ANCA Machine Tools Private Ltd 8/1 , Dr. M H Marigowda Road, Arekempanahalli , (Wilson Garden ), Bangalore - 560027, Karnataka, India T: +91 (80) 6759 2100, M: +91 96637 69911, E: indiainfo@anca.com, W: www.anca.com
www.mtwmag.com
Executive Publisher
Contents
Vol 1 Issue 11 | APRIL 2016
Shirish D.
IN FOCUS
CEO Shekhar D.
Editor Shilpa Dongre
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Marketing Team Ladoji Pendurkar, Amol Powle, Bhavin Shah, Bharat Shah, A.Purohit, Vinod Surve, Kavita Chaudhari
Mastercam: A heritage of CAM excellence
Designer & Layout Arun P. Shinde, Nandan S. Moghe, Dinesh S. Gawade
TECH PROFILE
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
COVER STORY
28
FIBRO Gas springs
UCAM: Benchmarking the excellence standards
CASE STUDY
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 APRIL 2016
42
Mr. Indradev Babu Managing Director, UCAM Private Limited
Flying success with Dunlop Aerospace Braking Systems
BUSINESS NEWS
TECH UPDATE
6
IPTEX-16 / GRINDEX 16 helped Power Transmission & Grind Finishing Industries to Showcase the Latest Technology Trends
8
BFW sets up Dr Kalam Center for Innovation 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.
40
10
COMPANY PROFILE
Robotics in machine tending
36
Electronica Hitech: The Tool Room Resource Company
37
14
Bionic profiling is setting new records “Machine Tool 4.0” as a milestone on the road to digital transformation
52
The Invisible Influence
58
ANCA FX Series CNC Tool & Cutter Grinding Machine
Mastercam & Edge Factor Balaji Diamond Tools Announce Strategic Partnership renowned for industrial diamond tools
22
46
38
Timken sets up Gear Service Facility in Raipur – First outside of the US
60
GROB Group - Competence in worldwide advanced technology
80
PROJECTS
84
PRODUCTS
Editorial Board
Editorial Index A Ador Welding ANCA
J 86 58
B Balaji Diamond Tools 37 Bharat Fritz Werner (BFW) 8 Birla Precision Technologies 84, 87 Mr. A.P. Jayanthram Managing Director Heidenhain Optics & Electronics India Pvt. Ltd
Mr. GK Pillai Managing Director & CEO
Walchandnagar Industries Ltd.
Mrs. Mohini Kelkar Managing Director Grind Master Machines Pvt. Ltd
D DMG MORI Dormer Pramet E Effica Automation Electronica Hitech EMAG ECM GmbH
46 36 16, 55
Effica Automation Ltd.
Renishaw Metrology Systems Ltd.
Mr. MIHIR Baxi President – Global Sales Jyoti CNC Automation LTD
H Haas Automation Hangsterfer’s Heidenhain India Hypertherm
K Kabelschlepp India
85
L Lakshmi Machine Works
86
Mastercam
10, 13, 32
MEC SHOT
87
Messe Erfurt
20
R Renishaw
42
S 40
G GROB Group Ms.Samina Khalid Marketing Manager
87
M 22, 26 48
F FIBRO India
Mr. Arjun Prakash Managing Director
JIG ENGINEERING
Seco Tools
27
Shavo Technologies
52
Steel Plant Specialities
65
60 T 12, 62 85 50 70
I INTORQ
Timken
38
U UCAM
28, 90
Z 37
ZIEHL-ABEGG SE
14
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
APRIL 2016
MACHINE TOOLS WORLD
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BUSINESS NEWS
IPTEX-16 / GRINDEX 16 helped Power Transmission & Grind Finishing Industries to Showcase the Latest Technology Trends The 4th International Power Transmission Expo (A Gear Engineering event) was held in Bombay Exhibition Centre, Mumbai, from 3rd to 5th March 2016. This expo was held along with GRINDEX 2016- The 2nd International Grinding and Surface Finishing Technology Expo. “These concurrent exhibitions were designed to benefit the visitors coming from various industry sectors to witness both Gear Engineering products along with Grinding and surface finishing products under one roof.,” said Mr. Raghu, Director, Virgo Communication s & Exhibitions P. Ltd who organized the Show. There were 75 exhibitors in the Show, both Indian and overseas combined. The key participants included Gleason, Timken, Shanthi Gears, Bonfiglioli, 3M, Beijing Gears, Electronica Hi Tech Machine Tools, Energetica, Hitachi, Klingelnberg, KTR Couplings, Liebherr, Francis Klein : Luoyang Hong, Mahr Technologies, Marposs, Pragati Transmission, Premier, Ringfeder, Rossi Gear, Supreme Industrial Works, Ucam, Universal Technologies and Wenzel South Asia just to mention a few. The 2-day Seminar held on 3rd and 4th March at the same venue added depth to the technology event. A number of interesting papers were presented by experts from the industry. These covered various
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MACHINE TOOLS WORLD APRIL 2016
Mr. Naveen Sahni, GM-Gears & Services, Timken India Ltd., presents a paper on ‘Gear Refurbishing’ at the Seminar aspects of design, manufacture, quality control and finishing operations. Among the overseas papers, the ones on ‘Advances in Surface Finishing Technologies’ by Mr. N.P. Yerriboina of Micro Chemical Korea; ‘The full scope of continuous generating gear grnding’ by Mr. Walter Graf, Reishauer A.G., Switzerland, and Modern Trends in Condition Monitoring of Gearboxes’ by Mr. Dieniel Lim, NGC Transmission, Singapore were notable. In the words of one of the key participants, “The event was well conceived. It allowed the leading Power Transmission companies to showcase their products and services. Also it was a good platform for networking among industry professionals. Asked what was the highlight of their show, this is what Timken said: We
showcased Timken’s products and services portfolio for the transmission industry. Our Raipur capability for refurbishment of gearboxes was appreciated by industry professionals. Our General Manager-Gears & Services, Mr. Naveen Sahni also presented a paper on ‘Modern Technologies for Upgrading & Refurbishing Gears’ at the seminar which was very well
received.” Indeed, both these complementing events provided an excellent platform for the participants to showcase innovative products, meet prospective customers, assess market potential, understand competition and identify new partners for networking for the benefit of all. - P. K. Balasubbramanian
ELECTROCHEMICAL DRILLING – MAKE QUICK WORK! SIMPLER
MORE STABLE
FASTER
MORE VARIABLE
LOWER COST
ELECTROCHEMICAL DRILLING PRODUCES ABSOLUTELY NO BURR OR DRILLING CAPS
HIGHLIGHTS +
Drilling produces no burr or drilling caps. This means no deburring – a crucial advantage for machining components which are difficult to access.
+
The material is not heated by the ECM process which means no negative effects on its microstructure and no micro-cracks.
+
A lot of ECM boreholes (20 or more) can be drilled at the same time; short cycle times and lean processes are a matter of fact. The feed rate can be up to 5 mm/min.
+
The process is suitable for hard and soft machining. The material hardness does not affect the feed rate.
+
The service life of the drilling cathodes is very long, even for hard materials. The tools suffer almost no wear.
EMAG India Private Limited I “Technology Centre” I No. 17/G/46-3 · Industrial Suburb I 2nd Stage · Yeshwanthpur I Bangalore · 560022 I Karnataka · India Phone: +91 8050050140 I Fax: +91 8042544440 I E-mail: sales.india@emag.com I Website: www.emag.com
BUSINESS NEWS
BFW sets up Dr Kalam Center for Innovation Bharat Fritz Werner (BFW), a leading manufacturer of machine tools for more than fifty years, inaugurated the Dr Kalam Center for Innovation at its premises in Bengaluru, India. This world class Research & Development centre, which has been set up with an investment of Rs 25 million, is a step forward towards increasing BFW’s global footprint, while simultaneously retaining its position in India. BFW expects to end FY 2016 with an annual turnover of Rs 900 crores. This Innovation Center named after Dr APJ Abdul Kalam is a tribute to the great scientist, researcher and innovator. This is BFW’s first Innovation Center spread over 3000 sq feet. The Dr. Kalam Center for Innovation was inaugurated by Shri A S Kiran Kumar,Chairman, Indian Space Research Organization. Scientists at this Centerwill work on core research to improve and develop energy efficient and alternative material machine tools. Also present on the occasion were Mr. G K Moinudeen, Director & Head, Karnataka State Office, Confederation of Indian Industry and Mr. J Sheik Saleem, grandnephews of Dr APJ Abdul Kalam. Speaking at the function,
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MACHINE TOOLS WORLD APRIL 2016
Shri Kiran Kumar said, “I am happy to be a part of this Center’s inauguration. Research and Development is vital for India’s manufacturing capabilities. At a time when we are looking at Indian manufacturing moving to the next level, BFW’s approach is laudable. This Center is a tribute to Late Dr APJ Abdul Kalam who was the guiding force for many scientific innovations. It is indeed a great initiative that BFW will collaborate with academic institutions for R&D.” Bharat Fritz Werner, acquired the Turning business of Chennai-based engineering firm Proteck Machinery 9 months ago. BFW is aggressively working towards import substitution and contributing towards the ‘Make in India’ mantra by introducing a plethora of machining options.
Shri AK Kothari, Chairman BFW said, “Our Group companies, stress a lot on R&D irrespective of the industry to which they cater. Innovation is at the centre stage of our corporate philosophy. At BFW, we believe our customers deserve innovative machine tools and, we are committed to making the right investments to reinforce customers’ trust in us.” BFW has transitioned from being a traditional machine tool manufacturer to becoming a NextGen solutions provider. The company aspires to be one among global top 20 machine tool manufacturers by 2020. Mr Ravi Raghavan, MD & CEO, BFW said “Spends on R&D in India are well below the global standard across industries. As a nation we need to pay greater attention
to innovate and transform. At BFW, we recognise our responsibility as one of the leaders and being a pioneer in this industry, we are striving to drive progress by singularly focusing on R&D. Our ambition is to be a strong global player and research is the backbone of our plans. In the coming years, we will continue to invest in cutting edge technology.” BFW has a leading share of the domestic milling market. With a subsidiary in Germany, the company today caters to the global needs of customers for high end milling needs. With the acquisition of Proteck Machinery, BFW has made a commitment to be a leading player also in the Turning segment. Mr T Subramaniam, Head of the Innovation Center, BFW said, “While BFW’s design capability is acknowledged worldwide, we need to complement this with inputs from core research. This is what the Innovation Center will help us achieve. Investments in manufacturing R&D are critical for a country’s progress and employment generation.” For more information, Website: www.bfwindia.com
Group GROB based y o n a rer f rm ufactu , offering The Ge g man es in d in a h is a le al mac epts univers g conc in in h 5-axis c a e and m v e ti v o ti innova Mold, Autom & for Die ustries. d allied in
G-Series
Precision at the highest level
A promising future with the G-series
Contact: GROB-WERKE GmbH & Co. KG Mindelheim, GERMANY Phone: +49 8261 996-0 E-Mail: info@de.grobgroup.com GROB Machine Tools India Pvt. Ltd. Hyderabad, INDIA Phone: +91 40 4202-3336 E-Mail: info@in.grobgroup.com
GROB_Indien_Anzeige_Magazin_die_and_mould_Maerz_2016_DINA4.indd 1
GROB 5-axis universal machining centers stand out due to their absolute precision and reliability in the automotive, medical and mechanical engineering industries, in tool and mold making as well as in the aviation industry. The proven 5-axis simultaneous technology with horizontal spindle position enables you to machine parts of various sizes and materials in a flexible and failure-free way while offering maximum stability of the machine. Fast chip-to-chip times and the innovative further development of our spindle technology guarantee a high economic efficiency and productivity. The GROB G-series – for the most versatile machining possibilities.
www.grobgroup.com
17.03.2016 15:51:15
BUSINESS NEWS
Mastercam & Edge Factor Announce Strategic Partnership Rooted in their mission to inspire the next generation of makers and fill the advanced manufacturing skills gap, the partnership between Mastercam and Edge Factor has been collaborative and longstanding. Mastercam, a widely-used CAM software company, and media production company Edge Factor, are proud to announce the continuation of their strategic partnership for 2016. Recognizing the need to fill the manufacturing pipeline, Mastercam is supporting the Edge Factor team as they focus on producing high impact media and interactive resources for educators and business leaders to inspire the next generation of makers, available through eduFACTOR memberships (edufactor.org).
the “Geek Out” technology video series and hands-on CNC machining and 3D printing projects. Building on the success of last year, Mastercam and Edge Factor are excited to move forward and partner together in 2016.
2016 Initiatives This year, the latest Edge Factor film “Masters of Resonance” is in postproduction and the crew will be producing three new films featuring students working on parts for NASA and the ISS, life changing inventions with MIT, and sustainably powered vehicles. Mastercam and Edge Factor
are partnering to create many eduFACTOR resources including 15 “Geek Out” technology videos, the 2016 version of the Rock MFG Day Kit, 3D printing and CNC machining projects, and tools based on the new films. “Mastercam holds over 20% of the Educational Market, and we are committed to the future of our industry,” said Meghan West, President of CNC Software Inc. “The need for manufacturing jobs over the next few years will be high, and partnering with Edge Factor allows us to help tell stories and create resources that inspire the next generation of our industry.”
As the network of schools and companies that use Edge Factor resources grows, there is a constant flow of new content that span industries and careers to meet the needs of industry and education face, as they seek to inspire audiences and raise up the next generation of manufacturers. “To accomplish the things we do, it takes a team. When we stop and think of partnership with Mastercam, we don’t just think of them as a big software company. We think of the amazing team of people and the Mastercam family that we have had the privilege of working closely with for the last several years,” said Jeremy Bout, Producer/Host of Edge Factor.
About Mastercam Looking back at 2015 In 2015, Mastercam and Edge Factor partnered on major initiatives including Rock MFG Day Kit event resources used by 734 organizations to host MFG Day events, a LaunchPoint TV episode that features the career pathway of one of Mastercam’s young female machinists, and the upcoming Edge Factor documentary “Masters of Resonance” that tells the stories of makers and musicians such as John Good from DW Drums, Bob Taylor from Taylor Guitars, and Neil Peart, the drummer from Rush. They also worked together on several eduFACTOR resources such as
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MACHINE TOOLS WORLD APRIL 2016
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
BUSINESS NEWS
Introducing the Haas F1 Team VF-16 – the latest, fastest, most exciting ‘machine’ to carry the famous Haas VF pre-fix The VF-16, Haas F1 Team’s first racecar, has arrived! The car was revealed February 21st to the world motorsport press at the Circuit de Barcelona – Catalunya, where it began pre-season testing, February 22nd. Of all Haas machines with VF nomenclature, this four-wheeled, Ferrari-powered model has been perhaps the most eagerly anticipated since Gene Haas stated his intentions to enter the world’s greatest race series, less than 2-years ago. Haas Automation Inc., the company Mr. Haas founded in 1983, is Haas F1 Team’s principal sponsor and the genesis of the F1 venture. “From an international standpoint, Formula One is the highest echelon of racing, and Haas Automation builds the highest-quality machine tools,” said Mr. Haas, who has grown Haas Automation Inc. into the largest machine tool builder in North America, with more than $1 billion in annual sales. “When you hear the words Formula One you know exactly what they stand for: a global racing series that invests in the latest technology and attracts the best talent in engineering and design. Haas Automation
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has an excellent reputation in the United States – for reliability, innovation, and value for money – and I want that reputation to continue to grow worldwide. Connecting Haas Automation with F1 in name and in practice is the best way to grow our business, and elevate Haas Automation to a premium, global brand.” The dark grey, light grey, and striking red-toned livery of the Haas VF-16 was derived from that of Haas Automation’s CNC vertical and horizontal machining centers, turning centers, and CNC rotary tables and indexers: a ‘complete’ line of highproductivity CNC products. The Oxnard, California-based Haas Automation Inc. employs around 1300 people, and exports approximately 60% of its annual production to more than 60 countries. There are close to 185,000 Haas CNC machine tools installed around the world, supported by a network of 170 Haas Factory Outlets (HFOs) – independently owned sales and technical service businesses, dedicated to providing industryleading support, wherever a customer is based. The VF-16 demonstrates Haas
Automation’s – and Gene Haas’ – commitment to technology and innovation to a passionate, global audience, many of whom are already Haas customers, or who perhaps work in the precision engineering and manufacturing sectors. “Just as Haas Automation’s CNC machine tools evolve continually, becoming better and more efficient as time goes by, our methodology behind the VF-16 was to make it the best evolution of a good F1 car,” explained Guenther Steiner, team principal, Haas F1 Team. “As we’re a new team, we studied what the successful F1 teams were doing, so we had a strong baseline for the direction we needed to go with our design. “We need to go out there and show that we can do the job – that’s our first objective,” states Steiner. “Then show we can finish races, that we are respected by the fans and other teams in the paddock and, of course, that we can score points. That’s the goal!” The VF-16 is being tested on-track at Barcelona Feb. 22-25 and March 1-4, before its debut race, the season-opening Australian Grand Prix, March
20, in Melbourne.
About Haas F1 Team: Haas F1 Team will debut in the FIA Formula One World Championship in 2016, where it will become the first Americanled Formula One team since 1986. Founded by engineer and industrialist Gene Haas, Haas F1 Team is based in the United States on the same Kannapolis, North Carolina campus as his championship-winning NASCAR Sprint Cup Series team, StewartHaas Racing. Gene Haas is the founder of Haas Automation, the largest CNC machine tool builder in North America, and he is chairman of Haas F1 Team. For more information, Website: www.HaasCNC.com
BUSINESS NEWS www.mtwmag.com
Mastercam’s New Community App Now Available
CNC Software has released an iOS App intended as a useful shop-floor tool for Mastercam users and non-users alike. The Mastercam Community App delivers practical information and calculators for any shop, coupled with immediate access to the Mastercam forum, knowledge base, and more for Mastercam users. Here are some of the features in the Mastercam Community App: Radial Chip Calculator – Dial in feed rate and spindle speed, based on step-over amount, feed-per-tooth, and surface speed to help you create the optimum conditions for your tool. The calculator works in inches and metric. Drill/Tap Chart – Quick conversions and easy reference to decimal equivalents and tap sizes of fraction, number, letter, and metric sizes, and all at the tip of your fingers. Knowledge Base – Users can
browse hot topics and articles from the extensive Mastercam knowledge base. Access to the Forum – Ability to jump right onto the users’ forum where you can learn about tips and tricks on Mastercam, and ask any questions you may have and get immediate answers from fellow Mastercam users. News Feeds of social media platforms – Stay up-to-date on the latest Mastercam news and tips. Videos – Access Mastercam videos; from new product release features to customer success stories. CNC Product Line – Find information on each of Mastercam’s products at your fingertips. My Reseller – For questions or inquiries, find out who your own local Mastercam Reseller is.
APRIL 2016
MACHINE TOOLS WORLD
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BUSINESS NEWS
Bionic profiling is setting new records The fan manufacturer ZiehlAbegg is once again applying knowledge gained from Nature to a current new fan development. The idea for this new latest generation of radial fans comes from the humpback whale; allowing for energy savings of up to ten percent. “Our engineers have therefore clearly underlined their role in the forefront of bionics and as a leader in fan technology” says Chairman of the Board Peter Fenkl, happily. Ziehl-Abegg delivers peak efficiency in excess of 70 percent in its radial fans.Every approach must therefore be used to optimise this. The angle at which the airflow meets the fan blade depends on the flow volume. The whale has to overcome similar challenges when swimming in the sea:the movement of the fins causes the angle to constantly change.If its pectoral fins were to be at too steep an angle to the counter-flow this would produce a lot of turbulence as the water passes over them. “The characteristic features of excessive turbulence are high flow losses and noise” says Dr. Walter Angelis, Technical Manager for Ventilation Systems at Ziehl-Abegg. Over millennia the humpback whale has optimised the design of its fins. For example, the leading edge of the whale’s fins contains golf ball sized bumps (technical term: tubercles). With its long pectoral fins, a whale weighing 25 to 30 tons can therefore swim very quickly and with great agility. “We have recreated this on the leading edge of the fan
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MACHINE TOOLS WORLD APRIL 2016
Ziehl-Abegg is applying knowledge of bionics gained from humpback whales to the new ZAbluefin radial fan, enabling peak efficiency to be achieved. blade and implemented it as an undulatingprofile” explains Angelis. The flow engineers have also taken a close look at the whale’s rear fin, the “fluke”. The v-shaped contour of the rear section of the wing delays potential flow breaks – enabling the fan to be used for numerous different pressure ranges.Overall, evolution has optimised the flow efficiency of the humpback whale in such a way that makes it a very good and agile swimmer despite its body size.Without this evolution its long journeys through the world’s oceans without taking in food would not be possible. The latest generation of radial fans at Ziehl-Abegg in sizes starting from 710 mm, is now benefitting from this knowledge gained in the field of bionics.The product name ZAbluefin is borrowed from the English. “We have also fitted a torsionto the fan blade”, adds Angelis.This creates an optimum angle of flow over the entire span. It’s not just the jagged trailing edges that
make the impeller run quieter. The undulating design of the blade surfaces reduces the noise level. The experts at Ziehl-Abegg have spent about two years on the new centrifugal impeller for air-handling units and industrial ventilation.A bionic profile has proven very effective in terms of efficiency and low-noise. With the bionic profile blades, unlike currently commercially available hollow profiled blades, there are no gaps into which dirt or condensation can penetrate, leading not only to corrosion but
The pectoral fins of the humpback whale which have been optimised in terms of aerodynamic flow over millions of years are being used as a model for the new generation of fans at Ziehl-Abegg.
also creating an imbalance. The steel is therefore pressed into a corrugated shape using a 600-ton press, creating the bionic profile – “this gives us additional strength and enables us to optimise the weight”, emphasizes Angelis. Less weight protects the bearings in the motor. The new radial impeller therefore possesses characteristics from two completely different approaches to the field of bionics: both in terms of aerodynamics (ornithology) as well as hydrodynamics (marine biology). For example, the trailing edges of the ventilator blades recreate the flight of an owl. “As the quietest bird of prey, the owl has already been used by us as a model for a number of designs”, says Fenkl. The serrated trailing edges on fans have since become one of Ziehl-Abegg’s trademarks. On the new fan however the edges have been slightly modified and softened. It’s not only in the design but also the manufacturing process that new approaches have been taken. “Where necessary we drew on the expertise of metals-processing experts at leading German universities”, said the Technical Director. Tools have been developed in conjunction with external experts; this will enable the new impellers to be manufactured entirely at ZiehlAbegg from autumn 2016.
For more information, Website: www.ziehl-abegg.com
BUSINESS NEWS
KOEPFER Gear Hobbing Machines: Standardizing the Production of Non-Circular Gears Non-circular gears are making headway in many areas of application—in machines, engines, and pumps they ensure perfectly tuned irregular power transmission. This allows the replacement of expensive direct drives, used to control the changes in power transmission electronically. The demanding production of the non-circular components does present a challenge, however. Currently the methods used, including EDM or gear shaping, are usually relatively expensive. The key question is, how can the components be produced more flexibly and more efficiently? The gear hobbing specialists at EMAG subsidiary KOEPFER in Schwenningen, Germany, have an innovative answer. Their new process makes it possible to machine mathematically definable non-circular contours on a standard hobbing machine, for significant reductions in production costs. Circular gears are not always the best solution for transmitting power in a machine
The quality of the finished gearing is comparable to that of standard circular gears. Even particularly complex shapes can be machined
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MACHINE TOOLS WORLD APRIL 2016
The machining process is carried out with perfectly synchronized and dynamic machine axes. The hob follows the exact contour around the component. or engine—on the contrary: in some areas of application, the resulting regular transmission of power even causes problems or adverse side effects. For instance, when deep drawing a component, the stroke motion of the drawing machine needs to be quite irregular: The drawing action has to be very slow, but the stroke of the tool before and after should be as fast as possible. This safeguards the quality of the produced components while shortening the production cycle. Non-circular gears are ideal for producing this continuously recurring, irregular motion relatively easily and, above all, with high precision.
Also practical for the automotive industry Another practical application of non-circular gears can be found in the automotive industry. They are used in an engine’s
timing assembly to prevent or compensate for undesirable oscillations. They do so by generating a kind of counteroscillation in the system. As early as the 1980s oval bicycle chainrings provided improved power transmission when pedaling. Pump motors also benefit from non-circular gears, to cite another example. They help to adapt the flow of the pumped fluid perfectly to the overall system. As their popularity increases, the search for an efficient way of manufacturing non-circular gears is being stepped up. Currently the complex geometric shapes are often still manufactured by EDM, sintering, or shaping. However, this incurs relatively high costs, especially at small and medium unit volumes—due to the need for new tools, for example. These methods are also relatively inflexible. Users are looking for solutions
that make it possible to respond quickly to changing requirements in gear production—from circular gears to non-circular gears and back again.
Standard gear hobbing machine in action From this perspective, machining by hobbing is an attractive alternative. This standardized process is highly precise and flexible. Non-circular machining does, however, pose a special challenge: “The noncircular form of the blank makes it necessary to continuously correct the position of the hob during the cutting process. But this can, of course, be done with the dynamic axes of a modern gear hobbing machine. What’s important is the perfectly synchronized control of those axes,” said Manuel Hofmeier from KOEPFER, pinpointing the essence of the challenge. The hobbing experts at
BUSINESS NEWS
Non-circular gears are making headway in many areas of application-in machines, engines, and pumps where they ensure perfectly tuned irregular power transmission the EMAG subsidiary have developed a new solution which can be used as needed on all standard 160 and 300 machines types with the current control system—only their software needs to be modified. The machine is then fully prepared for non-circular machining. “That is the critical point. In the past, we have created customerspecific one off solutions for non-circular machining. Now we have a standardized solution. The mechanical components of the machines do not need to be modified for it,” confirmed Hofmeier.
round blank and milling it to create an oval contour, for example. This is, however, only possible if the desired shape is not too eccentric. In both cases, the machining process is carried out with perfectly synchronized and dynamic machine axes. The hob follows the exact contour around the component. The procedure ensures that the teeth are cut in precisely the shape required. “Our approach has major advantages especially for small and medium volume production,” explained Carsten Rautschek from KOEPFER. “The user takes a few minutes to set up the standard machine for the non-circular component, and can then produce a few initial prototypes, for example. The user could then return to high volume production of some other gear. The geometric data of the oval component is stored
in the control system from that point on. Other methods cannot provide this kind of immense flexibility.”
“Extreme” gear shapes can be manufactured as well Truly extreme gear shapes can be produced on KOEPFER gear hobbing machines as well. However, unlike the less extreme forms, these shapes cannot usually be defined in a mathematically simple way. Complex calculations and formulas are required. “In these cases, the software needs to be adapted for each application. Naturally we make our expertise available to our customers for this purpose,” said Rautschek. “Ultimately our machines make standardized volume production of any convex contour feasible. It’s a whole new dimension of gear hobbing.” It will therefore come as no
Perfectly synchronized machine axes The user simply enters the mathematical data of the required contour into the software. The rest of the procedure depends on the component. • In the case of sharply eccentric contours, the blank itself will already be oval in shape. It is first measured in the machining area of the machine, and then the machine’s axes are synchronized to the position of the component. Next, the hobbing process starts. • Alternatively there is the option of taking an initially
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The dynamic axes of the KOEPFER gear hobbing machine, type 160, are perfectly synchronized for non-circular machining. This is achieved with new machine software
surprise that the gearing experts at EMAG KOEPFER believe their new technology has very strong market potential. There are, for instance, many applications in the machinery industry or in logistics where alternating torques are required within one system or where the transmission of power is irregular. “Our methods ultimately make it a lot easier to develop the mechanical solutions required for these tasks, which in turn require noncircular gears. They are much more costeffective to produce than, for example, an electronic direct drive with variable speed control. This realization still has to get through to developers in many industries, of course. As that occurs, we are very well placed with our technology,” said development engineer Manuel Hofmeier in conclusion.
BUSINESS NEWS
Additive Manufacturing – potential and challenges for the automotive industry Additive Manufacturing processes and 3D Printing have become well established in the automotive industry. Applications now go far beyond prototype production, but developments are usually kept out of the public eye. Rapid.Tech’s first “Automotive Industry” trade forum promises to deliver new insights, with high-profile representatives from industry and research. The automotive industry has once again proven to be an engine of innovation for technology, this time for Additive Manufacturing (AM) and 3D Printing. For example, the Volkswagen Group revved up development at the start of 2014 by networking the AMrelated activities of its individual brands via a corporate technology workstream. Dr Steffen Landua, Director of Technology Development, Toolmaking and Press Shop, heads up the related Metal 3D Printing Working Group together with his professional peers. Messe Erfurt is proud to have engaged this expert to present the keynote lecture on the third day of this year’s Rapid.Tech, which runs from 14–16 June. Dr Steffen Landua’s speech will cover the opportunities offered by metal 3D Printing in the manufacture of equipment and series components in the automotive industry, and what the resulting benefits are for manufacturers. In addition, Landua will illustrate the requirements placed on additive manufacturing by the automotive production sector
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with respect to aspects such as productivity, material selection, and installation spaces, as well as the readiness of 3D Printing technology for series production. The AM expert will also present real-world applications and describe the challenges inherent in the Additive Manufacture of series parts, thus indicating the essential areas of development that will enable further innovations. The keynote lecture kicks off the inaugural “Automotive Industry” trade forum, which will cover a wide variety of subject areas. Accordingly, the presentation by Martin Friedrich of the BMW Group will focus on the use and validation of an indirect process route, using additive tooling, for the manufacture of components for small series and niche applications with series-like properties. He will first examine the suitability of various tool materials and manufacturing technologies and then analyse the thermal tool properties, such as heat conductivity, and their effects on processes and component properties. Marc Vetterli, Inspire AG (Switzerland), will present the results of an industry project in which an innovative vehicle air conditioning system was produced using selective laser sintering (SLS) and
optimised material. The system enables a reduction of around 50 per cent in the emissions caused by the air conditioning system. Robert Stache, Volkswagen AG, will first demonstrate that the high design freedom and accuracy of selective laser melting (SLM) makes it possible to produce tools that enable an increase in productivity of up to 20 per cent in series production. However, the special material that has been used up to now represents a compromise due to its high cost and limited material properties. Stache will then present new test results with regard to the capability of using the SLM process to produce leaktight parts from a tool steel that is well established for use in hot forming. He will also discuss the open issues relating to its use in series production. Kay Sauber, Audi AG, will talk about the process chain and the fields of action in Additive Manufacturing. He will illustrate the production process, from Additive Manufacturing-compliant design, to the generation of suitable files for 3D Printing, to the actual printing process including powder right through to aftertreatment and quality inspection. Sauber will also discuss open issues and the challenges which arise from the requirement for a digital
process chain. Johannes Triebs, member of the Faculty of Production Engineering of EMobility Components (PEM) at RWTH Aachen University, will present the latest studies and applications in plastic-based Additive Manufacturing processes for the construction of prototypes and small series of electric vehicles. The presentation will cover overall vehicle concepts as well as rapid tooling. Christian Schilling, 3D Schilling GmbH, will describe an approach for the manufacture of large plastic parts from common industrial thermoplastics, with which Additive Manufacturing can be integrated in complex production processes. Thiemo Fieger, Daimler AG, will present a new approach for generic design guidelines for additive processes in the automotive industry as well as the results of initial testing on laser-beam-welded and resistance-spot-welded samples. The presentations at the new “Automotive Industry” trade forum, like all presentations at the Rapid.Tech conference, will be simultaneously interpreted (German<>English).Regarding both content and organisation, this forum has been prepared by Dr. Bernhard Mueller. The member of Rapid.Tech’s advisory board has been a recognised expert for additive manufacturing processes for more than 20 years. Since 2014 Mueller also acts as the spokesman of the Fraunhofer Additive Manufacturing Alliance, which coordinates the research expertise of the 15 Fraunhofer Institutes in this field.
BUSINESS NEWS
“Machine Tool 4.0” as a milestone on the road to digital transformation DMG MORI and Schaeffler Technologies will be presenting the innovation project “Machine Tool 4.0” as a milestone on the road to futureorientated production, process and maintenance optimisation at the EMO in Milan. Calculable availability of means of production ranks as a decisive factor in the realisation of cyber-physical production networks. This has led to the optimisation of service and maintenance processes progressively moving away from the back burner and into the limelight. That is why DMG MORI has collaborated with Schaeffler Technologie to start the innovation project “Machine Tool 4.0” taking the mill/turn centre DMC 80 FD duoBLOCK® as a specific example. To achieve their aims more than 60 sensors have been installed on elementary components of the FD machine. Together with other (obligatory) status information, all data are now captured in realtime and analysed using specially developed algorithms. As a result, the evaluation of the data provides
qualified insights into the probable occurrence of different process and production faults. This in turn enables users to take targeted measures in advance for the first time, where currently unplanned machine downtimes quickly render capacity planning a waste of time. The extent to which the above-mentioned theory is actually implemented in day-to-day machining routine can be experienced live by visitors to the DMG MORI stand at the EMO in Milan. Energy and running costs have also been reduced significantly in addition to the increase in availability and simultaneous reduction of service costs. This new “knowledge” also constitutes the basis for the sustainable optimisation of processes, products and machines.
Future-orientated joint project “Industry 4.0“ is the hot topic of the moment. The fundamental ambition of the 4th industrial revolution is the individualised manufacture of products in digitalized,
decentralised, self-controlling cyber-physical production systems. On this basis every customer is to be offered his/ her product customised to the conditions of mass production and have it delivered within the shortest possible time. So much to the vision. The status quo, of course, looks very different. Not even basic and more importantly globally coordinated rules and standards are in place yet. But DMG MORI and Schaeffler Technologies were no longer willing to wait. With their innovation project “Machine Tool 4.0” they have together developed an intelligent machine – namely the DMC 80 FD duoBLOCK® turn/mill centre. An example of this future-orientated “Machine Tool 4.0” will be on show at the DMG MORI stand in Milan. The second prototype will then already be up and running and in everyday use for series production in the Schaeffler Höchstadt plant and from there will enhance the EMO presentation with status data from the shopfloor.
Successful interplay of mechanics, electronics and information technology Both machines have an identical integral Industry 4.0 concept,
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from the sensor to the cloud, that connects existing technology with the new possibilities of digitalization and data analysis and thus masters the close interplay of mechanics, electronics and information technology. Comprehensively equipped with intelligent sensors, operating status and process data are collected here continuously in realtime and saved and processed both locally on the machine in CELOS® as well as in the cloud. In addition, the collected data are analysed in the cloud using specially developed algorithms in order to detect potential faults or problems in the process by means of qualified forecasts. This status information is then fed back to the machine. DMG MORI has developed a special CELOS® APP – the “Condition Analyzer” – that functions as the information centre on the ERGOline® control with CELOS® and via which all status information is visualised and from where the operator can immediately initiate any actions that might be necessary.
A small factory of the future within the factory of today “The DMC 80 FD duoBLOCK® is an absolutely high-end product“, explains Alfred Geißler as the Managing Director of DECKEL MAHO Pfronten GmbH, which is responsible at DMG MORI for the innovation project “Machine Tool 4.0”. And he goes on to stress: “With its pallet changer, numerous tools and complex capabilities of up to 5-axis simultaneous
BUSINESS NEWS www.mtwmag.com
“Machine Tool 4.0” we demonstrate what can already be implemented today, enable the possibilities of Industry 4.0 to be actually experienced and show ways in which companies can master entry into the digitalized world of production on their own.”
to the evaluation unit via which the information is both sent to CELOS® and made available to the cloud. Whereby the results of both pilot machines are analytically evaluated in the cloud thus increasing the quality of the forecast even further.
Maximum availability Intelligence as a standard milling in combination with sophisticated turning processes the machine is perfect for giving a representative documentation of the utilizable value of sensorintegrated intelligence.”
Gained in practice, for use in practice Seen from a practical point of view this applies to an even greater extent to a second machine already installed in the Schaeffler plant in Höchstadt, as the manager of the business division production machines at Schaeffler Technologies, Martin Schreiber explains: “With our products we are both a system partner of international machine tool construction as well as a user of machine tools. So with our investment in a new DMC 80 FD duoBLOCK® we have combined what is necessary with future-orientated developments, in that we as a user can now gain important experience with an intelligent machine directly from the factory environment and then as a system supplier pass on this plus in competence to our customers and partners.”
Enabling customer benefit to be experienced “The presentation of customer benefit is the focus of the innovation project”, stresses Alfred Geißler: “With the
The fact that even as a “Machine Tool 4.0” the DMC 80 FD duoBLOCK® still remains in principle a normal high-tech standard machine from the DMG MORI portfolio is bound to build confidence among users. Alfred Geißler: “The entire control and operation is not different from that of a standard turn/mill centre. This applies in particular to the CELOS® user interface as a centre of communication and organisation.” The only new elements are the machine’s internal network to which all additional sensors, actuators and evaluation units are connected and the CELOS® APP “Condition Analyzer” as an information centre on the machine. Linking in the cloud is effected via a gateway. Both the Profibus in the PLC for timecritical and process-relevant data and the OPC UA protocol to the Human-Machine-Interface (HMI) for other information are used to ensure the data exchange to the machine controller with CELOS®.
Knowledge-based added value A total of more than 60 additional sensors continuously measure vibrations, forces, temperatures and pressures on the sensor-intelligent DMC 80 FD duoBLOCK® and report the results
“Every day and every detected deviation from the preset standard parameters will enhance the informative value of the data analysis”, promises Alfred Geißler. After all the algorithms were permanently updated on the basis of the continuous data evaluation, so that ever more targeted status information with ever more qualified predictions of occurrence could be derived. And Martin Schreiber stresses: “This should enable us to come ever closer to maximum possible availability via the intelligence of the machine, sensors and evaluation.”Whereby, according to Martin Schreiber, the higher availability is the result of better machine utilization and more efficient planning of maintenance measures. ”In addition“, maintains Alfred Geissler, “the overall machining value added is higher due to the numerous possibilities arising from process and production optimization. And what is more thanks to the knowledge base described above, it is possible to make reliable forecasts concerning the quality of the
workpiece during or rather immediately after production.”
Cooperative partnership It will be interesting to see how the customers react to the innovation project “Machine Tool 4.0”. The EMO presentation is already a milestone for DMG MORI and Schaeffler Technologies – especially in view of the close cooperative partnership between the companies that took place within the framework of the project. “It would never have been possible to realise such a complex task in such a short time and with such high (practicable) quality had we worked alone”, sums up Alfred Geißler. Finally, Martin Schreiber brings the customers on board as well: “The close interconnection between manufacturers and suppliers is only the beginning. More than anything Industry 4.0 needs open interaction between all the parties involved in the valueadded chain.”
Data protection and data security Whereby DMG MORI and Schaeffler Technologies are fully aware that the issues of data protection and data security will be the next great challenges that need to be addressed if the elementary confidence so vital for Industry 4.0 solutions is to be achieved. “We are all wellacquainted with the problem of handling sensitive data“, they all claim in unison. “That is why we will do everything in our power to work together with users and other potential partners to find a secure communication environment,” both Alfred Geißler and Martin Schreiber agree.
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BUSINESS NEWS
Renishaw to highlight various metrology products at Diemould 2016 At the Diemould exhibition taking place at Bangalore International Exhibition Centre, Bangalore, India, from 6-9 April, Renishaw (hall 2A stand B38) will highlight a range of process control solutions that help tackle the increasing drive to lean manufacturing, from new technologies for preprocess machine calibration, to on-line and off-line postprocess measurement. There will also be a significant focus on the company’s additive manufacturing (3D printing) systems with the new PlusPac™ upgrade for its AM250 additive manufacturing machine. The company will have active demonstrations of itsEquator gauging system along with various machine tool software’s catering to Diemould industry. Renishaw is the UK’s only manufacturer of a machine that ‘prints’ metal parts and visitors to the Renishaw stand will be able to see applications that demonstrate the capabilities of the company’s additive manufacturing technology and Strain gauge high-accuracy machine tool touch probes - Unparalleled accuracy and repeatability make this technology the best choice for complex multi-axis work and machine calibration.
RENGAGE™ technology RENGAGE™ technology delivers true three dimensional (3D) measurement performance and submicron repeatability. So for exceptional performance, reliability & durability, why choose anything less? Conventional probes continue
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to fulfil a valuable role, which is why Renishaw maintains its position as market leader in the design, manufacture and support of these products. However, for numerous applications, the significant performance benefits offered by RENGAGE technology provide users with a competitive advantage, for both now and the future. RENGAGE technology is available with radio transmission in the RMP600; with optical transmission in the ultra-compact OMP400 and compact OMP600; and in the miniature MP250, offering an unmatched combination of size and accuracy.
The Primo™ system – opening up the world of precision manufacturing At Diemould Renishaw is highlighting the Primo system: an entry-level machine tool probing system that opens up the world of precision manufacturing to all types of manufacturing operation. A genuine breakthrough business model, the Primo system makes it easy for manufacturers to take their first steps towards higher-value manufacturing by automating their operations and achieving repeatable processes.
Renishaw fixtures: the new single source for metrology fixturing Following the acquisition of R&R Sales LLC in 2012, Renishaw has developed an extensive new range of modular fixturing designed specifically for coordinate measuring machines (CMMs), vision systems and
its Equator™ gauging system. Visitors to Diemould 2016will see that the new range offers a wide choice of base plates and components available in M4, M6 and M8 thread sizes, and can be utilised for measurement applications across multiple industries, such as aerospace, automotive and medical.
Automated gauging and process monitoring software for the Equator™ gauge Renishaw Equator™, a lightweight, fast and highly repeatable gauge, will be demonstrated in an automated cell. Equator’s innovative flexible gauging technology is based on the comparison of production parts to a reference master part, which can greatly increase throughput and reduce scrap rates at a fraction of the cost of an equivalent custom gauging system. Equator can switch between parts in seconds, perfect for flexible manufacturing processes or accepting parts from multiple machines. A new process monitoring window has also been added to the shop-floor user interface for the Equator gauging system. This instantly displays measurement results of inspected features to the operator on a bar-graph display. It also shows
the history of measurement on each feature so that process trends can be seen. The system’s re-mastering process can now be managed based on temperature limits, number of parts or time since last master.
Enhancements in metal 3D printing Visitors to Diemould will also see a new range of additive manufacturing technologies. Renishaw’s laser melting systems utilise a pioneering, additive manufacturing process capable of producing fully dense metal parts direct from 3D CAD, using a high-powered fibre laser. Parts are built from a range of fine metal powders that are fully melted in a tightly controlled atmosphere, in layer thicknesses ranging from 20 to 100 microns. The AM250, Renishaw’s first additive manufacturing machine is now available with PlusPac – an add-on kit which transforms the machine to meet the demand for cleaner process environments, improved surface finish and precision. PlusPac includes new Optical Control Software (OCS), a gas knife lens window protection system, and a high capacity filtration system. These updates give the user tighter control over the build process, enabling users to create even better components. Website: www.renishaw.com
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BUSINESS NEWS
Die & Mould competence across the board Its many years of experience and application-specific expertise enable DMG MORI to develop customised solutions for users from the die & mould segment. The machine tool manufacturer will be presenting 4high-tech machines and innovative production solutions for the die & mould industrylive in operation at its 144 m² booth in Hall 1A (position B43) at this year’s Die & Mould exhibition in Bangalore.Daily shuttle services to the DMG MORI Technology Center and dedicated seminars round off DMG MORI’s trade fair presentation. That advanced production solutions ensure competitive ability in the manufacturing industry is an undisputed fact. DMG MORI supports its customers in this respect with its many years of experience and holistic process competence. A key feature in the range of products and services of the leader of innovation is also its specific branch orientation. Thanks to innumerable projects in the die and mould making branch, DMG MORI has been able to build up a wealth of application-specific expertise from which its customers today benefit. Because experts from DMG MORI concentrate on developing future-orientated manufacturing solutions for branch-specific applications in dedicated competence centers.
HSC Center and Mould Laboratory – die & mould competence built on years of experience Die & mould applications have ranked high at DMG MORI for many years and this has resulted
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CELOS® from DMG MORI for Industry 4.0
in an enormous wealth of experience in this sector on the one hand and the development and continued development of path-breaking manufacturing technologies on the other. The HSC Center in Geretsried and the Mould Laboratory in Japanese Nara impressively underscore this competence with specialised application technicians who always develop optimum manufacturing solutions for the tool and mould making sector. Trials are carried out here, customers are given technological support and training courses are offered. The demands on precision, long-term accuracy and surface qualities are met by stable DMG MORI machining centers that are convincing with their thermo-symmetric design and innovative cooling systems. While spindles with shaft, flange and sleeve cooling ensure best surfaces, dynamic linear drives enable the required precision and at the same time shorter machining times.
At the Die & Mould trade fair in Bangalore, DMG MORI will be presenting its branch competence with the powerful entry-level vertical machining centreecoMill 600 V as well as thehigh-tech vertical machining centers DMC 650 V and NVX 5080 andthe universal milling machine DMU 65 monoBLOCK®. CELOS® is on board, as it is in all high-tech machines from DMG MORI. This uniform, app-based user interface enables consistent management, documentation and visualisation of order, process and machine data. In die & mold applications in particular, users benefit here from a seamless process chain.
The topic “Industry 4.0” is dominating the discussion of the future like no other, even in the sector of machine tool construction. As the leading manufacturer of metal removing machine tools worldwide, DMG MORI supports its customers on their way to digital transformation of manufacturing process chains with the app-based CELOS® system, which the machine tool manufacturer first presented around three years ago and which it has consistently continued to develop in a targeted manner ever since. Using this uniform user interface for machine and office PC, employees in shop floor and job scheduling can manage, document and visualise job order, process and machine data. Thanks to its open architecture, CELOS® allows the exchange of information with higher-level structures in addition to its effects in the shop floor area. So CELOS® offers customers complete integration of their machines in the company organisation while simultaneously creating today the interface of metal cutting production in the cyber-physical production system of the future. The benefits in day-to-day operation are convincing: a 30 percent time saving in tooling times and 50 percent lower time and effort for the calculation of technology values or the search for important information are just a few of the effects that can be achieved with CELOS®.
BUSINESS NEWS www.mtwmag.com
ecoMill V series – New revolutionary vertical machining centres in the new design with thenew DMG MORI Multi-Touch SLIMline® control With the ecoMill 600 V at the Die & Mould trade fair in Bangalore, DMG MORI is presenting the new generation of the ecoMill V series . DMG MORI has defined a new standard of performance in the sector of entry-level machines with the ECOLINE product line. Even at the very first glance, the vertical machining centre impresses with its new design that ensures further improved work ergonomics and a higher level of value retention. The ecoMillV series is based on a C-frame cast
iron bed for the best stiffness and vibration characteristics ensuring highest precision. Ball screws of the highest quality and a powerful 12,000 rpm spindle were combined to meet the highest standards in production. The performance of the ecoMill V machines even in
the smallest size is outstanding already in the standard version. The highest precision (without direct scales) can be realized, due to direct coupling in X / Y, no belt drive for no backlash. An optimized machine structure also increases stability during machining, and a high degree
of manufacturing flexibility is provided in the standard version by having 30 tool pockets in the tool magazine. The absolute highlight is the new 19 – inches DMG MORI multi-touch SLIMline® multi-touch control with Operate on SIEMENS (19” / Operate on SIEMENS / 400 V) with top screen resolution and touch functionrepresents the next advanced step for a modern user interface. The practical and ergonomically optimised 19” multi-touch display with its maximised resolution and 45° swivel range offers decisive user benefits.The new ecoMill V series is also available with DMG MORI SLIMline® Panel (15“ / MAPPS IV on FANUC).
Seco adds larger insert sizes to T4-12 square shoulder, helical milling cutters By adding larger insert sizes to its popular T4-12 line of square shoulder and helical milling cutters, Seco allows parts manufacturers to achieve increased depths of cut and higher metal removal rates when roughing and semifinishing steel, cast iron and other workpiece materials. In continuing the value and stability of the T4-12 line, these larger-sized inserts all come with four curved cutting edges that lower the tooling cost per part and ensure smooth machining operations. These inserts tangentially mount in their cutter bodies for increased performance stability and easier access to their mounting screws. Moreover, this type of mounting directs the cutting
forces to the thickest part of the inserts, which contributes to the higher metal removal rates of these products. Cutter diameters for the larger T4-12 square shoulder inserts range from 25 mm to 125 mm (1” to 5”), with corner radii up to 3.1 mm (0.125”). The inserts also come in a wide selection of grades and geometries.
Normal and close pitch versions contribute to successful slotting/ contouring and optimised contouring operations, respectively. Internal coolant channels within the cutters further maximise insert performance. Available mounting systems for T4-12 square shoulder cutters consist of various shank and arbor-style cutters.
Cutter diameters for the larger T4-12 helical inserts range from 50 mm to 100 mm (2” to 4”), with corner radii up to 3.1 mm (0.125”). The inserts also come in a wide selection of grades and geometries, including high positive rakes. Normal pitch cutters perform slotting and contouring operations, while close pitch versions only handle contouring, with a 30 percent radial width-of-cut capability in full axial depth-of-cut situations. Mounting systems for these cutters include Arbor, Weldon and Seco Weldon.
For more information, Website:www.secotools.com/in
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COVER STORY
UCAM: Benchmarking the excellence standards
Mr. Indradev Babu Managing Director UCAM Private Limited
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COVER STORY www.mtwmag.com
Q1. UCAM being the key player in rotary table space, Please brief us about recent initiatives undertaken in machine tool space? Which are your focus areas? Being a leading manufacturer in rotary tables arena for more than 25 years, UCAM has always focused on innovation and new technology developments. To cater to the need of machine tool industry for high speed and high efficiency rotary tables, UCAM’s innovative product is the Direct Drive Rotary (DDR) Tables. These Rotary Tables reduce the component machining cycle time significantly and are known for their high speed and dynamic performance. The High-Tech Direct Drive Rotary Tables with the backward integration of Torque Motors provide customer total solutions for both indexing and rotary interpolation applications. Customers are also looking for sophisticated high speed machines which will give them better accuracies and reduces the cycle time. In the global market the trend is moving towards 5 Axis machines from 3 axis machines. To address this market need, UCAM’s effort are to bring in new integrated 5 axis machining solutions like Cantilever Tables, Direct Drive Tilting Head, and Deep Tilting Direct Drive Tables for the machine tool builders and also Large Size Rotary Tables for India and International market. UCAM has also ventured into new verticals under the Brands of Nimble Machines and Nimble Electric. While the Nimble Machines focus on manufacturing high tech high performance Machine Tools such as
CNC Gear Hobbers, the Nimble Electric offers Torque and Specialty Motors for the Machine tool and allied sectors.
Q2. What are the market opportunities for UCAM products in India? How do you plan to position these producs? We hold the maximum market share for CNC Rotary Tables for all segments of the Machining market. We are very well accepted and dominate the mid to high segment. Our R & D has now developed products for the premium market. Our 5 axis units which were predominately exported till now are now being sought by the domestic clients too. Actually it is interesting to track the changing market demands. These changes indicate how the Indian Industry is maturing from just 3 axis to 4Axis, and now to 5 axis. Also the 4th axis performance expectations are also moving upwards. UCAM products add value with tailor made solutions to existing 3-axis machines and OEM’s machines respectively. With the Make-In-India initiative ushered in by the Government, and the estimated growth in defense, aerospace & infrastructure sectors, manufacturing in India will experience a positive trend.
Q3. What is your marketing strategy for India? It is really an exciting period for UCAM’s growth plans and products and we looking forward to significant growth prospects and serve our customers with timely value additions. Clear strategic plan are afoot for the next 5 years and I am unable to share our excitement at this juncture.
Q4. Product innovation through R&D is vital to be forrader in the competition, as per your opinion how does R&D plays the role of catalyst in the success process? R&D is for us more than a catalyst, I would say it is the key to stay abreast of competition and meet ever-raising expectations/demands of Customers. UCAM’s R and D arevery well recognized and contribute immensely. Our annual spend on R and D is clearly budgeted and is above Indian industry average. We believe that Innovation is key not only for product design, but for processes as well as key functions like marketing. Direct Drive Rotary(DDR) Tables, 5 Axis Rotary tables are some of the results of our sustained efforts in the area of R & D. Indian Machine Tool Industry is much ceased with in applying DDRs and I am sure you will see more results from Indian Machine Tool Producers.
Q5. Quality standards are benchmarked by the product performance; please brief us how do you maintain the quality norms since from product manufacturing to implementation? First of all we have stringent quality management system in place, which is continuously monitored and upgraded. Quality starts right at the design stage itself. For the subcontracted parts UCAM has quality certified vendors who adhere to UCAM standards. Critical components are subjected to strict tolerance so as to match the quality standards of the product. All parts are 100% inspected for acceptance. We employ all modern tools to find and
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COVER STORY resolve problems and complaints. UCAM products are continuously benchmarked with globally leading brands and also we follow industry laid down standards. UCAM can truly boast the investment it has made into quality and testing infrastructure.
Q6. Could you brief us on Indian & Global perspective of CNC rotary table industry? India is just maturing from a consumer of typical 3-axis machine to 4 and 5 axis machines, whereas western world pre-dominantly uses, only 4 and 5-axis Solutions. There is still a lot of scope for Indian machine tool users to adopt more and more of 4 and 5 Axis integrated machines. As of now machines available in India are with add on 4th & 5th Axis solutions. There is a huge opportunity for UCAM to export its special products to International machine tool builders for integrating it into their machines and we are making good head way in this. We expect to be one of few dominant players in the next few years in this product segment
Q7. According you what are the factors affecting to your business? Our business growth is directly linked to consumption of Machining centers
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in India and export push. We can see positive signs of revving up of the Machine tool industry. In the international market we are facing challenge because of being Indian brand.Our products will definitely break the barrier and pave the way for our country being recognized for quality machine tool products. We have a great responsibility and need to build our brand and prove our quality and reliability apart from being cost effective.
Q10. Please let us know the issues you need to address that are related to your industry.
Q8. What are the key technological trends that are driving your industry?
Q11. What is your advise to the Indian SMEs to achieve global competitiveness?
There is an increase in the popularity among Machine Tool Builders for Multi-axis machining solutions, where one can complete all machining operations in one set up. Also they offer high precision and improved reliability. There is a gradual increase in demand for high speed and accurate Direct Drive Rotary Tables across various industries.
Step one: SMEs need to expose themselves and benchmark against good producers across the world, in their area of business. Step two: Adopt, continually work and improve their QMS. Also important is to clearly demarcate their products and services offerings. Consider people management as an area for innovative practices.
Q9. What is your vision for your company? To be one among the top five preferred companies globally in the rotary table manufacturing space in the next 5 years.
Logistics and Supply chain still remains a serious area of concern which machine tool companies are focusing fighting to resolve. Skill and Manpower is another area, which needs to be addressed. We need to also nurture high quality sustainable vendors to make our products as a preferred global brand at par with countries like Japan and Germany.
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www.marposs.com
MARPOSS INDIA Pvt. Ltd. 147, Sector 7, IMT MANESAR 122 050 - Tel. +91 124 4735700 |sales@in.marposs.com
IN FOCUS
Meghan Summers West, President, Mastercam
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Q. Mastercam has gained substantial market share in machine tool industry , please brief its journey from the inception & share some its milestones? Mastercam was launched more than 30 years ago. It was driven by two brothersâ&#x20AC;&#x2122; specific set of skills in mathematics, programming, and shopfloor machining experience. Since then, weâ&#x20AC;&#x2122;ve maintained a tight focus on what made us successful from the beginning. We talk directly with machine shops
IN FOCUS www.mtwmag.com
around the world to see what’s needed and what’s coming. This means we not only provide practical programming tools to get jobs done quickly, but groundbreaking new techniques to inspire CNC programmers.
Q. Please brief us about company’s global reach & what are the global alliances that has been made in order to out-front the competition? Our reach extends across the globe, with many of our representatives having decades of experience with both their local market and with Mastercam directly. We choose our partners carefully to ensure that they can build long-term support relationships with Mastercam users. As the world’s most widely-used CAM system, we need to be able to work smoothly with virtually any machine tool. To this end, we’ve forged many mutually beneficial relationships with machine tool manufacturers that let us prepare for “the next big thing” as well as helping them demonstrate what their machines can do. Similarly, we have excellent relationships with CAD developers because our users require us to work with virtually any type of CAD file. And we do have excellent relationships with CAD developers. SOLIDWORKS® is a great example. We have a tightly integrated Gold Partner version of the software that runs within SOLIDWORKS®, and we have a good relationship with the company to help keep us on top of what’s going on in the industry.
Q. What are the market prospects for the Mastercam products in India and How do you plan to position these products? For us, India represents an unsurpassed
collection of talent, experience, skill, and opportunity. The economic growth outlook for the next few years is great by all reports. Large and rapidly growing sectors such as Aerospace, Automotive, Telecom, Medical, and even infrastructure expansion require the backbone of manufacturing that we can help support. Our strategy in India is similar at its root as our strategy across the globe. Understand the needs of the industries engaged in manufacturing and, more importantly, the practical needs of the people responsible for programming parts for those industries.
Q. Can you brief us about the marketing strategies that were applied in order to stand out in the competition of the industry? I can sum up our strategy in three simple words: Practicality, Support, and Advancement. By practicality, I mean that we strive to make sure every tool in the software solves a problem or improves a process that we’ve seen in day-to-day machine shops. We want to ensure that the toolset in Mastercam gives a programmer a way to complete any project they take. In the end, our goal is not our software itself, but the results it achieves for our users. Support is the second pillar of our strategy. We feel we have the best and most experienced global support network today. We have local representatives with decades of experience, ready to share their knowledge with their customers and with the entire Mastercam community. This is vital, because in many ways, machining is the most unforgiving part of the entire manufacturing process. CAD designs can be edited, but once metal is removed, it can’t be put back. Finally, advancement is crucial to make
sure that our users are as competitive and productive as possible. Our proprietary Dynamic Motion technology is a great example of this. It’s a cutting motion engine that drives many of our toolpaths. It can save up to 70% of machining time; at the same time it dramatically extends tool life.
Q. Brief us about the R&D and Quality policy for your business? Our development is built on a repeating cycle of constant creation and testing so that as many issues as possible can be worked out as quickly as possible. At the same time, we have a large R&D machine shop in our facility that constantly tests the software in a wide variety of real-world machining situations. Finally, we run a wide & extremely valuable public Beta program so existing users can try out new features and report back with comments and suggestions.
Q. What are the key technological trends that are driving your industry? The key trends in CAM software are simple but powerful: constantly increase the speed and efficiency of the software, automate where possible, deliver programming methods that make the best possible use of machine tools, tooling and material, and make the software capable of handling the increasing variety of jobs a shop encounters. I mentioned our Dynamic Motion technology earlier. It’s a good example of a software advancement designed to address many of these points. It can dramatically reduce machining time, it’s governed by “smart” algorithms that automate much of the complex work, and it generates cutter motion that is easier on the machine, extends the life of the tool, and
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IN FOCUS is smoother in the material.
Q. Could you brief us on Indian & Global perspective of machine tool manufacturing industry? What are the distinguishing factors? The machine tool market has seen dramatic ups and downs since 2009. During that year, the machine tool market as a whole took a sharp drop with some manufacturers losing as much as 80% of their orders. But as the global economy began to rebound, the pent up demand for those machine tools rose quickly and has stayed very healthy since. In the United States, the machine tool market is exceptionally strong, and there are many other countries that show strong machine tool consumption including China, Germany, South Korea, and Mexico.
Q. Please comment on the current machine tool scenario in India? India remains one of the top machine tool consumers, as well as a very large producer. However, the demand is surpassing the supply, potentially creating a gap and a demand for
more machine tools than are currently available. The industry is rapidly moving toward ever more advanced CNC equipment as segments such as medical, automotive, and consumer products demand it.
Q. In your opinion how can the Indian machine tool industry become globally competitive? From working with our Indian representatives, we feel the Indian machine tool industry is on an excellent path now. Although there may be a gap between the supply and demand of machine tools, it appears more companies are looking to fill that gap. And the equipment they appear to be filling the gap with (increasingly sophisticated CNC machines)should yield not only a stronger machine tool market, but even more competitive machine shops. Another powerful tool for increasing global competitiveness is heavy emphasis on manufacturing education. Whether it’s a machinist sharpening their Mastercam skills through training, or a classroom of students getting
prepared for and excited about the industry, manufacturing education is vital. This is especially true in any market where growth is expected – that growth will require new, intelligent, skilled people to sustain it. We’ve been dedicated to manufacturing education since we started, and it will always be an important part of our company.
Q. How do your perceive the future of the Indian machine tool industry? We’re excited by it. There are so many positives and so many manufacturing and machine tool opportunities that India represents for itself and for the world, and we’re eager to see how we can help.
Q. What is your vision for Mastercam? Our vision is to remain focused on the fundamentals that help make Mastercam shops successful every day – deliver software that makes day-today machining easy, that constantly offers creative new techniques, and that inspires machinists.
The Mastercam corporate headquarters in Tolland, CT, USA.
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COMPANY PROFILE
Electronica HiTech Machine Tools Pvt Ltd: The Tool Room Resource Company
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lectronica HiTech Machine Tools Pvt. Ltd., a group company of SRP Electronica group which was formed after the reorganization of the previously known Electronica group. Under the leadership of our Chairman Mr. S. R. Phophale, the group expanded into many areas like sheet metal components manufacturing, tungsten carbide manufacturing, machine tool trading and equipment finance. Electronica has always been on the forefront in bringing the latest technology to the Indian machine tool Industry. The company was started 40 years ago by our visionary Chairman Mr. S.R. Pophale with a vision to serve the machine tool Industry by indigenously manufactured products and by sourcing the best in class products from various multinational companies. Electronica Hitech has co-operated with many Multi national brands like Doosan, Hartford, Quickjet, Proth, Honor Seiki over last two decades for bringing advanced technology in metal cutting machines for the machine tool Industry. Electronica Hitech has
supplied more than 3000 imported cnc machines and they are being supported through its strong after sales service team of more than 50 experienced service professional spread across more than 10 branch offices covering major Industrial locations in India. Electronica is pioneer in developing one of the first indigenously manufactured cnc Wire EDM. Over last more than 30 years, Electronica has served the tool room industry by supplying more than 10000 EDM and Wire EDM machines. Electronica Hitech with its competent R & D team members with cumulative collective experience in EDM / Wire EDM technology of more than 140 man years has developed state of the art CNC Wire EDM machines. This is in line with the â&#x20AC;&#x153;Make in Indiaâ&#x20AC;? initiative launched by Government of India and this will be our latest offering for the Indian Machine tool Industry as well as Die mould Industry. We take great pleasure in launching this cutting edge technology in cnc Wire EDM machines at the Die and Mould India 2016 show at Bangalore. And this will be a feather
in the cap of our Product line up as a Tool Room Resource Company. India has become one of the fastest growing economies and best investment destination for the world. The next decade is expected to witness unprecedented growth for the Indian Industry. Machine tool Industry is a back bone for any industry. Currently more than 60% of the machine tool consumption is catered by foreign machine tool builders. What is need of the hour is that the Indian machine tool manufacturers to develop reliable international standard machines at competitive price. For this the Indian Machine tool industry has to invest in break through R & D, world class infrastructure, robust internal processes and build high performance teams. Electronica Hitech team feels proud of this moment of launching the Cnc Wire EDM machines. It has multiplied our enthusiasm to serve the needs of the Industry.
For more information, Website: www.electronicahitech.com
Global Manufacturing Solution provider
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COMPANY PROFILE www.mtwmag.com
Balaji Diamond Tools renowned for industrial diamond tools
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alaji Diamond Tools is one of the leading manufacturers of quality industrial diamond tools in India since 1986. Its manufacturing plant located at Coimbatore makes a wide range of standard and customized tools to meet the exacting customer needs and requirements. The range includes Single point diamond dressers, multipoint diamond dressers, Diamond grit impregnated dressers, Blade type diamond dressers, Forming & Chisel type diamond dressers, Diamond turning & boring tools, Hardness testing indentors, Diamond lapping compounds, Diamond Files, Diamond & CBN mounted points, Diamond & CBN resin and metal bond wheels, Diamond deep drills, Diamond & CBN honing
sticks, PCD/PCBN brazed tools, PCD/ PCBN inserts, PCD/PCBN Grooving tools and so on. Balaji’s products are available across 15 states in India through an extensive dealer network. The company also exports its products to countries like USA, UK and Latin America to name a few. “Our workforce comprises a highly
trained, experienced and motivated team of engineers who work with our clients to deliver excellent results,” says Mr. B. Praveen Kumarr, CEO. Its Management consists of highly qualified hardcore engineers, technocrats and personnel with rich and varied experience in the field for over three decades. The company takes utmost care at every stage of manufacture right from selection of raw materials to the finished tool. “Cent percent quality is ensured by our quality control engineers before final dispatch,” pinpoints Mr. Kumarr. The company strives to constantly improve the quality of its tools and to ensure that the best quality is provided at the most competitive price.
INTORQ : The brand of reliability We set the standards
The INTORQ brand stands for reliable brake solutions of the highest standard. Whether in cranes, wind turbines or lift systems – INTORQ products are used in the most diverse of applications. Rely on us to create the right solution for your drive – individually and reliably. With its broad scope of different versions, the modular range of INTORQ products is used in many motors and geared motors and has set standards
worldwide. With the establishment of facilities in Shanghai, Atlanta and Pune, we have also consistently expanded our international presence. So wherever you are in the world, our network of sales and service staff is always close at hand to support you. INTORQ at a glance
• Products: electromagnetic brakes and clutches • Sales volume € 51 million per year
• 800,000 units per year • 10,000 m² production area • Development and production in Aerzen • Companies in Shanghai, Atlanta and Pune • 250 employees • 63 sales partners in 49 countries
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COMPANY PROFILE
Timken sets up Gear Service Facility in Raipur – First outside of the US
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he Timken Company, engineers, manufactures and markets bearings, transmission products like gearboxes, belts, chains and related products and offers a spectrum of powertrain rebuild and repair services. An authority on tapered roller bearings, Timken today applies its deep knowledge of metallurgy, tribology and mechanical power transmission across a variety of bearings and related systems to improve reliability and efficiency of machine and equipment all around the world. The company’s growing products and services portfolio features many strong industrial brands including Timken, Fafnir, Philadelphia Gear, Carlisle, Drives and Interlube. Known for its quality products and collaborative technical sales model, Timken posted $2.9 billion in sales in 2015. With more than 14,000 employees operating from 29 countries, Timken makes the world more productive and keeps industry in motion. Timken India Limited, a subsidiary of the Timken Company, started its
operations in 1989. In order to cater to the growing market, Timken has subsequently set up a manufacturing facility in Chennai in 2008. The Timken Technology Centre in Bangalore is one of the four Timken innovation and development centers around the world, which provides its customers a unique opportunity to access global pool of engineering expertise and the latest technological advancements. In India, Timken has launched its first Gear Service facility outside of the United Sates, in Raipur. With a shop area of 33,000 sq. ft. and spread over 2 acres, this dedicated facility supports all servicing and repair requirements of large industrial gearboxes apart from offering a host of key services that address the gearbox needs of every customer.
mechanical power transmission components, and related products and services. In Bearings, it offers Tapered, Cylindrical Spherical, Ball Bearings, and Revolvo Split bearings. Under Power Transmission, it offers Gears, Chains, Gear Drives, Housed Units, and Couplings. Some of the allied products offered are Seals, Condition Monitoring Systems, Lubrication, Lubricators, and Augers. The company also offers a range of Industrial Services & Solutions which include Bearing Repair, Reliability Inspection, Chock and Roll Repair, and Gear Drive Repair. - P. K. Balasubbramaniian
For more information, Website: www.timken.com
Wide Product Spectrum
Timken offers a full portfolio of bearings,
Timken’s Gear Service Facility in Raipur
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Machine tool automation Machine calibration
Additive manufacturing / 3D printing
Material analysis
Gauging
Motion control
Dimensional measurement
Renishaw has supplied manufacturers in India and around the world with products that help to make products in less time, with more accuracy, higher levels of productivity, and with less waste. Today, our engineering and science based technologies are used in applications as diverse as jet engine, TV and solar-panel manufacture, through to 3D printing, dentistry and brain surgery. Contact one of our 6 Indian offices to find out more.
For more information visit www.renishaw.com
Renishaw India G.K Arcade, 3rd Floor, #125/1-18, T. Mariappa Road, Jayanagar 1st Block, Bangalore 560 011 T +91 80 6623 6000 F +91 80 6623 6060 E india@renishaw.com
www.renishaw.com
TECH PROFILE
FIBRO Gas springs
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he extensive range of FIBRO Gas springs constitutes an ideal supplement to and expansion of the traditionally used spring elements such as helical springs, disc springs and elastomer units. With their minimal space requirement, Gas springs close a gap where ever the accent is on accommodation of the utmost force component within a minimum of space or where exceedingly large travel is demanded. FIBRO Gas springs take care of both demands, even in combination. Their self-contained nitrogen charge
makes FIBRO Gas springs completely autonomous devices. Feeder pipes or storage vessel are not required. FIBRO gas pressure springs â&#x20AC;&#x201C; Safety comes first!
Safety and reliability are the highest priority at FIBRO. This particularly applies to our gas pressure springs, which are subject to the pressure equipment directive. Equipped with unique and innovative safety features, such as over stroke, return stroke, and overpressure protection, our gas pressure springs
are the only springs on the market that consistently fulfil the highest safety standards as well as the requirements of the BAK requirement specification. When analyzing the risks of what could happen when using a gas spring, three failure possibilities have been identified; Over-Stroke (S > Max), Over-Load (V>Max) and Over-Pressure (P>Max). During the years these features have been implemented in our gas springs to increase the safety level. Important: Always be sure you are using a FIBRO original product. In particular tools from China are often equipped with plagiarism of FIBRO gas springs, whereby you as buyer enter into a liability risk and risk of damage. This could put your employees and customers at risk. If you should experience such a case, we are on your side! For more information, Website: www.fibro.com
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CASE STUDY
Flying success with Dunlop Aerospace Braking Systems
Dramatic reductions
Andrew Cartledge, team leader of the hub and flange cell, speaks positively about the decision to employ Renishaw probing systems, “We’ve seen improvement both in machining cycle times and the overall set times every time we’ve introduced a component to the cell. This is critical to our New Product Introduction process (NPI) which we use every time a new wheel is introduced, essentially allowing us to ‘design for manufacture’.” Runners, repeaters and one-offs
Orders for wheels fall into three different categories according to the number of batches made each year. The ‘runner’ orders are classed as those wheels produced in more than 10 batches year; ‘repeaters’ less than Executive jet awith Dunlop wheelsare and brakes 10 batches a year. Dunlop Aerospace also supply one-off orders and recently succeeded in a very impressive project to re-manufacture components for the 1950s Canberra. This involved taking original drawings and re-programming the machining through the modern CNC process. Mr. Cartledge continues, “NPI involves a process we call Manufacturing Process Approval (MPA) whereby any machining process must be closely analysed to see if it affects the stresses and component strengths of a wheel assembly. All the main ‘runners’ and any ‘repeaters’ that are introduced to the new cell need MPA before production can start.”
Dunlop Aerospace Braking Systems, a part of Meggitt plc, is a global organisation that designs, develops and manufactures wheels and brakes for commercial and military aircraft applications. Aircraft production in the UK has experienced steady growth and to meet this demand the hub and flange cell at Dunlop Aerospace purchased 3 key CNC machines between 1998 and 2000, at that time actively specifying Renishaw probe systems. This has increased process consistency and has also had a marked effect on the manufacturing time. 42
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Investment in technology & automation
Between 1998 and 2000 Dunlop Aerospace chose to spend nearly £2 million on three state of the art multiaxis CNC machines; a multi-axis Mazak Integrex - a turning centre with full C-axis and driven tooling to give milling capability; a Mazak HV800 5-axis horizontal machine centre; and the
CASE STUDY www.mtwmag.com
Turret-mounted probe on Mazak Integrex setting the coordinate system by finding the position of a pre-drilled hole Wheels for a long distance executive jet most recent investment, a Mori-Seiki MT4000, at the time the first of its type in the UK. Probe systems make all the difference
The underlying technique made possible by the integration of the probe systems is the ability to identify the component position and material condition, updating and monitoring the deviation in the wheel forgings. This reduces cutting time, as it eliminates fresh-air cuts - this is because the probe ensures that the critical surfaces of forgings are accurately located and metal cutting starts immediately.
Turboprop passenger plane with wheels and brakes supplied by Dunlop Aerospace
The importance of one hit machining
During the cutting process stresses are relieved in the material, so one hit machining results in the cutting process achieving greater consistency. L77 aluminium is the most commonly used material and, with the high cost of each process, it is essential that Dunlop Aerospace keep scrap levels low. In-process monitoring and tool offset updating ensures process control and minimises scrap. The nature of the aviation industry demands ever-increasing accuracy and quality, ensuring both wheels and brakes can be reliable in all conditions and scenarios. Mr Cartledge sums up the changes to the process neatly - â&#x20AC;&#x153;We
Spindle-mounted touch probe setting the machine coordinate system relative to existing machined features, ensuring machining starts in the right place every time have now used probing systems on this cell for over 6 years and have cut costs and times, with a step change in process control and consistency.â&#x20AC;?
a strong history of innovation in product development and manufacturing. Since its formation in 1973, the company has supplied leading-edge products that increase process productivity, improve product quality and deliver cost-effective automation solutions. A worldwide network of subsidiary companies and distributors provides exceptional service and support for its customers.
About Renishaw
Renishaw is an established world leader in engineering technologies, with
For more information, Website: www.renishaw.com
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TECH TRENDS
Robotics in machine tending By Arjun Prakash, Director, Effica Automation Ltd., Coimbatore
T
he advent of continuously falling prices in electronics and power electronics combined with the ever increasing cost and scarcity of labour has certainly pushed us into the age of robotics. The fact that China, a country where all economic factors were identical to that of Indiaâ&#x20AC;&#x2122;s in the 1980s and a country that was known in the past decades as the worldâ&#x20AC;&#x2122;s manufacturing hub due to its low labour costs, is today also the worldâ&#x20AC;&#x2122;s largest consumer of industrial robots. This itself is a proof that we have already entered the age of robotics. They say people should think and machines must work. The youth of our country certainly have great aspirations and a job as menial as pick and place certainly does neither inspire them nor provide enough value addition to the end product to justify a fat paycheque. This is where robotics fits in with machine tending. Most CNC machines installed in India are typically used for mass production where a few variants of the same type of part are manufactured for long periods of time with no changes in design or dimensions. A CNC machine operator typically even with some knowledge of programming the machine is reduced to the task of loading the machine and
Part stacking magazines for various types of components
unloading the machine. This is certainly a waste of talent. Robotic machine tending
Robotic machine tending is the process of loading and unloading components for all types of industrial machines including CNC machining centers. The greatest advantage that is derived in the Indian context is the increased uptime from the CNC machine. Industrial Robots are generally not much faster than the human counterparts when they are timed on a single operation. But practically when you factor in human fatigue,
Multiple CNCs machines can be handled based on cycle time. 46
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refreshment breaks, inefficient night shifts and absenteeism in India, Robot users experience as much as 30 percent increase in machine uptime. In projects where one robot caters to 3 CNC machines, this is equivalent of getting one more CNC machine. With robotic machine tending solutions in India falling below CNC machine prices, this translates to instant breakeven from machine uptime alone. The manpower savings is completely a bonus. This is of course only true when factors like machining cycle time, CNC machine cost, payload and required reach permit it, but in most cases a major portion of the breakeven is achieved from the machine uptime alone. But of course this does not mean that implementing a robotic machine tending project is as simple as writing out a cheque. There are many technical considerations that need to be given careful thought and analysis. First, if a robot loads a CNC machine without human intervention, then we need to have a part stacking system so that the robot can operate at least a few hours without human presence before the entire stack is replenished again by a human. The same hold true
TECH TRENDS www.mtwmag.com
at the unloading side, where machined components have to be emptied time and again. Since robots programmed to pick or place the component at fixed location within a few microns accuracy and with the correct orientation to grip, the part stacking magazines need to be designed in such a manner that they accommodate the part. This can often be a challenge with castings and other molded products where flash is a hindrance. The shape of the product is also a consideration where it is not possible to stack in the correct gripping orientation with good volumetric efficiency of stacking. This is important as robots have a predefined reach. The other big hindrance can be the presence of burr after the machining operation. Burr is normally cleaned using a hand operated air gun manually. This can of course be automated by fitting an air jet on the robot, but the cycle time lost due to that should be kept in mind. If there is a possibility to fit permanent air nozzles close to the chucks and fixtures inside the CNC, where burr is typically a hindrance to the process, then it should be preferred. But sometimes even this does not solve the problems. In some types of steel and aluminium burr formation is often long coils and this gets stuck in chucks and fixture where heavy force
is required to clear it. This should be solved either by tool geometry design (Chip breaking inserts) or by poke-yoke deflectors before the machine tending project is taken up. Gripping in CNC machine tending is a straight forward process most of the time. Various types of two jaw and 3 jaw grippers are available. 3 jaw grippers are suitable for ID and OD gripping and 2 jaw grippers are suitable to hold long shafts. But again casting burr will lead to improper centering in 3 jaw grippers. This is a problem when the chuck center does not align with the part center. Even if sufficient clearance is provided in the chuck opening , enormous forces are subjected upon the robot wrist as the robot tries to resist the pulling related to the offset. This can be overcome using an offset compensator device.
Burr can sometimes be a serious hindrance to automatic machine tending
A typical compliance unit to compensate for component offset with respect to chuck Other considerations
Other considerations to be factored in are to ensure the safety of human operators. Since robotic accidents can even be fatal, it is important to completely cordon off the area with safety fences. Despite this, human access will be required, in the form of refilling and emptying magazine stacks. CNC machines also require frequent tool offset resetting and other minor changes. Doors and other openings need to be interlocked with safety switches and sensors. Conclusion
A complete robotic cell tending to two CNC turning centers
Finally having invested a great deal on the CNC machines and the machine tending project, it is always good to give some more thought to optimize the areas that tend to slow down the entire process. Non-machining activity like door open / close, chuck open close and where applicable tail stock and other accessories must be optimised for automatic operations and their speed can be considerably increased as sensors can be used to interlock their operation and prevent collision. The process of tool offset resetting should also be automated where it is very frequent, as no human should be present in an automated cell with 2 or 3 CNCs and one robot, or else the entire cell will come to a standstill while fixing one machine.
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TECH TRENDS
No room for complexity
P
ramet’s high feed Penta HF cutter offers a highly versatile and simplified milling option for multiple applications. Designed primarily for high metal removal operations, the Penta HF is suitable for machining a wide variety of materials, including corrosion-resistant steels, difficult-to-machine steels and heattreated steels. The cutter features a 19° entering angle, enabling a maximum feed per tooth of 3mm. By supporting faster feed rates, machining time is reduced. In addition, a special surface finish promotes increased corrosion resistance, as well as reduced wear and friction resistance. With its economical five cutting edge inserts design, the assortment is
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suitable for roughing to semi-finishing applications. Penta HF also supports internal coolant for deep milling and helical applications. A wide range of diameters from 32 – 100mm, as well as a choice of shank and bore styles, offers a number of options for the user. In a recent case-study in North America, the Penta HF cutter with PDMW inserts was able to machine an entire component of structural steel without stopping to index the inserts. This compared to a competitor’s insert, which needed to be indexed three times to complete the same application, provided a significant saving on machine downtime. Website: www.dormerpramet.com
TECH TRENDS
Software version 4 provides new, user-friendly features TNC 640 with New Highlights By Abhilash Tripathi, Associate Director (Sales & Service), Heidenhain India Since its market launch, the TNC 640 has increasingly been becoming the first choice for high-end controls with efficient and highly precise milling operations. Why? Because it makes milling so simple, because HEIDENHAIN has expanded its functions in a practical, userfriendly way with a keen sense of workshop needs, and because in addition to milling it also enables turning on the same machine.
T
he new features of software version 4 currently being dispatched for the TNC 640 range from the programming and simulation of operations directly on the machine to setup and configuration, as well as many machining functions. This makes milling even more simple, safe and precise. Operators also program for turning operations just as simply as for milling. The TNC 640 masters both forms of machining without complex switching over.
3-D simulation graphic with a host of benefits
The most extensive new feature is certainly unique, true-to-detail 3-D simulation graphic functionality. This helps the HEIDENHAIN TNC 640 operator to identify missing information or inconsistencies in the program prior to machining, and without any risks to workpieces, tools or machines. It displays the workpiece at random viewing angles and simulates both milling and turning
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operations in a single view. Not only cuboids are displayed but also cylindrical forms such as cylinders, tubes and rotationally symmetric blanks. During simulation, several new view options expose a precise and freely selectable view of details. The graphic simulation is so detailed that the machine operator is able to identify undesired machining effects from NC programs, such as sub-standard surfaces, at an early stage. With maximum 3-D simulation resolution, the control can also display the block end points with corresponding block numbers in the display of tool motion as a 3-D line graphic. With externally created NC programs generated with CAM systems this facilitates the analysis of point distribution and pre-evaluation of the expected surface. The operator can choose to view only the workpiece, only the tool paths or both simultaneously. Views also enable display of the original workpiece blank dimensions as a frame with highlighted main axes, or with the workpiece edges as lines for improved spatial perception. The â&#x20AC;&#x153;transparent workpieceâ&#x20AC;? view option also enables a view of inside machining, even with rotationally symmetric workpieces. Color highlighting of the workpiece with a new color used for each new tool helps the operator to identify individual work steps and makes it easier to assign the tools used. The operator can also display the tools either completely or transparently and of course hide these at any time. Several advantages are provided for the operator by 3-D simulation on the TNC control. For example, he can rapidly and simply run through machining programs created on the machine. But simulations
on the control are also highly useful from programs he adopts from CAD/CAM systems, because the 3-D simulation graphic of the TNC 640 takes into account the kinematics model saved on the control, optimally modified according to the actual machine tool geometry, to realistically simulate machine movements. Milling and turning in one setup
Does your workpiece, after complex milling operations, also have to be set up on a lathe for further machining? Here the TNC 640 helps you to save a great deal of time! A milling/turning machine equipped with the TNC 640 machines the workpiece in one run, combining milling and turning in any sequence. For this purpose, the control simply alternates between turning and milling mode according to the program and completely independent of the machine and axis configuration. During switchover, the TNC 640 assumes all necessary internal changes (such as switching to diameter display, or setting the datum in the center of the rotary table), as well as machinedependent functions (such as clamping the
The new 3-D simulation graphic: displays that are rich in detail focus on undesired effects
TECH TRENDS www.mtwmag.com
Turning and milling in a single setup: the TNC 640 alternates between machining modes as desired according to the program
Always supplying the right values: the context-sensitive cutting data calculator of the TNC 640
tool spindles). In this way the TNC 640 not only saves space as well as money for an additional machine, but thanks to doing all operations on a single machine, it also avoids inaccuracies possibly caused by workpiece rechucking. The operator can create turning contours as usual in the HEIDENHAIN plainlanguage dialog, and he also has contour elements such as recessing or thread undercutting as well as cycles for turning shoulders, recessing, contour machining and thread machining. He can also use FK free contour programming to easily create contour elements or simply import contours in DXF format with the help of the DXF converter. In more sophisticated contour turning cycles, the TNC 640 uses the same techniques as used for milling. Here, too, there is no need for the TNC programmer to learn new ways of programmingâ&#x20AC;&#x201D;he build on what he already knows and quickly find his way into the world of turning on a milling machine. Another highlight of the TNC 640 is the blank form update feature. Based on the defined blank, the control calculates the newly created intermediate product with each step to adapt the following machining cycles accordingly. This avoids air cuts and optimizes approach paths.
importance. The latest software version 4 simplifies program creation and input of technology data on the TNC 640. With the contextsensitive cutting data calculator, the operator can calculate spindle speed and feed rate for the specific machining process and transfer these values directly into the open feed-rate or shaft-speed dialog. The calculator recognizes the open dialog window and automatically asks only for the required input data. Face milling cycles, of course, have long been a part of the performance range of HEIDENHAIN TNC controls, although this does not mean that familiar features cannot be improved. For example, a new face milling cycle enables the definition of up to three sides for limiting face machining on side walls or shoulders. For corners between by adjacent sides, even the corner radii can be specified as desired. Faces can be milled with various machining strategies: meandering, line-byline (with or without overrun) or helically. Operators can also specifically define the machining direction, for example for directing the operating pressure against the fixed vice jaw. In addition to such expansions and optimizations, many other detailed improvements have also been integrated that are too extensive to describe here. The new software version 4 for the TNC 640 converts a wide range of customer requirements into workshop-oriented solutions.
Optimized motion control for clean surfaces and perfect contours
An insufficient quality of data in NC programs frequently causes an inferior surface quality of the milled workpieces. The Advanced Dynamic Prediction feature (ADP) expands the previous look-ahead of the permissible maximum
Achieving maximum contour accuracy and surface quality - machining without (above) & with Advanced Dynamic Prediction (below) feed rate profile, thereby enabling optimized motion control of the feed rate axes with 3-axis and 5-axis milling. In this way, clean surfaces can also be milled with short machining times on contours characterized by strong point distribution deviations in adjacent tool paths. The control dynamically calculates the contour in advance and can therefore use acceleration-limited motion control with smoothed jerk to adapt the axis velocity at contour transitions in good time. ADP shows its strengths for example during bidirectional finish milling through symmetrical feed behavior on the forward and reverse paths as well as through particularly smooth feed rate curves on parallel milling paths. Fine tuning with attention to detail
The TNC 640â&#x20AC;&#x2122;s quickly understandable user interface ensures an even better overview during programming and setup. The individual screen areas are clearly distinguished and the operating modes are indicated by unambiguous symbols. Value inputs, comments and syntax elements are color-highlighted, and error messages are categorized with colors according to
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TECH TRENDS
The Invisible Influence by Rushil Shah
Electrostatic solutions from Meech are designed to answer the requirements of increasing line speeds and the usage of more and more synthetic materials.
S
tatic electricity causes problems in terms of productivity7, quality and safety in a whole range of different industry sectors because attraction or repulsion may cause dust pollutions or errors on the product. “A multitude of factors such as air, humidity, material
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and temperature changes influence the emergence and stability of electrostatics,” explains Ralph Simon, area sales manager, MESA at the British anti-static and web cleaning experts Meech International. “Plastic films, especially, can contain charges over long periods of time due to their high resistance.” Every time the elementary structure of the plastic material changes, an electrostatic charge is created that automatically leads to problems within the working area. “With stricter accident protection guidelines, requests for more efficiency and cost savings, as well as higher demands by consumers, manufacturers need to get a grip on their electrostatic issues,” continues Simon. “For these
necessities, we have worked out innovative solutions that are often adapted to the specific needs of the individual customer.” Static in flexible packaging
If static energy is present, problems may arise in the production processes especially with synthetic products such as PE, PP and PS. The risk of contaminating the final product rises significantly and sparks may cause severe injuries to operating personnel in hazardous areas. Contamination affecting the print quality is one of the main reasons for high waste rates, especially within the food, pharmaceutical and medical industries where high quality packaging
TNC 640 â&#x20AC;&#x201C; The new High-End Control for Milling and Turning Operations The new TNC 640: for the first time, milling and turning are combined in one TNC. Now users can switch as desired between milling and turningâ&#x20AC;&#x201D;within the same NC program. Switchover is independent of the machine kinematics. It automatically takes the respective operating mode into account and without any additional action.This new simplicity is complemented by dialog-guided plain language programming, the optimized user interface, powerful programming aids as well as comprehensive cycle packets taken from amply field-proven HEIDENHAIN controls into the new TNC 640.
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
TECH TRENDS
is absolutely necessary. Meech highly recommends the usage of electrostatic control in production environments. How technologies for electrostatic discharging and charging are used in today’s industries is illustrated by the following examples provided by the experts at Meech. “Digital printing lines in the label industry should definitely be free from electrostatic charges,” says Simon. “A massive static charge may be created by the unwinding of coated Paper or film from a roll. These charges are capable of attracting dust onto the web within a diameter of several metres, which is especially counterproductive if the material is located close to the ground.” As soon as the dust has touched the paper, printing quality can be affected in a negative way. Another fact one should consider is that high static charges lower the adhesion of inks on the material surface, thus decreasing product quality. Such a scenario does not only lead to higher production costs but al so slower production speeds. In the rewinding process, even small amounts of electrostatic energy may cause significant problems due to the so-called ‘battery effect’. Besides high dust attraction, this phenomenon is capable of shocking the operator, causing fires or damaging equipment. Advantageous charges
On the other hand, electrostatic charges may also be beneficial within a production line. “In the production of plastic bags, for example, charges are advantageous when they are applied in small amounts onto the punched-out parts,” underlines Simon. “By means of the adhesion of the handles, electrostatic energy makes sure that the bags do not fill themselves
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with air. At the end of the production line, static electricity is used to tack the bags together before winding them u0p. Consequently, the size of each roll can be reduced by 30%, thereby lowering later transportation costs. Companies like Meech have recognized the problems associated with electrostatic energy for many years and since then raised awareness within the applicable industries. Ionisation bars are the most well-known products to control the physical phenomenon. “One of our latest innovations enables operators to supply ionization bars with supply unit,” reports Simon.. “Moreover, it offers surveillance of the ion current by measuring the performance of the bar and sending out an alarm signal to the operator if it needs to be cleaned.” While the standard version of the bar is reported to deliver an outstanding electrostatic control in most s=applications, more complex installations require an absolutely exact discharge. This is enabled by an enhanced version with integrated distance measurement and cycle feedback system. Another new model supplied by Meech is a ‘plug and play’ bar with ion current surveillance, which triggers an alarm if the performance is lowered and the bar needs to be cleaned. This bar is suited to applications with short to medium range (up to 450 mm). The original parameters can be changed by the operator on a programming device in order to match machine requirements. This is especially advantageous for applications demanding a high degree of exactness such as RFID processing lines. Moreover, the bar can be used in environments where spray water may occur, for example as in food packaging lines.
The author, Mr. Rushil Shah is Managing Director at Shavo Technologies Pvt. Ltd.
TECH TRENDS www.mtwmag.com
PECM from EMAG: Move into the Fast Lane in Blisk Machining Blisk (bladed disk) volumes in aircraft production are increasing massively. Large engines now have several of these high pressure compressors which are manufactured from a single piece of high performance, often exotic alloy materials. The efficient machining of these materials is therefore becoming a focal point for project planning with a wide range of potential methods and combinations thereof available, from mechanical cutting to water jet cutting. A recent study by the Fraunhofer Institute for Production Technology (IPT) and the Laboratory of Machine Tools and Production Engineering (WZL) at RWTH Aachen (Germany) has now shown that Precise ElectroChemical Machining (PECM) from EMAG drastically cuts costs for users, particularly for dressing the component surface.
Richard Keller, member of the Board of Directors at EMAG ECM GmbH: â&#x20AC;&#x153;PECM technology can significantly reduce the costs of blisk machining. EMAG can supply a wide range of machines for this purpose which can be tailored individually to the machining requirement.â&#x20AC;?
C
omponents inside an aircraft engine are exposed to extreme stresses, high temperatures and long service lives. Developers, therefore, use very hard, heat-resistant materials such as nickel-based super alloys for the construction of blisks and disks with single blades. This development presents a range of problems to manufacturing engineers, since conventional cutting methods become uneconomical as the material hardness increases and the service life of expensive tools drops, therefore causing unit costs to rise. A recent study by the specialists at Fraunhofer IPT, together with WZL and EMAG ECM GmbH, compared a total of seven different blisk machining strategies, from multi-axis milling, combined with polishing to high pressure water jet cutting combined with PECM dressing.
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TECH TRENDS and hardware interfaces and efficient automation solutions. Components certified for practice
The results are impressive: for an assumed production volume of 800 nickel-based HPC blisks, the unit costs can be reduced by more than 50 percent compared to mechanical cutting if users adopt the correct machining strategy. PECM dressing proves to be the essential final process to make radical improvements to the efficiency of the production process. (see info graphic) Gentle material removal – fast processes
In view of this, the PECM technology supplied by EMAG ECM based in Germany is currently being studied very closely by many OEMs and their suppliers. The electro-chemical process removes material without contact and causes minimal tool wear while being fast and reliable. The basic principle is simple to explain: during the process, the workpiece becomes the positive anode and the tool the negative cathode. An electrolyte solution flows between them, removing metal ions from the workpiece. The form of the cathode (tool), with its active, conductive zones results in material removal from the workpiece at the required component contours. Ring ducts, grooves, bell hollows and other contours can be produced without contact, but with very high precision and excellent surface quality. With their PECM technology, the experts from EMAG ECM have developed this process in a targeted manner and tuned it to perfection. Two factors play a major role in this: firstly, the gap between the workpiece and tool, through which the electrolyte solution flows, is particularly narrow. And secondly, the supply of electrolyte solution is enhanced by a mechanical oscillation motion. Both factors together ensure that that material removal
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is even more effective and precise. From single turbine blades to the blisk
EMAG ECM has two machine types for the different machining tasks of engine production: while the small model PO 100 SF is designed for machining single turbine blades, the larger PO 900 BF is for machining the complete, and therefore much larger, blisk. The systems differ in machining area size, footprints, generator capacity and the number of machining axes with precise PECM technology and EMAG high performance components available in both. “We launched the PO 900 BF in 2011 for blisk machining. The PO 100 SF development was the second stage in 2013 when an ever increasing number of customers demanded an electrochemical machine solution for single blades. We now have an ideal basis for the development of precise, cost-efficient production solutions for small and large engine components,” says Richard Keller, member of the Board of Directors at EMAG ECM GmbH. Both these machines also provide the user with central EMAG innovations such as a Mineralit® polymer concrete machine base, intelligent software
This method has already been implemented into actual production with top results. For example, a well-known engine manufacturer has already certified single blades made on the PO 100 SF for use in aircraft in 2014 – unusually quickly after the start of production of the machine at a supplier’s plant. A similar stage is currently pending for blisk production. Components from a whole host of engine companies are currently in the qualification phase for use in practice. “The technology is currently in the validation phase in a number of test programs” states Keller to sum up the current work of EMAG ECM. “The longterm strategic focus on these components and application technology is proving successful and each additional certification of components manufactured with PECM will only boost our sales success.” The geometric machining precision is one of the main factors behind the technology’s success. In addition, it produces high surface quality with low peak-to-valley heights. Subsequent finishing processes on the blades, such as slide grinding, are therefore no longer required or can be completed much quicker – both of which result in a further reduction in unit costs. This is a massive plus point for a component which is becoming ever more important and whose volumes are rising massively. Webdite: www.emag.com
Participate in the Regionâ&#x20AC;&#x2122;s best Machine Tool Exhibition
Book your stall today
TECH TRENDS
ANCA FX Series CNC Tool & Cutter Grinding Machine
T
he FX Linear includes a significant number of importantnew technology releases and a complete body redesign that is both aesthetically pleasing and technologically beneficial The range is ideal for everything from light manufacturing, to regrinding and even full production. It can grind tools up to a diameter of 200mm (7.8”). Many new noteworthy features have been included in the range to make an operator’s work easier. These include a new touchscreen customisable with Windows, handheld pendant for easier set-up and an easy to access loader door for slide out pallets. The FX Linear machine is compact but also has a larger working envelope. It of course benefits from ANCA’s 40 years of experience in designing tool grinders and developing user-friendly, versatile Tool Room software. Every part on the machine, from the positioning of the grinding wheel on the C-axis centreline
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to reduce thermalinfluence, to the ANCA designed linear motors, have been designed to enhance accuracy, increase productivity and make the operator’s day easier.
have some drawbacks when usedwith tool grinders. A cylindrical design overcomes these drawbacks which iswhy ANCA developed this particular design of Linear Motor for their new FX Linear range.
LinXLinear Motors
Performance: The FX Linear range uses ANCA LinXLinear Motors for axis motion (X & Yaxes). In conjunction with linear scales, a high level of machine precision andperformance is able to be achieved,resulting in superior tool accuracy and surface finish. With LinX Linear Motors there is no loss of machine accuracyover time due to wear and it is notaffected by temperature variations. ThLinX Linear Motor has higher axis speedand acceleration leading to reducedcycle times. It achieves this whilemaintaining a smoother axis motion.
Reliable: The cylindrical LinX Linear Motors experience less wear as there areno contacting parts. They have beenspecially designed for a lifetimeof operation in harsh grindingenvironments. As the magnetic field iscylindrical there is no additional downforce on the rails or machine base.
Unique Cylindrical design: Existing flat bed type of linear motors can
Does not need a separate chiller unit: The LinX uses less energy than an
Rated to IP67 : With the unique cylindrical design the LinX Linear Motor is sealed toIP67. This sealing keeps out grindingcontamination helping to extend the lifeof the linear motor.
TECH TRENDS www.mtwmag.com
equivalent flat bed style linear motor and has the same power consumption as a ball screw system but with moreefficiency. The design of the motor also naturally isolates any heating effectsfrom the machine. Because of thisreduced heat load the LinX does not need a separate chiller unit anduses the machine’s regular coolantsystem reducing required floor spaceand power. An affordable first step into CNC tool grinding, or an economical, good quality basic machine.
Whatever your needs this machine provides thekind of technology and rigid accuracy not usually available at this price. Enhanced AccuracyUpgraded TechnologyFX5 Linear 1 Spindle Design – HSK40F taper provides increased rigidity and accuracy for improved tool surface finish results 2 C-Axis Pivot Point – as the grinding wheel is positioned on the C-axis centreline axis motion is reduced which is ideal for bullnosegrinding to ensure accuracy is maintained 3 Easy Machine Access – ergonomically designed for the operator. Easy access to the headstock workholding, wheel pack andspindle for quick set-up and job change-over. 4 Wheel Changer – Options for 2 and 6 stationwheel changer for maximum flexibility andproductivity Software
ANCA’s versatile software is what sets ANCA and itscustomers ahead of the competition. ANCA has 40 years of tool grinding experience and is well-known for its userfriendly and flexible tool design software. ANCA’s Tool Room software suite caters for a wide range oftool types and applications with an easy-to-use interface toinput tool geometry parameters. Toolroom ensures that the FX Linear machines will efficiently handle any regrinding ormanufacture challenge. The machine operator is able to easily and quickly set up or modify tool programs, depending upon the required tool type.For more proficient users, advanced software pages exist toaccess complex tool designs and operations.Toolroom supports the grinding of drills, end mills, profiletools, burrs, routers and many other special applications.
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TECH TRENDS
GROB Group - Competence in worldwide advanced technology
A
s a global player in the development and manufacturing of machines and production lines, the GROBWERKE heart beats in Mindelheim, Bavaria since 1968. Our customers include the world`s most prestigious car manufacturers, their suppliers and many other renowned companies from various industries. With our production plants in Mindelheim (Germany), Bluffton, Ohio (USA), SĂŁo Paulo (Brazil) and Dalian (China), and worldwide service and sales subsidiaries, we are represented around the globe. The product portfolio ranges from the universal machining center all the way through to highly complex production systems with individual automation, and from ancillary assembly machines in the machining process through to fully automated assembly lines. Our know how in designing production systems combined with state-of-theart technology, enables Grob to offer solutions for high volume production. Those solutions are individually designed to meet the specific customer needs. The production systems mainly consists of modular machining centers and specialpurpose machines, interlinked with the latest automation solutions. With its universal machines, GROB has for the first time in its successful machine building history introduced a standalone machining center which proves the technological know-how and developing competence of the GROB engineers in this market segment, which is relatively new to the company.
G-modules. Beside these machines GROB also offers an Asian series in two different sizes, GA350 and GA550. These machines are based on the successful G350 and G550 universal machines series and are made in Dalian according to German quality standards. As all modules from the G-series, they originate from the same modular construction system, are characterized by their compact design and enable excellent visibility and best accessibility to the work areas. GROB 5-axis universal machining centers stand out due to their absolute precisionand reliability in the automotive, medical and mechanical engineering industries,in tool and mold making as well as in the aviation industry. The GROB engineers completely revised the drive concept in the workpiececarrying NC axes â&#x20AC;&#x201C; A and Y â&#x20AC;&#x201C; to improve the performance of the G350 and G550 machines. In addition to the B-axis, the A-axis is also equipped with a non-wearing torque motor, effectively doubling acceleration. The Y-axis drive relies on two ball thread drives arranged symmetrically relative to the centre of the A-axis, and their force application points have been moved considerably
towards the TCP (Tool Centre Point) to significantly increase both the static and the dynamic rigidity of the workpiececarrying machine assemblies. This advantage could already be demonstrated in a practical test, in which the 5-axis simultaneous processing main time was reduced. Higher degree of accuracy especially for tool and die construction
Customers of the G350 and G550 universalmachining centers demand anincreasing degree of workpiece accuracy,especially in the tool and die sector.To meet these demands the GROBengineers have evolved a multi-levelapproach for the electronic compensationof geometric and thermal displacement. The basis is the volumetric compensationof shifting of the tool touchpoint in the working area supplied byleading control system suppliers. EachNC axis can be corrected in the threetranslatory and rotational directions ofmovement specifically for any machiningposition in the space. It is importantin this context how the universal databaseis supplied with
5-axis-technology for a broad range of applications
The universal machining centers G350, G550 and G750 successfully complement the G-series and open up an even larger application range for the existing
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GROB 5-Axis Universal-Machining-Centers
TECH TRENDS www.mtwmag.com
Unique machine concept
information. This isa central question on which GROB engineershave focused on in detail.As a first step a measurement strategywith a probe was used to optimize thegeometric basic alignment in the assemblyprocess. This geometrically alignedmachine then undergoes a second measurementoperation with different tableloads up to the maximum workpieceweight. The generated correction dataare saved as a so-called weight compensationin the control unit and subsequentlyused in the NC program. Assignmentto the actual workpiece weightis carried out automatically by evaluationof the holding current in the verticalY-axis. The third component serves toincrease the machine accuracy to compensatefor thermal displacement. This ismeasured at the GROB plant for the individualmachine types and then saved inthe control system where it can be activatedby the user.
G750 â&#x20AC;&#x201C; top end of the range
After the successful introduction of the G350 and G550 universal machines in the market in recent years, it was only a question of time until GROB would enter larger dimensions with this innovative machine concept. The G750 rounds off the G-series at the high end. The G750 has an outstanding working area of X, Y, Z 1,000 x 1,100 x 1,170 mm. This means that large workpieces from mould making, the aviation industry and general mechanical engineering can be processed ideally.Like all G-modules in the universal machine segment,the access to the working area of the G750 is generously designed.
can be extended to 212 tools with an additional magazine. Optionally, GROB also offers machines with HSK-A63 tool holder with 46 and 206Nm (40% ED), as well as a spindle with 30,0000 rpm and 63Nm. In the milling/turning version with HSK-T100 interface, the motor spindle delivers 306Nm and can be used for turning. For a workpiece diameter of 1,280mm, the turntable will allow a max. speed of 500rpm and generates a drive torque of max. 4,050Nm. The drive concept of the workpiece-carrying A, B and Y axes corresponds to that of the smaller G350 and G550 machines. The feed axes X and Z, located on the spindle side, are executed in linear motor technology. These non-wearing drives guarantee a lasting high positioning accuracy and control precision. The rigidity of the entire machine construction was optimized by means of FEM simulation, whereby the guide systems and turntable bearings are generously dimensioned.
For more information, Website: www.grob.de
Wide range of options for the G750
A hydraulics-free pallet changer can be added to the front as an option. The machine is available with the spindle versions 340 and 575 Nm (40 % ED) with a tool holder type HSK-A100. The tool magazine contains 60 tools that
Axis arrangement and drive concept - Three linear and two rotary axes permit 5-sided machining, as well as 5-axis simultaneous interpolation.
One concept for a broad range of industries e.g. tool and mold industry
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TECH TRENDS
Machining group believes in a Haas future
In the prodution area of HPF, the Haas machines work 15 hours a day, six days a week
B
ased at Flagogna, near the town of Udine, in the mountainous region of northeast Italy, HPF SpA is part of AmiL Srl, the holding company of the Lualdi family – owners of successful manufacturing businesses operating in sectors such as medical, aerospace, and automotive, since 1945. HPF specialises in the production of hot forged, thermally treated and machined metal components. Its machine shop is being rebuilt around the latest Haas CNC machine tools. As well as producing OEM products for markets such as medical and veterinary, HPF also machines parts on-demand for the aerospace, automotive, and power generation sectors, typically from materials such as titanium alloys, cobalt-based alloys, stainless steel, precipitation hardened steel, and aluminium alloys. The company also has a busy R&D department, where product development, evaluation, and testing take place. HPF uses its Haas machine tools for R&D and production tasks. Among the models on site (acquired from local
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“Recently, we carried out an analysis to determine the best brand,” explains technical director, Marco Zappa. “We discovered that Haas is the machine that gives us the best price-quality ratio, the best accuracy, and the best technical capability.”
TECH TRENDS
HPF machines parts typically from materials such as titanium alloys, cobaltbased alloys, stainless steel, precipitation hardened steel, & aluminium alloys
HFO, RF Celada Macchine Utensili SpA) are two VF-2SS Super-Speed vertical machining centres, a pair of VM-3 vertical mould-making machines, a VF-2 vertical machining centre, and four SL series lathes, including an SL-20T model. “We buy Haas CNC machine tools because they offer a good price-quality ratio,” states technical director, Marco Zappa. “The machines in the R&D department run for 8 hours every day; we try not to let them stop. If there is a gap in our R&D work, we load them with smallbatch production to avoid idle time.” In the production area of HPF, the Haas machines work 15 hours a day, six days a week, which will help fuel company growth of 25 to 27 percent in 2015, with a further 20 percent expected in 2016. “We must invest wisely, and we are trying to standardise on machine tool brands, because we currently have seven or eight different ones, and that is not good,” says Mr. Zappa. Haas machines are also in use at another AmiL group company: Lima Cor-
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porate (AmiL is Lima spelt backwards), a world-renowned specialist in reconstructive orthopaedic solutions that include large joint implants for hip and knee systems. Due to the typical complexity of such products, the Haas machines already in place at Lima include a UMC-750 fiveaxis universal machining centre, and an ST-20Y CNC lathe with Y-axis. “Recently, we carried out an analysis to determine the best brand,” explains Mr. Zappa. “We discovered that Haas is the machine that gives us the best price-quality ratio, the best accuracy, and the best technical capability – plus, the support from HFO-Celada is excellent! Our intention, therefore, is to continue with Haas, and to eventually standardise our machine shop, to make things simpler and more efficient. Haas offers such a wide range of CNC machine tools, there’s a suitable machine for everything we do currently, and everything we aspire to do in the future.” Website: www.HaasCNC.com
HPF uses its Haas machine tools for R&D and production tasks. Among the models on site are two VF-2SS, a pair of VM-3 machines, a VF-2 and four SL series lathes, including an SL-20T model
HPF, based in northeast Italy, specialises in the production of hot forged, thermally treated and machined metal components
TECH TRENDS www.mtwmag.com
Increasing Die & Tool Life using Japanese Cold-Welding Technique
D
ie, mould and tool wear are major reasons for production downtime and increased costs in most industries. Apart from using strong base metals for making dies, a few effective treatments can be administered to dies to increase their service life. Even if possible, such treatments are not feasible for all metalforming units. This article introduces a practical and economical technique to increase die, mould and tool life. The technique can be easily adopted by all metal-forming units, big and small. Popular treatments to increase die life
Mr. Srikar Shenoy, Director Steel Plant Specialities LLP
or repair / reclaim forging dies:
1. Nitriding
Gas Nitriding / Plasma Ion Nitriding are popular surface hardening treatments carried out on dies. With an initial die hardness of 42 HRC, the nitriding process can further harden the surface of die up to 64 HRC. Many large forge shops in India carry out nitriding of 100% of their forging dies. However, very few forging companies have an in-house nitriding facility. Nitriding is found effective in many cases. The skill of the nitrider, flawless nitriding facility and process play a vital role in the success of this technique. Nitriding is also a capital-intensive technique and not many companies can afford the finance, space and skilled workforce to set up an in-house nitriding
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TECH TRENDS in dies is carried out. Flood welding of the dies is also carried out to completely reclaim the dies. However, this technique also poses its own limitations: Limitations of Conventional Welding: 1. Requirement of skilled welders 2. Requires open space or effective ducting for carrying out welding operation 3. Time consuming process as forging dies must be taken to welding area 4. Pre and post welding heat treatment / stress relieving is necessary Usually, conventional welding is a ‘Repair-Oriented’ technique. It is carried out after the dies are damaged or worn out. New Protective Treatment to Increase Can be Used by Anyone, Anywhere
facility. Getting the dies nitrided from commercial heat treat shops is not always feasible. Finally, additional efforts are required to carry out selective nitriding and mask areas of components where nitriding is to be avoided. 2. PVD, CVD Treatments like PVD (Physical Vapour Deposition) and CVD (Chemical Vapour Deposition) are popular in the machine-tool industries in America and European countries. These techniques are yet to evolve completely in the Indian forging industry. PVD is slowly gaining share in the Indian machine-tool treatment market. It ensures surface hardness of up to 90 HRC. However, the result of PVD treatment on forging dies is not documented. Cost of PVD is approximately Rs. 800/- per kg. of metal that is treated (as on date of this article). CVD technology is not yet introduced in India. 3. Welding to repair / reclaim worn out dies Apart from the mentioned treatments, the only option available is to repair and reclaim the dies through welding. Conventionally, welding of the worn out areas of dies or welding of cracks
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Die Life: Japanese Cold Welding
A new Japanese cold-welding technique enables appropriate surface hardening of dies, moulds and tools to increase their service life. The technique involves electronic coating of tungsten carbide on selective wear-prone areas of dies/ moulds / tools through Japanese Cold Welding Technique. Cold welding is carried out as a ‘Preventive Maintenance’ technique on new dies. It is a surface hardening technique, similar to nitriding and PVD, but is administered using a completely different methodology. Hardness of tungsten carbide layer deposited by cold-welding on dies can surpass
TECH TRENDS
nitriding to reach hardness of more than 70 HRC. Benefits of Japanese Cold Welding Technology:
1. Skilled welders not required. Can be carried out by anyone 2. Open space not required. No fumes are generated during cold welding 3. Time saving process as dies need
not be removed from forging equipment 4. Pre and post welding heat treatment not necessary. No stresses are generated during cold welding as it is a cold process. Additional benefits of Japanese Cold Welding Technology:
1. Nitriding of dies not required as hardness of tungsten carbide coating is more than 70 HRC, which is higher than nitriding hardness (6264 HRC). 2. Increased die life due to high wear resistance. 3. Substantially reduced maintenance downtime of dies and tools. 4. Can be carried out on selective areas of dies that are prone to wear. Does not require the complete die to be treated/ protected. Compact Cold Welding Equipment & Applicators
Argon gas cylinder is shown in the photograph. It is recommended to be used during the cold welding process to avoid oxidation of carbide electrode.
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TECH TRENDS www.mtwmag.com Principle Of Operation:
Consumable electrode made of alloys and intermetallic compounds are deposited on the die by means of electronic spark at a frequency f 10-1 to 10-3 second for one to millionth of seconds per spark. Direct current from the power supply will heat the electrode to 8,000 to 25,000 deg. C., only at the contact areas and transfer a small quantity of electrode to the work piece under an ionized state. A strong metallurgical bond is thereby produced. Characteristics of carbide coating:
1. Wear resistant: Due to inherent strength of tungsten carbide, the wear resistance is high. If the die is hard and heat treated well, a good forging die life can be expected after carbide protective coating. 2. Heat resistant: The coating is heat
resistant and will not cause heat checks. Excessive heat leading to die wear will be prevented in protected areas. 3. Scuffing resistant: Scuffing and bruising is the initial stage of having serrations on die. This scuffing will be prevented or substantially delayed. 4. Lubricity: Many times, due to very smooth finish of new dies, the forging / casting die lubricant does not adhere to the die. This problem is not faced in the case of carbide coated dies. It is observed that die can be lubricated better than before.
Japanese cold-welding technique. Some photographs and results are given below: SUMMARY
Japanese cold welding technique of electronically overlaying protective carbide layer on metal-forming dies and tools holds promises of increased die & tool life, reduced maintenance downtime, convenience of operation and better productivity. As the concept is proven, it is a requirement in every modern metal-forming unit seeking cost reduction and increased profitability.
Successful Cold-Welding Case Studies in the Indian Metal Forming Industry
A number of esteemed Indian metal-forming Organisations have tried out carbide coating on wear-prone areas of their dies and tools using
For more information, E-mail: info@steelplantspecialities.com Website: www.steelplantspecialities.com
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TECH TRENDS
Hypertherm Introduces New Gouging Shield for Powermax Air Plasma Systems
H
ypertherm, a manufacturer of plasma, laser, and waterjet cutting systems, is now offering a new gouging shield for people wanting even greater control when gouging with Powermax® air plasma systems. This new Max Control Gouging shield is designed for jobs in which the operator needs to remove a very precise amount of metal. The tip of the shield is engineered and machined in a way that allows the operator to create a very shallow gouging profile. The introduction of the Max Control gouging shield expands the offerings of Powermax gouging consumables which includes the existing Max Removal Gouging shield and HyAccess™ extended gouging consumables. Max Removal shields are designed to remove a large amount of metal and leave a deeper gouging profile while HyAccess provides the extra reach needed when gouging in hard to reach or confined spaces. Max Control, Max Removal and HyAccess Gouging consumables are available for Powermax systems using a Duramax or Duramax Hyamp™ torch. This includes the Powermax65® through the Powermax125® and older systems with Duramax retrofit torches such as the Powermax600®, Powermax900® and Powermax1650®.
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“Hypertherm is continuously investing in market research and engineering development to ensure we meet the needs of our customers,” explains Brenda Mahoney, a torch and consumable product manager. “The end result is eleven different patented torch styles for our Powermax systems alone, plus an array of unique consumable offerings that make it easy for people to choose the right tool for each job.” Hypertherm is seeing a steady increase in the use of plasma for gouging as more companies realize the many advantages of plasma instead of alternative methods such as carbon arc. Plasma gouging allows for cleaner gouges with no carbon contamination, easier clean-up, and a safer work environment for the operator since it produces fewer fumes, creates less noise, and does not blow metal shavings back into the operator’s face. Customers who have converted to plasma gouging report operational efficiencies between three and ten times faster than carbon arc gouging which translates into a significant cost savings. Powermax customers interested in purchasing the new shield or any Hypertherm product can do so by visiting an authorized Hypertherm distributor. Hypertherm designs and manufactures advanced cutting
products for use in a variety of industries such as shipbuilding, manufacturing, and automotive repair. Its product line includes plasma, laser and waterjet cutting systems, in addition to CNC motion and height controls, CAM nesting software, and consumables. Hypertherm systems are trusted for performance and reliability that result in increased productivity and profitability for hundreds of thousands of businesses. The company’s reputation for cutting innovation dates back nearly 50 years to 1968, with Hypertherm’s invention of water injection plasma cutting. The 100 percent associate owned company has more than 1,400 associates along with operations and partner representation worldwide.
For more information, Website: www.hypertherm.com
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PROJECTS
Airport / Aviation Airport / Aviation
Mining
The airport is coming up at Mattanur in Kannur district of Kerala. The Director General of Civil Aviation has given the required clearance. The airport is likely to begin commercial operations in September, 2015. The runway length would be 3,400 metre. The work had started in 2014.
Oil & Gas
Place: Kerala
Automobile Chemicals & Fertilisers Defence Electricals / Electronics
PROJECT
Manufacturing
Railways Power
UPDATE
Transport
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Contact: K.P Jose, Chief Project Engineer, New Municipal Building, 2nd Floor Maruthai Road, Mattannur Kannur - 670702, T: 0490-2474463, F: 2474464, E: kpjose@kannurairport.in
Civil Aviation Department - Uttar Pradesh Plans to construct an international airport in Kushinagar district on a public private partnership (PPP) model spread over 569-hectares land. The state government has cleared the first instalment of Rs 80 crore for con- structing the runway.
Place: Uttar Pradesh Contact: Aryan Lal, Civil Engineer, Civil Aviation Department, Govt of Uttar Pradesh Lucknow Airport, Lucknow, UP. T: 0522–2436504, 2437565, F: 2435780, E: dsca@bsnl.in
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
Automobile Scania Swedish commercial vehicle and engine manufacturer plans to double its production capacity at its plant located in Karnataka by 2020.
Place: Karnataka Contact: Royce Roy, Manager (Marketing & Communication), Plot #63 (part), 64-66, 88-97, Naraspura KIADB Industrial Area, Achhatanahalli Village, Naraspura Hobli, Kolar - 563133, Karnataka. T: 0815-2288300, E: royce.roy@scania.com Mahindra & Mahindra As part of its expansion plan, the company plans investment to the tune
PROJECTS www.mtwmag.com
of Rs 8,000 crore on its automotive plants located at Nashik, Kandivali, Igatpuri and Chakan in Maharashtra over the next seven years. The company has signed Memorandum of Understanding (MoU) with the state government in this regard
Place: Maharashtra Contact: Roma Balwani, Sr VP & Group Head - Corp Comm, Mahindra Towers, Media Cube, G. M. Bhosale Marg, Worli, Mumbai - 400018, T: 022-24975176, F: 24900830, balwani.roma@mahindra.com
Honda Motorcycle and Scooter India Pvt Ltd Automobile major has commissioned its fourth manufacturing plant in India at Vithalapur in Ahmedabad distict of Gujarat.
scooters per annum. The unit is spread over 250 acre and got completed in 13 months.
Place: Gujarat Contact: Y S Guleria, Vice-President (Sales and Marketing), Plot No. 1, Sector 3, IMT Manesar, Gurgaon - 122050, Haryana. T: 0124-2290911-19, 2290926, www.honda2wheelersindia. com
Chemicals & Fertilisers Rashtriya Chemicals and Fertilisers (RCF) Plans to set up a new urea plant with a capacity of 1.27 million tonne per annum at its Thal unit in Maharashtra. PIB clearance is expected soon.
Place: Maharashtra Contact: S.D Pandare, GM
Place: Ahmedabad Gujarat Contact: Vibhuti Dimri, Communications and Media Relations, Commercial Complex II, Sector: 49-50, Golf Course Extension Road, Gurgaon - 122018, Haryana. T: 0124-6712800, F: 6712999, E: vibhuti.dimri@ honda2wheelersindia.com Honda Motorcycle and Scooter India (HMSI) The company has recently commis- sioned its fourth plant for manufactur- ing scooters targeting 600,000
(Corporate), 10th Floor, Priyadarshini, Eastern Express Highway, Sion, Mumbai - 400022, T: 022-25523087, 25523025, sapandare@rcfltd.com
Defence Reliance Group Reliance Group company Reliance Defence plans to set up a centre for research, development and innovation in aerospace technolog at Rambilli near Vizag.
Place: Andhra Pradesh
Contact: Daljeet S Singh, Senior Executive Vice President, Reliance Centre, 19 Walchand Hirachand Marg, Ballard Estate, Mumbai – 400001, Maharashtra. T: 022-30327000, 30345522, M: 9312014099, E: daljeet.s.singh@relianceada. com Reliance Group Plans to set up a new naval shipbuild- ing facility in Andhra Pradesh.
Place: Andhra Pradesh Contact: Daljeet S Singh, Senior Executive Vice President, Reliance Centre, 19 Walchand Hirachand Marg, Ballard Estate, Mumbai – 400001, Maharashtra. T: 022-30327000, 30345522, M: 9312014099, E: daljeet.s.singh@relianceada. com
Mahindra Group Plans to build a plant for the assembly of its M777 Ultra Lightweight Howitzer artillery guns. British defence giant BAE Systems has chosen India’s Mahindra group to build a plant to assemble howitzer artillery guns.
Place: Maharashtra Contact: Sunil Gate, General Manager-Group Communications, Mahindra Towers, Worli, Mumbai 400018, Maharashtra. T: 022-24916633,
F: 24900830, M: 9823093000, E: gate.sunil@mahindra.com
Electricals/ Electronics Havells India Ltd. Plans to set up a new manufacturing unit on the outskirts of Bengaluru. The company has eleven plants across seven locations, and its proposed plant on a 50-acre plot near Bengaluru.
Place: Karnataka Contact: Anil Sharma, Head Corporate Communications, QRG Towers, 2D, Sec- 126, Express way, Noida - 201304, UP. T: 0120-4772015, 3331000, F: 3332000, E: anil3.sharma@havells.com
Eveready Industries India Ltd. Bagged an order from Energy Efficency Services Ltd for supply and maintenance of 75 lakh LED lamps. The lamps are to be installed in Madhya Pradesh.
Place: Madhya Pradesh Contact: Ashish Poddar, EE, 2, Rainey Park, Kolkata - 700019, West Bengal, India, T: 033-30587824, 24864961
Manufacturing Rotolok India UK-based Rotolok Holdings Ltd subsidiary in India
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has commissioned its manufacturing unit at Sri City spread over 2-acre plot. The facility, equipped with the latest CNC machinery. Rotolok manufactures all key bulk solid handling equipment.
250 million tonne (mt) output by 2020. As part of this plan, new mines such as Garjanbahal and Siarmal in Basundhara area located in Sundargarh district and Gopalprasad will be opened.
for beach sand minerals like ilmenite, rutile, zircon, garnet and sillimanite over an extent of 17.88 sq km at Bhavanapadu.
Place: Odisha
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
Place: Andhra Pradesh Contact: Prassanna.V Director, Sri City, 1375 Jeedi Drive, Sector 28, Sri City, Sathyavedu mandal, Chittoor District, Andhra Pradesh-517588, M: 8099454384, E: sales@rotolok.in
Mining Gujarat State Electricity Corporation Ltd (GSECL) Global bids are invited for developing and operating its coal mine in Chhattisgarh. The company intends to select a Mine Developer and Operator to develop, operate and mine coal from the Gare Palma Sector-I Coal Block (Phase I).
Place: Chhattisgarh Contact: C G Parekh, EE, Sardar Patel Vidyut Bhawan, R C Datt Road, Vadodara-390007, Gujarat. T: 0265-6612005, E: eefuel2.gsecl@gebmail.com, cefuel.gsecl@gebmail.com
Mahanadi Coalfields Ltd (MCL) MCL has unveiled a capital expendi- ture plan targeting
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Contact: M L Prajapat, GM Project & Planning, P.O. - Jagriti Vihar, Burla District, Sambalpur - 768020, Odisha. T: 0663-2542461, 2542767 South Eastern Coalfields Limited (SECL) Coal India Ltd (CIL) subsidiary is setting up largest coal washery in India with a capacity of 25 million tonnes per annum (MTPA). The Kusmunda coal washery will come up in Korba district of Chhattisgarh.
Place: Chhattisgarh Contact: B.B Singh, Staff Officer Civil, Office of GM, SECL, Kusmunda Area, Post Office Kusmunda, Korba - 495455, Chhattisgarh, T: 07815-271233, M: 09425533008
Place: Andhra Pradesh
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) Place: Andhra Pradesh
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
Oil & Gas
Trimex Industries Pvt. Ltd.
Oil and Natural Gas Corporation 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
Plans to drill a 406 development wells in oil fields of Gujarat’s Cambay basin. The proposed drilling is expected to be undertaken at the company’s Ahmedabad asset located in Gandhinagar, Ahmedabad and Kheda districts.
Place: Gujarat Contact: Sanjeev Sharma, Head (Public Relation and Corp Comm), Jeevan Bharti, Tower-II, 124-Indira Chowk, New Delhi – 110001 T: 011-23301243, 23320032, F: 23357860, E: ongcdelhicc@ongc.co.in
Railways Ministry of Railways The CCEA also approved construction of an additional bridge and doubling of the Rampur Dumra-TalRajendrapul sector in Bihar for Rs. 1,700.24 crore
Place: Bihar Contact: Anil Kumar Saxena, Addl. DG (PR), Rail Bhavan, Raisina Road, New Delhi-110001, T: 011-23381332, F: 23385215, M: 9810046241, E: dpr.railways@gmail.com Ministry of Railways The Cabinet Committee on Economic Affairs has recently approved doubling of the 190-km Hubbali-Chickajur railway line.
Place: Karnataka Contact: Anil Kumar Saxena, Addl. DG (PR), Rail Bhavan, Raisina Road, New Delhi-110001, T: 011-23381332, F: 23385215, M: 9810046241, E: dpr.railways@gmail.com
PROJECTS www.mtwmag.com
Ministry of Railways The Cabinet Committee on Economic Affairs has recently approved the 160-km RamnaSingrauli line
Place: Madhya Pradesh Contact: Anil Kumar Saxena, Addl. DG (PR), Rail Bhavan, Raisina Road, New Delhi-110001, T: 011-23381332, F: 23385215, M: 9810046241, E: dpr.railways@gmail.com
Power National Thermal Power Corporation Ltd “Plans to assign the infrastructure works for plant Package for BRBCL’s Nabinagar Thermal Power project (4x250 MW) of Bhartiya Rail Bijlee Company Ltd. (A joint venture of NTPC Ltd. and Ministry of Railways) at Nabinagar, Distt. Aurangabad, State of Bihar.”
Place: Bihar
The plant would be spread over 47.5 hectare at Parsa village in Surguja District. Greencindia consulting is the environmental consultant. Rajasthan Rajya Vidyut Utpadan Nigam (RRVUNL) has assigned the task of Mining, Develop- ment and Operation of Parsa East Coal Block and supply of beneficiated coal to Surguja Group.
Place: Chhattisgarh Contact: S Verma, Manager, First Floor, Urjanidhi, 1, Barakhamba Lane, Connaught Place, New Delhi-110001, Delhi. T: 011-23456123, 23456102, 23456000, E: cspfccl@gmail.com Bharat Heavy Electricals Ltd. Plans to assign testing, commission- ing of spare generator transformer package for 2x500MW units of Koderma, Jharkhand project.
Contact: DGM (CS-I)/ Place: Jharkhand
Sr. Manager (CS-I), Sixth Floor, Engineering Office Complex, Plot A-8A, Sector-24, NOIDA-201301, Uttar Pradesh. T: 0120-4948656, E: neerajkumar02@ntpc.co.in
Contact: S Ganguly, AGM, DJ-9/1, Sector-II, Salt Lake, Kolkata-700091, West Bengal. T: 033-23398229, F: 23211960, E: sganguly@bhelpser.co.in
Chhattisgarh Surguja Power Ltd.
UP Rajya Vidyut Utpadan Nigam Ltd
Plans to set up 4x135/150 MW thermal power plant based on coal washery rejects.
Plans to add 1x660 MW coal based super critical unit to existing 665 MW capacity at
Harduaganj Thermal Power Project at Kasimpur, Aligarh District, Uttar Pradesh.
Place: Uttar Pradesh Contact: R K Trivedi, Director (Project), Environment & Safety Unit, 7th Floor, Shakti Bhawan Extension, 14-Ashok Marg, Lucknow-226001, Uttar Pradesh. T: 0522-2288557, director.project@uprvunl.org
The project comprises two corridors: JP Nagar-Hebbal corridor of 32 km covering Bannerghatta Road, Kanakapura Road, Mysuru Road, eastern boundary of Jnanabharati campus, Magadi Road, Peenya Industrial Area, BEL Circle, Lottegol- lahalli and Hebbal; the second corridor comprises Vijayanagar Tollgate-Ta- varekere corridor covering 10 km. The completion of this project is targeted in four years.
Neyveli Uttar Pradesh Power Ltd
Place: Karnataka
JV of NLC Ltd & UPRVUNL plans to set up super critical imported coal based Ghatampur Thermal Power Station of 1980 (3x660) MW capacity at Tehsil Ghatampur, District Kanpur Nagar, Uttar Pradesh. The total project area is 1886 acre including ash pond area and township. Land is already acquired.
Contact: C Jayaram, Director (Projects), Bangalore Airport Rail Link Limited, KSFC Bhavan, No.1/1,Thimmaiah Road, Bengaluru- 560052, Karnataka. T: 080-22200110, E: barl.hsrl@gmail.com
Place: Uttar Pradesh
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.
Contact: K Chandran, CEO, AE 55,Officer Colony, Panki Power Plant, Kanpur-208020, Uttar Pradesh. T: 0512-2260030, E: ceo.nuppl@nlcindia.com
Transport Bangalore Airport Rail Link Ltd Plans to implement 42-km of Light Rail Transit System (LRTS) under public-private partnership in Bengalu- ru.
Delhi Metro Rail Corporation
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 APRIL 2016
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PRODUCT SHOWCASE Shrink Fit Holder Technology & Advantages Shrink Fit tool holder can provide tremendous holding strength and TIR for critical high speed or high precision cutting applications, which is not possible with most tool holders.
How it works: Each Shrink fit tool holder is manufactured with an inside diameter slightly smaller than the shank diameter of the cutting tool. A heat induction unit is used to quickly heat the holder end of the Shrink fit, expanding this inside diameter. At this point, the tool shank slips easily into the holder. As the holder cools, the resulting thermal contraction exerts a tremendous, uniform pressure around the entire surface of the tool shank leaving total concentric gripping strength. Removing the tool is just as simple — you simply reverse the process! Tool changes can be accomplished in seconds, dramatically increasing machining productivity by reducing tool change downtime. Shrink fit technology and design provides; Best possible TIR (Total Indicator Reading) • Best possible balance • Best available gripping power • Increased tool and spindle life • Thin profile holders for machining hard-to-reach places • Design and build custom holders for any application • Short gauge lengths available for increased rigidity • Ability to preset for required tool length • Ideal for end milling, drilling, reaming, boring and all other critical rotary tool applications regardless of cutting tool material • Eliminates wrenches, collets, set screws and other accessories • Reduces costs associated with tool changes, holder maintenance & machine downtime
For Product Enquiry Contact Birla Precision Technologies 206 Dalamal House, 1st Floor, Jamnalal Bajaj Marg, Nariman Point, Mumbai - 400 021 Web: www.birlaprecision.org Email: himanshu.bhatt@birlaprecision.com
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Conclusion - The Shrink fit tool holding System is by far the most economical system in the world today. The increased productivity and increased tool life can be measured. Additionally, reduced tool change down time will contribute to the considerable reduction in costs. Birla Precision offers wide range in Shrink Fit adaptors on BT/DV/CAT & HSK tapers. Extra long gauge lengths are available to approach machining deep areas. Bore size ranging from 6 mm to 32 mm & ¼”to 11/4” In Inch sizes.
PRODUCTS www.mtwmag.com
Hangsterfer’s CC 10 - 22 Straight Cutting Oils For Deep Hole Drilling • CC 10 & CC22 oils are • Chlorine-Free • Non-Staining • Can be used safely on all materials • Non-Toxic • Non-Irritating • Non-Corrosive • Easy to recycle and waste treat • Lower misting • Fewer residues Hangsterfer’s neat cutting oil CC10 is recommended for Deep Hole Drilling /Gun Drilling application. CC10 (Viscosity 10) has all the capability to outperform. Hangsterfer’s neat cutting oils are recognized by various machine manufacturers around the world. These oil improves tool life and surface qualities to the large extent. In addition to the lubricity provided at the cutting zone, Hangsterfer’s cutting oils provide excellent lubrication for the machine’s slides, guide bushings, bearings, and spindles. For Product Enquiry Contact Hangsterfer’s Laboratories, Inc. USA Sanjay Tools & Adhesives Mobile : +91 9822028518, +91 9892516810 E-mail: hangsterfers@sanjaytoolsnsk.com Web : www.hangsterfers.com
CC 10 - This is the lowest viscosity in the series. CC 10 is ideal for Gun Drilling application which allows for more heat removal with high pressure. CC 22 - This oil is ideal for use in BTA application. It has enough lubricity for the more demanding operations and materials, including lubrication of the guide-bushings.
EasyTrax: Extremely fast cable laying thanks to easy cable insertion 1. 2. 3. 4. 5. 6. 7. 8.
Sturdy two-component design: hard cable carrier body, flexible film hinge Chain links made of plastic Extensive unsupported length Inside space is gentle on the cables – no interfering edges Extremely low noise due to integrated noise damping For inside/outside opening Dividers and height separations for cable separation Single-part end connectors with and without integratable strain relief
Selection criteria for EasyTrax • • • • • For Product Enquiry Contact Kabelschlepp India Pvt. Ltd. B-14, ITI Ancillary Industrial Estate, Mahadevapura (P.O), Bengaluru-560 048 Tel.: +91-80-41158997, Fax: +91-80-41158998 E-Mail: mail@kabelschlepp.in, Website: www.kabelschlepp.in
Where extremely fast cable laying is required For high fill levels Where an extensive unsupported length is required Where rigidity is required For low noise applications
Features • • • •
Fast and easy installation of cables and hoses Very high filling level High side stability Divider systems for reliable cable separation
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PRODUCTS
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
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.
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
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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 ever-growing 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.
PRODUCTS www.mtwmag.com
Tyre Mould Cleaning Machine
For Product Enquiry Contact MEC SHOT Blasting Equipments P. Ltd. E-279, M.I.A., Phase II, Basni, Jodhpur 342005. Tel.: 0291-2740609, 2744068 E-mail: mail@mecshot.com, Web : www.mecshot.com
After certain number of molding process, these foreign particles need to be removed without affecting the dimensional tolerances and finish of the mold to obtain consistent quality of molded products. The mold is clamped in horizontal position on the turn table using centering plates & four heavy duty T-slot clamps. The turn table is tilted hydraulically at suitable angle. The work car with turntable and mold is driven inside the cabinet. The turn table is rotated through electric motor with gear box arrangement. A spring is provided for holding the gun arrangement to avoid fatigue of operator. The abrasive is pressurized in a pressure vessel by compressed air and then forced through the nozzle to blast clean the tyre mold. The used abrasive and dust created during blasting are sucked to reclaimer where usable grit is reclaimed and collected in a storage tank and is transferred to pressure vessel at the bottom of storage tank for recycling and dust is collected inside the fabric bag dust collector whereas clean air is discharged into the atmosphere.
A filter a day keeps maintenance away
For Product Enquiry Contact JIG ENGINEERING 103/A, Mandpeshwar Indl. Estate, Opp. M.C.F. Club, Gymkhana Road, Borivali (W), Mumbai - 92. Tel.: +91 98693 84124 / 97699 64468 Web : www.edmwirecutfilter.com
How important it is to replace your filter element on your CNC EDM wirecut machine. I will explain about my own story. We used to delay filter replacing and also we used inferior quality filters, for our CNC wirecut machine. Slowly our machines started giving more maintenance, all water jets get choked up with the sludge, and this affects the finish of the job too. Later we started using our quality filters. With imported (german) paper, and found out, zero maintenance, good finish of the job. Also by using EDM grade resin, We got better precision, and faster cutting. Hence we came to know good consumables can give you better performance and increases machine life. We already have a forty years experience in this dies and mould industry, So we chose the best quality, filters, resin Diamond wire guides, carbide contacts.etc. Also our range of CNC machines are latest in technology, as per requirements of a tool room.
AT3 Class Tool holders Birla Precision Technologies Limited, erstwhile Birla Kennametal Ltd is established in 1986 as a Joint Venture with Kennametal Inc USA, primarily to manufacture CNC Rotating Tool Holders and accessories. We have constantly endeavoured to acquire new skills and technical expertise to produce engineered products and become cost competitive for addressing the needs of our customers. With BPT brand we are committed to provide; • AT3 Class Tool holders that ensure high precision, ease of operation & increased tool life • Products with unbeatable run out accuracy and balance quality • Full lot traceability of all tool holders for maximum reliability and process control. • Reliable & efficient engineering support to cater to your special requirements • World class quality at competitive prices. For Product Enquiry Contact Birla Precision Technologies 206 Dalamal House, 1st Floor, Jamnalal Bajaj Marg, Nariman Point, Mumbai - 400 021 Web: www.birlaprecision.org Email: himanshu.bhatt@birlaprecision.com
Our all Tool Holders are manufactured in AT3 Class accuracy, with Shank DV/BT/CV/ HSK & Front Ends - ER/DA & TG Collets Chucks, Drill Chucks, End Mill / Shell Mill / whistle notch / Morse Taper / Jacob Taper Adaptors & Shrink Fit Tool Holders. We also produce the angle heads & rotary coolant adapters.
APRIL 2016
MACHINE TOOLS WORLD
87
ADVERTISERS INDEX COMPANY NAME
PG. NO.
A
COMPANY NAME
PG. NO.
COMPANY NAME
ELECTRONICA HITECH MACHINE TOOLS PVT LTD.
11
JYOTI CNC AUTOMATION LTD.
PG. NO. INSIDE BACK COVER
ACE MANUFACTURING SYSTEMS LTD.
BACK PAGE
EMAG INDIA PVT. LTD.
7
L
ACMEE - 2016
88
ENGIMACH - 2017
75
LAKSHMI MACHINE WORKS LIMITED
35
ADOR WELDING LIMITED
71
F
LAPP INDIA PVT. LTD.
44-45
AMTEX - 2016
78
FATTY TUNA INDIA PVT. LTD.
49
M
ANCA MACHINE TOOLS PRIVATE LTD
3
FIBRO INDIA PRECISION PRODUCTS PVT. LTD.
41
MACHINE TOOL EXPO - 2016
57
MARPOSS INDIA PVT. LTD.
31
MEC SHOT BLASTING EQUIPMENTS PVT. LTD.
69
B BIRLA PRECISION TECHNOLOGIES LIMITED
G 19
C CNC SERVICING & SOLUTIONS (I) PVT. LTD.
15
CNC SOFTWARE, INC.
25
COSMOS IMPEX (INDIA) PVT. LTD.
17
D
GLOBAL INDUSTRIAL EXPO - 2016
74
GROB MACHINE TOOLS INDIA PVT. LTD.
9
H HARTING (INDIA) PVT. LTD.
67
HEIDENHAIN OPTICS & ELECTRONICS INDIA PRAIVATE LIMITED
53
DMG MORI INDIA
INSIDE FRONT COVER
I
DOWEL ENGINEERING WORKS
73
INDIA MACHINE TOOLS SHOW - 2017 J
E EFFICA AUTOMATION LIMITED
77
63
JIG ENGINEERING
R RAJKOT MACHINE TOOLS SHOW - 2016
76
RENISHAW INDIA (PUNE)
39
S SANJAY TOOLS & ADHESIVES
13 & 59
SHAVO TECHNOLOGIES PVT. LTD.
21
W 65
WIN INDIA - 2016
APRIL 2016
72
MACHINE TOOLS WORLD
89
Mr.
Indradev
Inside Story
Babu
Managing Director, UCAM Private Limited
My Lifeâ&#x20AC;&#x2122;s Goals Aim & Ambition: Make the Indian Flag fly higher globally with my contribution in the Machine Tool Industry. Inspire my family and UCAM team to actively participate in nation building by their contributions.
Vision: To put UCAM as one among the top 5 Rotary table producers in the world within the next 5 years.
Social Goal: To be ethical even under pressure; to be a role model in society; to continually contribute and work towards building an ecofriendly environment.
Business Goal: To grow at least 30% CAGR, but more importantly to earn good profits to sustain R+D, Marketing and CSR spends at par with the bench mark rates while meeting CAPEX and other needs.
My Leisure Choices Favorite holiday spot: Goa Beaches, Jungle Lodges, Siena- Italy. Music I like : Beegees, Harry Belafonte, The Beatles, Sunidhi Chauhan. Pastime and Sports I Love : Aero Modelling /Drones and Soccer
Ask my Taste Buds Favorite food: Creamy Mushroom Risotto, Beijing Duck. Favorite Drink: Semi Dry Tuscany Red Wine.
In Awe of Prakash Padukone (after I heard Deepika Padukone read his letter).
90
MACHINE TOOLS WORLD APRIL 2016
RNI No. MAHENG/2015/64267 Postal Reg. No. THC/173/2015-2017. Posted at Mumbai Patrika Channel Sorting Office G.P.O. Mumbai 400 001 on 15th of every month and Published on 10th of every month
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