscopic shaver motors range from 4,000 to 7,000 RPM, while maximum continuous torque is 117 mNm and 119 mNm. What’s more, Portescap solutions maintain high torque without stall better than competing solutions. Portescap’s large bone drill brushless dc mini motor solutions
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offer a cannulated gearbox and motor combination to allow for in-line pin and k-wire driving and provide high torque at operating speed. These battery powered solutions excel at meeting extreme torque demands without stall during joint replacement surgeries such as those of the knee, hip, and shoulder. Our recommended large bone drill motor offers a no-load speed of 950 RPM with maximum continuous torque of 818 mNm. Ear, nose, and throat (ENT) brushless dc mini motor solutions provide the high speed and high torque required by powered surgical hand tools used in minimally invasive surgical procedures of the ear, nose, and throat as well as arthroscopic surgeries of small joints. With no-load speeds of 11,800 RPM and a maximum continuous torque of 39 mNm, these solutions are designed to perform precise cutting of tissue and clean burring of bone. For high-speed drilling in spine, cranial, maxillofacial, and otologic (ear) surgery, Portescap’s spine
drill motion solution will provide 90,500 RPM of no-load speed and 9.2mNm maximum continuous torque. Custom windings, bearings, and output shafts are available upon request. To learn more about our new solutions and how we can help you optimize your surgical application, please visit our website at www. portescap.com/asm to download specifications and literature, or contact your closest regional Portescap office to speak with an applications engineer.
For more information, Website: www.portescap.com
TECH UPDATE www.mtwmag.com
First Time In India Scientific Mechanical Shearing Machine
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e have made 1250x 1.63mm (16 gauge) M.S. cutting capacity Scientific mechanical shearing machine (innovative). We will product this innovative machine in all series (as per customer requirement length And thickness of metal sheet) offering with Affordable price & best quality. An ordinary mechanical shearing machine is working system with load wheels & clutch system and our innovative machine system has no load wheels so, machine life become more and maintenance comes low. This innovative mechanical shearing machine cuts metal sheet with normal presser stroke with the help power of gear drive’s force so the life of the machine become long & maintenance become very low. Comparison
An Ordinary mechanical shearing machine
Scientific mechanical shearing machine (innovative)
Power saving
Electric motor running continuous.
Electric motor does not run continuous.
Lubricating system
Oil filling system due to metal bushing.
Long lasting greasing system due to bearing system
Maintenance
Due to bushing and load wheel and clutch system maintenance come high
Due to bearing system & gear drive system, maintenance come low
Power loss
This machine works on pulley and v belt system so power loss is created.
This machine works on direct motor shaft to gear box shaft with couple set, so no power loss.
Affordable price
This machine’s cost with electrical & belt 1250x2mm cutting capacity approximately price Rs.1.70lacks + tax.
machine’s cost with electrical motor 1250x1.63mm cutting capacity. Rs.1.40 lacks + tax benefit of Rs.30,000
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TECH UPDATE
First SMD Antenna in the Market with LF & NFC Performance Integrated PREMO, worldwide technology leader in RFID automotive antennas, launches a new 3D-coil with double functionality in both Low Frequency (125 kHz) and High Frequency applications (13.56MHz). All in one package.
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n the last few years, Communication technology by Near Field Communications (NFC) has experienced a lot of improvements. New tablets, smart phones, etc, has been announced with this NFC functionality for E-Wallet application. Besides it, the high security level for data transmission that low frequency offers, makes think that the ideal solution should be one component in which both communication techniques are feasible. The new 2D1D15 Series, provides 2D orthogonal coils designed for working at low frequency (standard 125 kHz) and a third orthogonal coil with this low frequency 2D which works at high frequency (standard 13.56 MHz). This innovative and extremely compact antenna has a high surface resistance NiZn ferrite core material (>10Mohm/mm) and medium initial permeability to work at high and low frequency. This provide a very stable performance in a wide range of temperature (-40ºC to +85ºC). The 2D1D15 Series, has the same format as 3DC15 (125kHz) transponder family and they can be provide with same mechanical performance: label, cap and/or foam. The 2D1D15 Series is offered with 4.77 mH @125 kHz and 6 uH @13.56 MHz as standard inductance values. This antenna can be ordered with custom inductance parameters to fit the desired performance. Its Surface Mounting Device (SMD)
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configuration allows an easy integration in an automatic printed circuit board assembly process (lead-free reflow), avoiding handling of the piece that could damage winding wire of the piece. The 2D1D15 series meets the AEC-Q-200, one of the most restrictive quality standards for electric components in automotive applications. This implies a guarantee and security in the performance of the component in applications for both domestic and industrial environments. The inductance and “Q” factor of the NFC coil has been measured at 13.56MHz and are suitable for RFID applications with ISO15693 (vicinity: I-CODE) and ISO 14443 (proximity: MIFARE) interface.
of RFID automotive antennas and one of the main electronics components manufacturers worldwide. Our state-ofthe-art product portfolio includes NFC & RFID antennas, power transformers, inductors & chokes, current sensors, EMC filters, PLC components and accessories with special focus on the growing market of HV&HEV, Smart Metering, IoT, telecommunications, and industrial electronics. The company has over 53 years’ of design experience and is ISO TS certified.
PREMO
PREMO is an influential and global technology leader in the development
For more information, Website: www.grupopremo.com
TECH UPDATE
New Development: Compact Paint Circulation Pumps For The Automotive Industry
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he new high-tech pump generation from Timmer GmbH is especially compact and space-saving. Highlights are the innovative drive concept and the focus on high functional safety and durability of all components. The electrically-driven piston pumps also have a number of process-engineering
advantages. Particularly noteworthy are the low-pulsation and materialprotecting conveying, the high process safety along with the low energy consumption. The very simple handling is achieved via the intuitive TimPro software. The pumps have been successfully tested and approved in the automotive industry. The piston pumps round out the product range of the pump manufacturer in the paint supply sector for the automotive, painting and print industry.
For more information, Website: www.timmer.de
Paint circulation pump
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CASE STUDY
HAAS : Dürkopp Adler Case Study
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ased near Hannover is Haas Automation customer, Dürkopp Adler AG, well known manufacturer of industrial sewing machines. As well as its facility in Germany, the company has another two manufacturing plants: there’s one in Minerva, in the Czech Republic, and one in Romania. Under increasing competitive pressure from the Far East, Dürkopp Adler is undergoing a long-term restructuring and retooling programme, including standardizing most its CNC machine tools and machining operations.
Frank-Michael Kuhnt – Group Head of Production, Sales and Logistics:
We are competing with manufacturers
based in China and the Far East, but we want to keep as much of our production as possible in Germany. So, our aim is to ensure all manufacturing operations can be controlled and monitored closely from here, in Bielefeld. For example, one centralized server will share all programmes and CAD drawings, etc., and all machining and production data will be presented in real-time. The business in Minerva employs seventeen Haas CNC machines, supported by local Haas Factory Outlet, Teximp. The factory in Biefel, which also houses the company’s business and marketing teams, has four Haas CNC machine tools, supported by HFO ARO-tec. Currently there are only Haas vertical
Dürkopp Adler’s business in Minerva employs seventeen Haas CNC machines and the factory in Biefel has four Haas CNC machine tools
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Dürkopp Adler AG is a well-known Germany industrial sewing machine manufacturer, with facilities in Germany, the Czech Republic and Romania
CASE STUDY www.mtwmag.com
Frank-Michael Kuhnt – Group Head of Production, Sales and Logistics at Dürkopp Adler machining centres at this plant. We have a Haas EC-400, for when we need to use more tools – the machine has 72, and when we need to reduce set-up times for a part. We have a similar machine doing similar jobs at our Romania factory. Batch sizes can be anything from 10 – 1000 off. But, there are 15,000 different parts, most of which need 4-axes to machine, so we also use Haas CNC rotary tables. We group parts in families,
so it’s quick and easy to assign parts to machines. The standard table on our Haas VF-6 vertical machining centre is big enough that we can easily mount three fixtures. We use it mostly for small quantities of a part – it’s quick to set-up. Many of our Haas machines are considerably more than 10-years old. However, the older machines are still going strong and have served us very
The company have a very thorough strategy for the next 4 years to standardize machine types as much as possible – to focus on Haas
well. Of course, we get much better production with the newer Haas machines – probably 20-30% better, so our aim is to replace them all, eventually. We have a very thorough strategy for the next 4 years, taking the company to 2020. Part of the plan is to standardize machine types as much as possible – to focus on Haas. They’re such good value we easily earn back in time savings what we invest. We’re particularly interested in the latest Haas turning centres, as they can provide affordable Y-axis and live tooling. On all Haas machines, stability is excellent. This matters a lot for the parts we make, as they’re so small and tolerances are tight. Our intention is to machine all the critical steel parts here in Germany; probably 60-70,000 parts a year. However, where we used to employ 3000 people, locally, we now only have 250, so productivity is the issue. Investing in Haas means we can move away from complex, expensive machines, which are no longer costeffective. When we make healthy profits, we can continue to invest.
For more information, Website: www.HaasCNC.com
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CASE STUDY
FKM Sintertechnik orders LaserCUSING systems from Concept Laser FKM Sintertechnik GmbH based in Biedenkopf has been an important pioneer in selective laser sintering (SLS) in Germany and Europe since 1994. According to the company, it is one of the largest providers of additively manufactured products in Europe, yet its 3D metal printing capacity is still experiencing expansion with an eye toward the future. Beside the existing 3000 m2 production area, a new 700 m2 production hall is currently being built in Biedenkopf to meet the vigorously growing demand for additive products made of metal.FKM Sintertechnik GmbH is betting on machine solutions from Concept Laser for this facility and has ordered several machines in the medium and large build-chamber range.
FKM Sintertechnik bets on machine solutions from the Concept Laser Company
Harald Henkel, Managing Director of FKM Sintertechnik GmbH, commented: “The market is currently developing toward batch production of 3D metallic products. In addition to the classic small batches and prototypes, industrial production lot sizes with a distinctive serial character are appearing now as well. With the strategic expansion of our 3D printing capacity, we want to be able to respond to increasing demand in a very flexible way and also to get in on increasing product dimensions.”The FKM Sintertechnik machine park already features the Mlab cusing and M2 cusing models from Concept Laser, as well as models from other suppliers. They were accompanied by a new M2 cusing Multilaser last fall, and as Harald Henkel explains, there’s more to come: “We have ordered another M2 cusing Multilaser for 2016. Build rates and the suitability of Multilaser technology for
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batch production fit very nicely with our business strategy, and we also want to be involved with very large build chambers. A new X line 2000R from Concept Laser featuring the world’s largest build envelope for powder-bed-based laser melting with metals will be delivered to us here in Biedenkopf in Q1 2016.” Machine solutions from Concept
Laser impressed the decision makers at FKM Sintertechnik GmbH thanks to the systems’ high-quality and rugged design and the stringent safety standards applied in accordance with ATEX directives for the safe processing of reactive materials. In addition to their “external values,” the systems’ high performance and excellent surface quality are also impressive.
CASE STUDY www.mtwmag.com Investing in the medium build-chamber
Investing in the largest build-chamber
range – The M2 cusing Multilaser
range – The X line 2000R
The new M2 cusing Multilaser has been outfitted with a new and modern set of “clothes,” but the changes are more than skin deep. The machine also features a fully integrated design, which means that “satellite solutions” are no longer used for laser sources and filter technology. This closed solution is advantageous to the user thanks to the accessibility of system components and a reduced space requirement. This new machine design doesn’t just underscore further development of system technology externally, though. The new M2 cusing also features a new filter concept with a filter surface five times greater in size, having increased from a previous 4 m2 to 20 m2 now. The new filter module was designed with fixed piping and to be fully integrated into the system. As a result, the filter’s replacement intervals can be extended considerably, which increases overall system availability. This is especially noticeable when using Multilaser technology and from the resulting increase of smoke particles. This is why significantly faster build rates require safer filter replacement concepts. Every filter replacement has to be fast and easy. The new filter technology was developed with a primary focus on safety aspects. This is why the M2 cusing is outfitted with a water-floodable filter as standard, so as to ensure safe handling during filter replacement.
Coming in at 800 x 400 x 500 mm3 (L x W x H), the new X line 2000R from Concept Laser features the world’s largest build envelope currently available and boasts high build rates using Multilaser technology. The X line 2000R increases build volume in comparison to its predecessor model by nearly 27% from 126 L to 160 L and works with two 1,000-Watt lasers. This enables exposure of the build area from two positions simultaneously. The X line 2000R also has a rotating mechanism which allows two build modules to be used reciprocally, thus guaranteeing constant production with no downtimes. The sieving station is also new, whereby a quiet vibration sieve is used instead of a tumbler sieve. This makes for a more compact design, as the over-sized grain container is smaller and integrated into the sieving station. The new sieve module reduces the system’s footprint and is visually fully clad, which makes for a clean and tidy environment. The newly designed dosing unit enables full dose chamber filling within a single cycle.
For more information, Website: www.concept-laser.de
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CASE STUDY
Mounting box production directly from the sheet metal storage system Order based variant manufacturing of a modular mounting box series, batch size 1 – how Striebel & John GmbH & Co. KG safeguards the flexibility and high efficiency of its mounting box production with a high degree of automation and a KASTO sheet metal storage system
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rocessing about 9,500 tonnes of steel sheets a year in a range of qualities and with various surfaces (black, galvanised) as coils or plates for power distribution systems – a complicated task for the ABB Group company Striebel & John GmbH & Co. KG based in Sasbach, Baden-Württemberg. Founded in 1958 by Franz Striebel, this company has evolved into a specialist in the development and production of mounting box and power distribution systems, in which the ABB Group participated in 1993 with 51 % and employs today a workforce of about 450. Above all, the ABB management were highly impressed by the high innovativeness of Striebel & John that had found and still finds testimony in its great many pioneering products and system developments. It goes without saying that Striebel & John sees itself today as a leading manufacturer and supplier of power distribution systems for the electrical trade and switchgear production. Divided into consumer units; compact distribution boards; and wall mounting, meter, floor standing, and switchgear cabinets, the product portfolio covers every conceivable application in both commercial and industrial environments. The electrical system planners and designers receive sound support in the
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form of services like, for instance, the software package StriePlan, and the fitters and system builders benefit from the fast availability of the mounting boxes, cabinets, and accessories for the internal configurations. In turn, the fast availability and the renowned high quality of Streibel & John products are due to a very high level of inhouse production, an output that can be regulated with the corresponding flexibility, and – of course – the appropriate machinery and indispensable expertise. The objective: consistent automation from sheet metal storage system to final mounting box production
Roland Schnurr, Head of Production at
Striebel & John, expresses the production philosophy as follows: “At our sheet metal parts production and assembly lines, we have to manage four series, namely compact distribution boards, meter and other cabinets, and the TwinLine and TriLine series. Our customers in the electrical systems wholesale and switchgear production sectors no longer manage storage systems, so we are forced to provide a highly flexible job controlled manufacturing of batch sizes from single batch. This is economically viable only with a certain, very high, yet practical degree of automation. For this reason, automation extends to a great many of the processes in the preproduction of parts, like punching, bending, and shap-
CASE STUDY www.mtwmag.com
ing, and in the final production involving welding and bonding. In addition, we also apply powder coatings in the standard colours on site, whereas special colours are handled by external providers. In addition to the product variants in size, width and depth as well as technical function, also the type of interior design distinguishes in different regions, from which the customers are also the kind of interior finishes, so that the assembly is primarily manual work. “ When a modular system now needed new products, the following specifications were formulated for their production: Delivery time 48 h, batch size 1 in sheet metal parts production and assembly welding, inline setups, continuous component provision, production stock from ongoing orders for no-break final production through welding, access to all preproduced
and order relevant components. The last of these are standardised rear panels in a range of sizes that are welded to other components to form complete mounting boxes or cabinets in final production. This takes place in a robot system that consists essentially of welding and spot-welding robots with glue application, two changeover table served by a gantry robot system and an automatic sheet metal storage system of the type UNITOWER B 3.0 from KASTO Maschinenbau GmbH & Co. KG of D-77855 Achern-Gamshurst. Reality: Batch size 1 in the many variants of mounting box production
The task of the automatic inline storage
system is to supply the welding cell with the various rear panels mentioned above. It therefore functions as a buffer and interim storage system that can be supplied externally and inline with parts that are needed either immediately or at a later time. The sheet metal storage system presents a total of 35 pallet storage locations arranged in two blocks that then provide the required quantities of the various rear panel geometries. The pallets are designed for payloads up to 2500 mm long, 1545 mm wide, 130 mm high, and 3 t in weight. The operating gantry crane traverses between the two shelf blocks and handles all of the storage and removal operations. Outside of the cell area downstream of the transverse storage station, it utilises the carriage for the removal and return storage systems. Inside the welding/ gantry robot cell, it utilises the carriage for the longitudinal transfer system. The pallet changeover time from the transfer station to the gantry robot system is just 135 seconds, starting from the carriage’s parked position. This 135 second cycle includes the carriage’s traverse into the shelf block, the return of the pallet no longer needed, the retrieval of the requested pallet, and finally the traverse to the position for transfer to the gantry robot system and automatic loading on the changeover table. The 135 second cycle runs parallel to the welding cycles of the robots.To minimise storage and removal times, the operating gantry crane traverses in the hoist at speeds up to 16 m/min, and the push/ pull mechanism for the pallets up to 20 m/min. When asked about the particular features of this custom storage and material flow solution, Martin Stöckle, Head of Sales Team 1 at KASTO Maschinenbau GmbH & Co. KG, answered as follows: “We’re working here with two pallet carriages that operate independently of each other. The storage/removal carriage for transverse station I features a hydraulic lifter with pistons for the crane or side loader provision and removal of the pallets as well as an optical contour monitor. The
carriage for transporting the sheet metal into the transfer station for the gantry robot system also has, of course, an optical contour monitor and, in addition, a fanning magnet for the reliable separation of the stacked metal sheets. The controller for the KASTO storage system UNITOWER 3.0 and for the two carriages is responsible for all storage and material flow operations, and it interfaces with the controller for the gantry and welding robot cells. In practice, it’s possible to switch in auto or manual mode. The system is therefore available at all times for the constant supply of material.” The success: 50% growth in capacity with 40% fewer personnel hours
According to Roland Schnurr, this works so well that the worker at the setup station need only insert the side panel elements, secure these in the clamps, and then release auto mode initiation. “The gantry robot retrieves a rear panel on the carriage in the transfer station and places it precisely in the receivers for the spot-welding operations and glue application. The robot system tools itself according to the mounting box type and signals to the storage system controller which of the stored rear panel variants must be provided next. Afterwards, everything proceeds automatically. After the boxes are welded and glued, they are placed on a pallet by the robot. The operator removes only the pallet loaded with cabinets. “Aided by the robot system and the automated material supply, we were able to increase our capacity by about 50%, and that with 40% fewer personnel hours compared with the costly manual operations earlier. This growth in capacity allowed us to master with ease the sudden increases following the start-up phase for the new product line, and that without additional personnel. This, of course, had a very encouraging effect on our ability to deliver in time,” summarised the Production Manager at Striebel & John GmbH & Co. KG. “At the same time we are capable to flexibly provide our customers with batch size 1 in a very short time”, was the conclusion of Roland Schnurr.
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CASE STUDY
Perfect machining results due to 1:1 simulation on the PC With the DMG MORI Virtual Machine, Airbus Defence and Space increases process reliability and manufacturing quality on a DMC 125 FD duoBLOCK®
Wolfgang Simon (right), Head of Mechanical Production, and Gerhard Engelhardt, responsible for NC manufacturing
Established from the previous EADS in 2014, Airbus Defence and Space is responsible for the areas of defence and space as a subsidiary of the Airbus Group. With headquarters in Ottobrunn, Germany, the company focuses amongst others on the development and construction of engines for the Ariane 5 launch vehicle. Airbus Defence and Space meets the high demands on quality with long-standing experience in machining and state-of-the-art CNC technology. Among recent acquisitions are two DMU 70 eVo linear machines and one DMC 125 FD duoBLOCK®. The company also uses the DMG MORI machines as 1:1 image on the PC in the form of the DMG MORI Virtual Machine. The software can be used in a preliminary PC simulation to safely check the complex machining of the highly expensive workpieces. This makes manufacturing completely safe and enables process optimizations already at a preliminary stage to increase efficiency in machining.
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fully loaded Airbus A380, which is approx. 590 tons, launches with a thrust of around 1,200 KN. These figures are just provided here to convey some idea of what it means to send an Ariane 5 launch vehicle weighing 775 tons into orbit – admittedly vertically – with almost 12,000 kN thrust. The latest version of the European launch system has been launched regularly and above all completely reliably from the Space Centre Kourou in French Guiana since 2005. This reliability is crucial, as the Ariane 5 always carries expensive cargo like geostationary satellites, unmanned cargo crafts for the ISS or comet probes like Rosetta. A launch failure would often be synonymous with financial losses running into billions. Airbus Defence and Space GmbH is crucially involved in the development and construction of Ariane 5. The main engine as well as the upper stage are manufactured in Ottobrunn, as well as other components for the aerospace industry. What all applications have in
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The DMG MORI Virtual Machine can display the entire production process including tool changeover common is the uncompromising quality. “The value of the blanks alone can run up to several thousand Euro”, says Wolfgang Simon, head of mechanical production, with regard to the pure material value of some components. In view of such figures, the same rule in production applies as it presumably
does in Kourou: “The first shot must be a winner.” Top level machining
The range of materials includes aluminium as well as titanium, but also high-strength stainless steels and nickelbased alloys like Inconel, probably one
CASE STUDY www.mtwmag.com
of the most complex materials at Airbus Defence and Space. “The interaction of stability and weight is crucial here”, says Wolfgang Simon. Every additional kilo costs a lot of money at the launch. So it is understandable that every gram counts for the complex components. The production manager gives an example: “If we are at the upper limit within the tolerance range and not at the lower, this might already be too much.” Naturally he is speaking of hundredths, not tenths of millimetres. The high demands placed on precision and complexity are only one part of the challenge in manufacturing, as Wolfgang Simon explains: “Competition is extremely high, which means that we must produce as costeffectively as possible and above all adhere to deadlines.” What is ideal is a balanced ratio between quality, costs and adherence to schedules. Airbus Defence and Space ensures the specialist know-how required for this with consistent training and induction of junior employees. On production technology side, the company regularly invests in state-of the art machine tool technology, most recently in three machining centres from DMG MORI: two DMU 70 eVo linear machines and one DMC 125 FD duoBLOCK®. Furthermore, the DMG MORI Virtual Machine was acquired for all three, to further optimize manufacturing processes and quality. With this software, DMG MORI enables exact
The machine park at Airbus Defence and Space also includes two DMU 70 eVo linear machines in the field of milling simulation of machining on the PC, in an exact 1:1 image of the real machines. “The high quality standard in production requires machine tools that consistently work precisely”, says Wolfgang Simon when explaining the decision for DMG MORI. Versatility is another factor: “The 5-axis simultaneous machining and milling-turning technology enables applications that could otherwise never be resolved economically.” In order to gain additional process reliability and optimize production, Airbus Defence and Space relies on an extensive simulation of the NC programs for
complex manufacturing tasks. “After all, we need to guarantee collisionfree production of the expensive components”, says Wolfgang Simon and adds: “When an NC program is installed on the machine, it has to work.” A suitable simulation software was found with the DMG MORI Virtual Machine, as it already produces a very realistic simulation of the programs on the PC in the preliminary stage. Virtual machine including geometry, kinematics and control
Airbus Defence and Space currently makes great advances in production
Airbus Defence and Space also uses the DMC 125 FD duoBLOCK® as DMG MORI Virtual Machine.The software simulates the complete machine geometry and kinematics as well as the actual Siemens control
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CASE STUDY with the DMG MORI Virtual Machine. The software is able to display the DMG MORI machine tools one-to-one on the computer, including the actual machine geometry and kinematics as well as the original control and the real PLC. Gerhard Engelhardt, who is responsible for NC programming, sees enormous benefits in this virtual solution: “We can exactly simulate machining of the expensive components completely safely on the PC, and check the program for general machining feasibility or possible collisions.” Gerhard Engelhardt also uses simulation of the CAM software, but: “We still simulate the final NC code on the DMG MORI Virtual Machine to achieve optimum process reliability.” A measuring probe is also integrated in simulation, which performs realtime measurements like on the real machines. The measured results are also acknowledged in the virtual machine. “Accuracy here is sufficiently high, so that we can already see on the PC whether machining meets our expectations”, says Gerhard Engelhardt. Another feature of the DMG MORI Virtual Machine is shop floor programming. As the actual Siemens control software forms the basis, users can also take full advantage of the ShopMill functionality. This also enables further optimization of the programs based on the simulation, increasing the quality of the
finished parts in turn. The process reliability is an important aspect for Wolfgang Simon, also from the operators’ perspective: “For particularly sophisticated components, you can first of all familiarize yourself with the machining on the virtual machine before working on the valuable workpiece.” New skilled personnel can also be trained in this virtual environment. “Production is much more relaxed for each operator when he can rely on the process already having been tested.” In addition to process reliability and enhanced quality, Wolfgang Simon as head of mechanical production also regards the complete production processes as advantage of the DMG MORI Virtual Machine: “We can
This filler neck is another example for the complex component diversity at Airbus Defence and Space
Discharge cap of the Vulcain engine of the Ariane rocket
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organize and accelerate our processes completely differently.” On the one hand, we already know exact machining times in the preliminary stage, on the other, verification of the programs on the PC is much faster than on the machine. “Furthermore, the lengthy running in of programs can largely be omitted, and setup times are minimized.” Consequently, significantly higher machine running times can be realized and productivity can be markedly increased. Continuous modernization of production with innovative solutions like the DMG MORI Virtual Machine has a high priority for Airbus Defence and Space. Wolfgang Simon expects the complexity of products and their quality requirements to increase further. The cost pressure is also expected to grow independent of this. So the production manager sees this very clearly: “We can only stay competitive if we not only develop the products that we manufacture further, but also ourselves and our production. A crucial step in this direction is the use of the DMG MORI Virtual Machine.”
For more information, Website: www.dmgmori.com
Support component of a satellite
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PROJECTS www.mtwmag.com
Automotive Components Bosch India The company plans to invest Rs 1,000 crore to expand its capacity in Karnataka during 2016-17.
Place: Karnataka
Power
Contact: Roohie Menon, Assistant Manager, Post Box No. 3000, Hosur Road, Adugodi, Bengaluru-560030, Karnataka. T: 080-22992440, 41768204, F: 22992181, E: roohie.menon@in.bosch.com
Transport
Amara Raja Group
Automotive Components
PROJECT
Aviation Hydro Power
UPDATE
Mining
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.
Place: Andhra Pradesh 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
Aviation 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 Contact: “L N Tatwani, Gm Engineering, Chennai International Airport, Chennai - 600027,
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PROJECTS
Tamil Nadu. T: 044-22564027, 22561122, F: 22560512 E: apdchennai@aai.aero
Hydro Power Maharash- tra State Power Generation Company Ltd (MahaGen- co) Government of Maharashtra plans to undertake renovation and modernisa- tion of the old hydroelectric projects in Maharashtra with private participation on a build, operate, transfer (BOT) basis. The projects include hydro projects such as Vaitarna, Veer, Yeldari, Koyna foot leve, Koyna stage III and Bhatghar.
Place: Maharashtra Contact: K Gawande, Superintending Engineer, Hong Kong Bank Building, 3rd Floor. MG Road, Fort, Mumbai-1, Maharashtra. T: 022-22608300, 366, 22675907
OM Metals Infraprojects Ltd Bagged a contract for detailed engineering and designing, procure- ment, manufacturing, inspection, shop assembly, testing, painting, transporta- tion, site storage, site erection, installation, testing and commissioning of hydro mechanical works of Vyasi HE project in district Dehradun from Uttarakhand Jal Vidyut Nigam Ltd. The contract is to be executed over
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a period of 25 months.
Place: Andhra Pradesh
Place: Uttarakhand
Contact: Deepak Rathod, GM (Technical), Trimex Tower, No. 1, Subbaraya Avenue, C.P. Ramaswamy Road, Chennai-600018, T: 044-24988822 / 24988813, E: deepak@rimexgroup.com
Contact: S K Jain, CEO, J-28, Subhash Marg, C-Scheme, Jaipur - 302001. T: 141-5163323-33, F: 4044283, E: jaipur@ommetals.com, skjain@ommetals.com
Mining Trimex Industries Pvt. Ltd. Plans investment on mining beach minerals at Bhavanapadu. The Group company - Trimex Heavy Minerals Pvt Ltd (THMPL) will execute this project. In-principle approval of the Govern- ment is already received for mining lease for beach sand minerals like ilmenite, rutile, zircon, garnet and sillimanite over an extent of 17.88 sq km at Bhavanapadu.
Place: Andhra Pradesh Contact: Deepak Rathod, GM (Technical), Trimex Tower , No. 1, Subbaraya Avenue, C.P. Ramaswamy Road, Chennai-600018, Tamil Nadu. T: 044-24988822 / 24988813, F: 2498 6047, E: deepak@rimexgroup.com
Reliance Power Ltd The company has sought to raise its coal mining capacity from 16 tonne to 19 million tonne to meet its coal requirement at Sasan UMPP in its plea before the Delhi High Court with regard to challenging the Government of India’s decision to cancel allocation of Chhatrasal coal block, which was allocated for Sasan UMPP.
Place: Madhya Pradesh Contact: Daljeet Singh, Group Vice President (Corporate Communication), 3rd Floor, Relieance Centre, B Wing, Maharaja Ranjeet Singh Marg, Connaught Place, New Delhi-110002, M: 9312014099, E: daljeet890@gmail.com, W: www.reliancepower.co.in
Power PFC Consulting Ltd
Trimex Industries Pvt Ltd Plans investment on mining beach minerals at Kalingapatnam in Srikakulam district. The project would be executed by group company - Tri- mex Ores Pvt Ltd (TOPL)
The Power Finance Corporation’s arm has invited request for proposals (financial bids) for the Warangal transmission project. The project comprises 765kV Warora-Warangal and Chilakaluripeta-Hyderabad-
Kur- nool transmission link into the southern grid. Adani Transmission, Power Grid Corp, Reliance Power Transmission, Sterlite Grid and Essel Infraprojects are in the fray for this project.
Place: Warangal Telangana Contact: Sanjay Kumar Nayak, Manager (Technical), Urjanidhi’, 1, Barakham- ba Lane, Connaught Place, New Delhi-110001, T: 011-23456141, 23456000, 23456144, M: 9871611467, E: pfccl.itp@pfcindia.com Adani Group Plans to expand the power generation capacity of Udupi Power Corporation thermal power plant from 1,200 MW to 1,600 MW.
Place: Udupi Karnataka Contact: Devendra Amin, Sr VP (Corp Comm), Sambhaav House, Judges Bungalow Road, Bodakdev, Ahmedabad - 380015 T: 079-25555157, 25556900 E: devendra.amin@adani.com Jyoti Ltd Bagged order from DRN Infrastruc- ture, Hubli, Karnataka in December 2015. The order is for the design, manufacturing, supply, erection, testing and commissioning of 5 Nos. metallic volute pumps along with allied mechanical, electrical and instrumentation equipment, 220 KV
PROJECTS www.mtwmag.com
sub-station, tools-tackles, spares for TubchiBa- bleshwar Lift Irrigation Scheme under Karnataka Neeravari Nigam Ltd.
design, engineering, manufacture, supply, erection, commissioning & civil works for the Main Plant Package. The commissioning is targeted by August, 2019.
Place: Karnataka Place: Tamil Nadu Contact: J. Mukhopadhyay, DGM (Marketing), Nanubhai Amin Marg, Industrial Area, P.O. Chemical Industries, Vadodara - 390003, Gujarat. T: 0265 - 3054631, 3054444, F: 2281871, E: jmukhopadhyay@jyoti.com Bharat Heavy Electricals Ltd Bagged an order from TANGEDCO for setting up supercritical thermal power (STP) project involving one unit of the country’s highest rating 800 MW sets in Tamil Nadu. The project shall be commissioned by August, 2019.
Contact: Mukundan M, Addl GM, Jeevan Tara Building, 5 Sansad Marg, New Delhi-110001. T: 011-23347335, F: 26499683, E: mmukundan@bhel.in Diamond Power Infrastructure Ltd Bagged an order from Powergrid NM Transmission Ltd. for the supply of Conductors for 765 kV D/C Nagapat- tinam - Salem Transmission Line associated with Nagapattinam Project under TBCB route.
Contact: Mukundan M, Addl GM, Jeevan Tara Building, 5 Sansad Marg, New Delhi-110001. T: 011-23347335, F: 26499683, E: mmukundan@bhel.in BHEL Bagged main plant package contract for the 1x800 MW North Chennai Supercritical TPS Stage III from Tamil Nadu Generation and Distribution Corporation (TANGEDCO). The scope of the contract includes
Place: Rajasthan Contact: Tan Reddy, Vice President (Corporate Affairs & BD), F-1, Mira Corporate Suits, 1 & 2, Mathura Road, Ishwar Nagar - 110065, Delhi. T: 011-49962200, M: 310490976, E: grid.communications@ sterlite.com
Transport MP Group
AGM (Marketing), P.O Box No. 3008, ‘Essen House’, 5/12, BIDC, Gorwa, Vadodara - 390016, Gujarat. T: 065-2284328, F: 2280528, M: 9327237075, E: umeshbhatt@dicabs.com
The Group has received contract from Noida Metro Rail Corporation (NMRC) for plying buses within Noida and Greater Noida. The bus network will traverse prominent areas with 13 different route plans. The company has developed a Special Purpose Vehicle (SPV) to implement its NMRC project for City Bus Service operation. The buses will be procured by the MP Group whereas infrastructural support in the form of ticket revenue collection and more will be provided by the NMRC.
Sterlite Grid
Place: Noida Uttar Pradesh
The company has recently commis- sioned transmission project involving laying of a 200 km line of 400 KV double circuit transmission line passing through Rajasthan and Madhya Pradesh. The transmission line is linked to the Rajasthan Atomic Power
Contact: Ganesh Sumbhe, Accounts Manager, MP Group, 2nd Floor, Chiranjeev Apartments, Karve Road, Erand- wana, Deccan, Pune-411038, Maharashtra. T: 020-25442780, M: 8380021657 E: ganesh@etsl.co.in
Place: Tamil Nadu Contact: Umesh Bhatt,
Place: Tamil Nadu
Project (RAPP) project. The work was completed in 12 months.
Delhi Metro Rail Corporation The work is going in full swing for the extension of Badarpur - Escorts Mujesar metro route upto Ballabgarh in Faridabad district. It is likely to become operational by the end of 2017.
Place: Badarpur Delhi Contact: Anuj Dayal, ED (CC), DMRC, Metro Bhawan Fire Brigade Lane, Barakhamba Road, New Delhi - 110001, Delhi. T: 011-23417910/12, 534171, E: anujedcc@dmrc.org, nmusahari@gmail.com 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.
Place: Mumbai Maharashtra Contact: Yatin Sakhalkar, Executive Engineer, Bandra-Kurla Complex, MMRDA, Office Building, Bandra-Kurla Complex, C-14 & 15, E Block, Bandra (East), Mumbai - 400051. Maharashtra T: 022-26591239, 26590001, M: 9969022244 MARCH 2016
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PRODUCTS
PRODUCT SHOWCASE KING CUT PRO – The Large Gantry Type CNC Cutting Machine Ador’s KING CUT PRO is a CNC portal cutting machine which is very precise and reliable. The machine has one head for plasma sheet metal cutting and one head for flame cutting of sheet metal with a dual side longitudinal drive with AC motors. The standard equipment comes with a basic machine package with CNC controller, one torch, central gas diffusion with manometers and a remote flame ignition.
The following equipment are supplied as required by the customer: Additional Equipment: • Plasma power source KJELBERG with machine torch • Programming software MOST 2D • Support table for sheet metal with segment extraction system • Extraction-filter system • Laser position indicator for determining the cutting point Optional : • Extension of the longitudinal rail • Additional cutting head
The CNC Controller – Phantom:
For Product Enquiry Contact Ador Welding Limited Akurdi Chowk, Chinchwad, Pune 411 019 Tel.: 020- 4070 6000 Email: cmo@adorians.com Web: www.adorwelding.com
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The Phantom brings you the performance of a cutting edge CNC that is built on more than 40 years of experience in the motion control and cutting industries. This controller is designed for multiple axis cutting machines and features the latest advances in CNC technology on a proven platform engineered to increase productivity, reduce costs and enhance profitability. The software provides flexibility, ease of operation and technologies that put Ador’s experience and expertise in your operator’s hands, resulting in extremely good cut quality and high productivity. The Phantom can operate any cutting machine and interface with virtually all plasma systems. Following are its standard features: Bright touch screen interface, Touch screen interactive display, Expandable shape library, True multi-tasking environment, Fast Dxt file conversion, Go to(Job interrupt), Quick plate alignment, and Monitor & track consumables. Advanced Plasma Process Control (Plasma Process Wizard) is available as optional extra. Ador offers cost-saving height control unit for simple plasma cutting applications. The KHC1 system provides all the essential functions that are needed for good cuts and optimum utilization of work-piece.
PRODUCTS www.mtwmag.com
Fastener for Machine tools light & heavy engineering Industries We have developed some Fasteners which are useful in Machine Tools, Light & Heavy Engineering Industries. Components are Hex Socket type Allen Bolt, Hex Socket to Socket type Grub Sc, Plunger Screws, Eye Bolt, Hex Bolt Nut Washers, Machine Bolt, Hex Nut std, Lock, Dome, Nylock, Flanged Castle, Long Nuts. Washers plain, Machine Spring Star, Disk Fan, Bearing Wave, Disk Spring, Tapper Washers, Circlip, Knurled Safety lock washers. BSP, BSPT, NPT Tapper plug, Sq hd, Hex hd, Tapper plug, Hex hd Collar plug, Allen plug. BSP Copper washers. Philips Star Punch and Slotted Machine Sc, Self Tapping Sc, Rivet, Stud, Carriage Bolt, NIB Bolt, Sq hd Bolt, T-Bolt, Set Sc, Solid Dowel pin, Tapper pin, Spring Dowel pin, etc. Components as per sample or drawing. For Product Enquiry Contact ZENITH INDUSTRIAL PRODUCTS ABC INDUSTRIAL FASTENERS E-122, Ansa Industrial Estate, 1st Floor, Sakivihar Road, Sakinaka, Andheri East, Mumbai - 400 072 Tel.: 022-2847 0806 / 2847 0705 / 6692 3987 Email: zenith@zip-india.com / abc@precibolts.com Website: www.zip-india.com
Standard Reference: It can be supply as per IS, BS, JIS, DIN, ISO, ASTM & GOST Standard Threads: MM Size Coarse & Fine Pitch, BSW, BSF, UNC, UNF, BSP, BSPT, NPT/NPTF, 6BA to 0BA, 4 to 12No. Size NC/NF. Material’s Grades: M.S. 4.6gr, En - 8gr, 8.8gr, En - 19, 10.9gr, En - 24, 12.9gr, Brass, Copper, Nylon, SS 202, 303, 304, 316 & 410, HTS RST & V grade.
Grinding Oil 1- Straight Grinding Oil for Gear Grinding Features of Grinding Oil No.1
• • • • • • • •
Translucent and low odor Superior cooling properties Non irritating / Non corrosive Produces excellent surface finishes Excellent filter-ability All grinding wheel compatible Superior lubricity package Excellent oxidation Stability / Long sump life
Grinding Oil 1 is compatible with all types of grinding wheels. It can be used for grinding high-speed steel, cobalt, carbide, ceramics and hardened steel. Grinding Oil 1 can also be used in grinders that require the same oil for both lubricating the machine and the wheel / work-piece interface. Unique advanced synthetic and natural lubricity additives in Grinding Oil 1 help keep the grinding wheels clean and free cutting allowing them to function properly. Conventional oils can allow build-up and packing of the wheel. This can lead to burned parts, smoke and scrap parts. Grinding Oil 1 helps maintain part integrity, surface finish and an overall great working environment. Grinding Application:
For Product Enquiry Contact Hangsterfer’s Laboratories, Inc. USA Sanjay Tools & Adhesives Mobile : +91 9822028518, +91 9892516810 E-mail: hangsterfers@sanjaytoolsnsk.com Web : www.hangsterfers.com
• • • • • • • •
Creep feed Grinding Gear Grinding - Profile & Warm Crush Grinding ID and OD Grinding Center-less Grinding Cylindrical Grinding Diamond & CBN Wheel Grinding Tool & Cutter Grinding
MARCH 2016
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PRODUCTS
Ha-VIS eCon Switches: 16 Ports in the most compact space
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
The installation of additional communication infrastructure within production facilities can be achieved quickly, cost efficiently and flexibly with Plug&Play HaVIS eCon Ethernet Switches. Thanks to the compact design, customers require only a minimum of space in the electrical cabinet. The rapidly growing number of Ethernet-capable end devices in the field calls for a corresponding increase in the number of ports for the Ethernet switches. With 16 RJ45 ports, the new variants of the Ha-VIS eCon family offer the perfect solution for these demands. Developed and optimized for deployment in tough industrial environments, the “unmanaged” Ethernet switches allow a low-cost expansion of existing network infrastructures, and also the creation of new industrial networks. With approvals for industry, the maritime market and for transportation, the switches can be optimally selected for every application. The switches of the Ha-VIS eCon Family fit in anywhere, thanks to their compact dimensions. Users can choose exactly the combination of performance characteristics and port combinations from the over 200 switch models that will perfectly match their particular application. Two different compact and space saving housing designs guarantee the best possible utilization of the available space in switching cabinets.
Indexable inserts
For Product Enquiry Contact Dormer Pramet Unit 4 Lindrick Way S43 4XE Barlborough, Chesterfield, United Kingdom T: 0870 850 4466 F: 0870 850 8866 Website: www.dormerpramet.com
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Pramet’s Force AD range provides an ‘all-round’ milling option. The universal 90° cutter features Pramet’s ‘AD’ program of indexable inserts, including the ADMX07, ADMX11 and ADMX16. All offer improved stability in a wide range of applications, even under unfavourable cutting conditions. Combining solid performance with the ability to support multiple materials and heavy machining, the Force AD assortment is an ideal option for numerous operations, including ramping, helical interpolation and plunging. Pramet’s Force AD line is suitable for use in a wide variety of materials, including steel, stainless steel, cast iron, titanium and nickel, and in some cases hardened steels, copper and aluminium. A durable and versatile milling cutter with a wide range of diameters available, from 10 – 175mm, the assortment provides reliable clamping of the inserts, particularly within the helical range. In addition, its specially grooved body promotes fast and efficient chip removal. Both these features combine to give a more accurate cutting process and excellent operating safety with high stability during machining. Meanwhile, the Force AD line offers a variety of insert styles, with geometries for aluminium and high feed applications recently added to the assortment. A positive geometry - with a rake angle of 25° - allows for a reduction in cutting forces, offering good productivity, lower machine power consumption and longer tool life. Its cutting edge shape has been optimised to provide higher impact resistance and smooth machining. This, in turn, promotes a better work piece surface finish. Compatible with a wide range of cutter bodies, internal coolant supply is supported across the entire range.
PRODUCTS www.mtwmag.com
Steady Volt Servo Voltage Stabilizers Frequent voltage variations are a menace that can damage electronic components like power supplies, drives, PLCs, controllers, etc. Their effects are widely felt in CNC, printing and textile machines as well as laboratory, data processing, medical & telecommunication equipment. Frequent breakdowns of such machines are costly to repair. This apart, the downtime and frequent interruptions in operation brings substantial loss of revenue. Steady Volt from Unity Controls is a state-of-the-art Voltage Stabilizer designed to protect such equipment from voltage variations and its ill-effects.
Following are some of its unique features: • • • • • • •
For Product Enquiry Contact Unity Controls Pvt. Ltd 405, Sapphire Arcade, 42 M.G. Road, Ghatkopar (E), Mumbai 400 077 Phone: 022- 2501 3832 / 33 E-mail: sales@unitycontrols.in Web: www.unitycontrols.in
Intelligent microprocessor-based system(available in new digital models) Digital interface with large LCD display and keypad Auto re-start, adjustable output voltage, trip bypass, fault list No hunting, oscillation and noise generation Innovative transformer design to minimize power loss Constant output voltage across a wide input voltage range Single phasing prevention, surge suppressor and EMI / RFI filter
With the best-in-class response time and correction rates, Steady Volt offers improved power quality and greater energy efficiency, thereby saving the cost of breakdowns and energy utilization. Apart from protecting your equipment from damage, Steady Volt also saves energy during continuous operations.
JV Kraft-Vertical Machining Centre
For Product Enquiry Contact Lakshmi Machine Works Limited Machine Tool Division, Arasur Coimbtore 641407 Tel : +91 422 3021300, E-mail: mtd_marketing@lmw.co.in
LMW Machine Tool Division has introduced an All New Vertical Machining Centre “JV Kraft” in the X 800mm range which caters to the needs of diverse industrial segments from Aerospace to Job shops. The machine is equipped with robust spindle, constructed to minimize axial and thermal expansions and is dynamically balanced to ensure extremely low run-outs. The high precision feed mechanism provides high accuracy, rigidity and repeatability. The highly reliable swift Automatic Tool Changer (ATC) adds a new dimension to vertical machining. This state-of-the-art machine has been designed to meet the evergrowing demand for speed and accuracy of the user industry for high quality and high volume production. The machine is designed with the motto of best price-to-performance ratio and true to the goal of providing value creation through innovation, says I.N. Bhattacharya, General Manager-Marketing & Sales, MTD, LMW.
Looking for industrial Products for your plant/workshop ??? Connect to right manufacturers & suppliers http://www.mtwmag.com/enquiry/product MARCH 2016
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ADVERTISERS INDEX COMPANY NAME
PG. NO.
A
COMPANY NAME
PG. NO.
E
COMPANY NAME LAPP INDIA PVT. LTD.
44-45
ACCURATE INDUSTRIES
69
EFFICA AUTOMATION LIMITED
35
M
ACMEE - 2016
80
ERWIN JUNKER MASCHINENFABRIK GMBH
15
MGM-VARVEL POWER TRANSMISSION PVT LTD
ADOR WELDING LIMITED
29
G
B BONFIGLIOLI TRANSMISSION (PVT) LTD.
31
C
INSIDE FRONT COVER
GLOBAL INDUSTRIAL EXPO - 2016
70
GUJARAT LATHE MANUFACTURING CO. PVT. LTD.
57
59
CNC SERVICING & SOLUTIONS (I) PVT. LTD.
3
HEIDENHAIN OPTICS & ELECTRONICS INDIA PRAIVATE LIMITED
CNC SOFTWARE, INC.
BACK PAGE
J
D
H
JYOTI CNC AUTOMATION LTD.
DIEMOULD INDIA - 2016
71
DOWEL ENGINEERING WORKS
49
NEMADE ENGINEERS PVT. LTD.
7
P PRANAV VIKAS (INDIA) PVT. LTD.
11
S 17
INSIDE BACK COVER
L LAKSHMI MACHINE WORKS LIMITED
41
N
GLEASON WORKS (INDIA) PRIVATE LIMITED
CHHANIARA ENGINEERS PVT. LTD.
PG. NO.
SANJAY TOOLS & ADHESIVES
13 & 55
SHANTHI GEARS LIMITED
9
SPRAYMET SURFACE TECHNOLOGIES PVT. LTD.
43
U 19
UNITY CONTROLS PVT. LTD.
MARCH 2016
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Mr.
Pardeep
Inside Story
Aggarwal General Manager, Gleason Works India Pvt. Ltd.
My Life’s Goals
Aim & Ambition:
I believe in living my life in a balanced way. I strive to do better in all aspects of life with positivity and optimism. I want to give my best in whatever I do and then leave the result to destiny. I like to share my thoughts and experiences with the younger minds and make a small contribution for their betterment.
Vision:
To serve the community to get them educated & understand about hygiene. Support environment where People love to co-exist peacefully together and with nature so that earth can be a better place to live for many generations to come.
Social Goal:
I would like to work towards keeping our cities clean and pollution free. Cleaner environment helps not only keeping us healthy but make us think better and in a positive way.
Business Goal:
Gleason is leader in providing Gear Manufacturing solutions with innovations for many decades to meet industry requirements. Gleason machines proving to be consistent performersfor a long period backed by aftermarket support. Indian Market is moving up in the value chain in terms of quality and new manufacturing challenges. Gleason has tremendous opportunities to offer complete solutions in different market segment. Therefore, as a business goal, I would like to continue topromotesolutions/support new applications where quality, accuracy and productivity is important.
My Leisure Choices
I am an avid reader and like to read books on spirituality and new developments. Favorite holiday spot: Hill stations like Shimla & Manali in Himachal. I like going to mountains and experience nature. Music I like : Anything which sounds good, especially Classic Instrumental and Bollywood music. Sports I love : Cricket & Lawn Tennis
Ask my Taste Buds
Favorite food: Vegetarian Indian food cuisines - like to try food from different states Favorite Drink: Black Coffe
In Awe of
The honorable Prime Minister of India – Mr. Narendra Modi and his vision for a better India.
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RNI No. MAHENG/2015/64267 Postal Reg. No. THC/173/2015-2017. Posted at Mumbai Patrika Channel Sorting Office G.P.O. Mumbai 400 001 on 15th of every month and Published on 10th of every month
BE DYNAMIC!
THE FUTURE OF EFFICIENCY & SPEED IS HERE – MASTERCAM’S DYNAMIC MOTION TECHNOLOGY Since 2008, Mastercam has been building Dynamic Motion into our software. That means it has been shop-tested and proven in real-world environments. Dynamic Motion toolpaths carve out massive amounts of material quickly, reducing cycle times by up to 75% – while doubling and even tripling the tool life – immediately putting more money in your pocket. Sounds unbelievable, right? But as the market leader, we’ve had our Dynamic Motion toolpaths tested in most every conceivable work environment around the world. It works.
For more information, visit www.Mastercam.com 800-228-2877
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