Machine Tools World May 2016 by Divya Media Publications Pvt. Ltd.

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 12 | MAY 2016

Shirish D.

IN FOCUS

CEO Shekhar D.

Editor Shilpa Dongre

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

The Future of Metrology

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

Online Division Ganesh M., Pradeep M. Pillalamarri

Innovation is a part of our culture: Satish Bhat

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

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

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

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

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

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

MACHINE TOOLS WORLD MAY 2016

COVER STORY

Going forward, we would focus more on high precision, high speed power transmission: Rajiv Moorth Mr. Rajiv Moorthy, CEO, Shanthi Gears Ltd.

BUSINESS NEWS

Mastercam® X9 for SOLIDWORKS® Brings Speed, Efficiency and Automation

Top-tier Japanese Manufacturers Look to Build on RAMPF’s EPUMENT Mineral Casting

Christian Thönes Appointed Chairman of the Executive Board

Customization of process for higher productivity is the key to getting a bigger market share: Ashok Sheth

COMPANY PROFILE

Bright Roller Burnishing Tools for complete burnishing solutions

The most exciting thing at NRB is our focus on empowering the younger generation: Harshbeena Zaveri

Shavo Technologies offers high-tech tailor- made solutions

The field of robotics is in a massive growth phase similar to what IT was in late 90’s: Arjun Prakash

Open House 2016 – in the Region of the 10 Thousanders where the Swabian Alb is at its highest!

MEPL - The Leader in Resistance Welding

PROJECTS

PRODUCTS

Editorial Board

Editorial Index A Ador Welding B Bright Roller Burnishing Tools

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 Dürr Ecoclean

13, 52 24

E Effica Automation Elesa and Ganter India ExxonMobil

36 80 23

F F. Zimmermann GmbH FARO India G Gleason Works Grind Maste Mr. Arjun Prakash Managing Director Effica Automation Ltd.

Ms.Samina Khalid Marketing Manager

Renishaw Metrology Systems Ltd.

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

Kennametal

L Lantek

M Mastercam Mechelonic Engineers

6 42

N NRB Bearings

O Onshape

P Prime Industries

R RAMPF Group Rapid.Tech Renishaw

8 22 46

32, 76

10 12

77 38, 56

H Haas Automation Hangsterfer Hermle AG Hypertherm

50 77 14 24

K KASTO

S Shanthi Gears 26, 82 Shavo Technologies 40 Solitaire Machine Tools 33 T TaeguTec U Unity Controls

18, 78

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

MAY 2016

MACHINE TOOLS WORLD

BUSINESS NEWS

Mastercam® X9 for SOLIDWORKS® Brings Speed, Efficiency and Automation Mastercam X9 for SOLIDWORKS is a CAM application that is fully integrated into Dassault Systèmes’ SOLIDWORKS. The latest release features Dynamic Motion technology improvements, 3D Milling Enhancements, Multiaxis Improvements, and much more. And, Mastercam for SOLIDWORKS Lathe, Mill, or Multiaxis is included with your purchase of the comparable standalone Mastercam X9 product. Says Suchit Jain, Vice President, Strategy & Business Development, SOLIDWORKS, “Mastercam for SOLIDWORKS combines one of the world’s leading modeling software with the world’s most widely used CAM software so you can program parts directly in SOLIDWORKS, using Mastercam’s toolpaths and machining strategies.”

Dynamic Motion Technology Dynamic Motion toolpaths follow a proprietary and sophisticated set of rules that take into consideration a broad data set. To create the most efficient cutting motion possible, Dynamic toolpaths calculate not only the area where material will be removed; they also take into account the changing condition of the material throughout various stages of machining. With Mastercam for SOLIDWORKS X9, 2D HST Dynamic Mill, Peel Mill, and 3D Dynamic OptiRough support a Conventional feed rate when you are set to a Zigzag cutting method.

been greatly improved. 3D HST Waterline toolpaths now include an option to machine your part from bottom to top. And, Hybrid flat area processing is now available. You can choose to include the flat areas of your part in the toolpath, ignore the flat areas, or only machine the flats.

Multiaxis Improvements Now available for Port Expert, Minimize tilting creates the most efficient toolpath possible through a port. Multiaxis toolpaths are displayed as normal tool motion instead of vectors in the graphics window. All Advanced Multiaxis toolpaths, such as Port Expert and Blade Expert, are now processed through the Multi-Threading Manager, leaving users free to work while processing. And, the new Multiaxis Link toolpath allows users to link multiple toolpaths together to create a safe linking move between them.

Also available in Mastercam X9 for SOLIDWORKS: • Option to project the selected

items to the Toolplane has been added to the Chain Manager for 2D Toolpaths and for 3D Toolpath Containments. When SOLIDWORKS Solid Bodies, Faces, Features, or Surfaces are selected, a silhouette of the selected items will automatically be generated. • Multiple Mastercam Simulator improvements such as the new Adaptive Quality tool, motion controller support, and more. • Lathe C-Axis operations, as well as Lathe Misc Op operations, are

now available. • Ability to insert, delete, or otherwise rearrange holder segments using the right-mouse context menu. • Barrel tool support, as well as Thread Mill support, has been added.

About Mastercam Developed by CNC Software, Inc., Mastercam is Windows®-based CAD/CAM software for 2- through 5-axis routing, milling and turning, 2- and 4-axis wire EDM, 2D and 3D design, surface and solid modeling, 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.

3D Milling Enhancements 3D HST roughing has been consolidated from six toolpaths down to two toolpaths – Dynamic OptiRough and Area Roughing. The efficiency of Rest roughing linking heights for 3D HST toolpaths has

MACHINE TOOLS WORLD MAY 2016

For more information, Website: www.mastercam.com

VERTICAL TURNING CENTER VM 9 – QUICK AND PRECISE MACHINING FOR SMALL PRODUCTION RUNS ERGONOMIC

PRECISE

PRODUCTIVE

HIGHLIGHTS

+ + + + + +

MAXIMUM PRODUCTIVITY: With highly dynamic axes for short idle times and quick machining processes. SIMPLE HANDLING: All service units are easy to reach. MAXIMUM PERFORMANCE: Short distance between workpiece machining functions. HIGH SURFACE ACCURACY: Axis monitoring by rotary, indirect absolute encoders. All axes with an optional, fully encapsulated linear glass scale IDEAL FOR HEAVY-DUTY MACHINING: With a generously dimensioned main spindle, maintenance-free spindle motors and rigid guideways VERY HIGH WORKPIECE SERVICE LIVES: B-ecause the machine body is made of MINERALIT®, which has 6 to 8 times better damping properties than gray cast iron

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 8042544400 I Fax: +91 8042544440 I E-mail: sales.india@emag.com I Website: www.emag.com

FAST

BUSINESS NEWS

Top-tier Japanese Manufacturers Look to Build on RAMPF’s EPUMENT Mineral Casting EPUMENT mineral casting from RAMPF is rapidly gaining popularity, also in the Japanese market. Leading manufacturers of cutting-edge machine beds and components are looking to use the epoxy resin-bonded material with its outstanding properties – especially unmatched vibration damping – as an innovative alternative to metallic materials. Today’s production equipment needs to satisfy growing demands in terms of process accuracies under static, dynamic, and thermal loads. In their quest for finding new and improved machine bed materials that can tackle these challenges, leading Japanese manufacturers have turned to RAMPF and its EPUMENT mineral casting material.

Outstanding vibration damping In a series of comprehensive laboratory tests carried out by Ono Sokki, a leading measuring

Bed made from EPUMENT of a high-speed milling machine with precisionreplicated surfaces, guides fitted, and high-precision bonding of bed and gantry 8

MACHINE TOOLS WORLD MAY 2016

Graph: Comparison of material-damping properties of EPUMENT mineral casting 145B and grey cast iron material FC 300 instrument manufacturer, and commissioned by renowned Japanese manufacturers, the damping properties of EPUMENT mineral casting 145B were put to the test against grey cast iron material FC 300, which is comparable with HT 300 in China, No. 45 in the US, and GG 30 in Germany. The result: the EPUMENT mineral casting from RAMPF exceeded expectations. Graph: The comparison of decay curves for cast iron FC 300 and EPUMENT mineral casting clearly shows the superior damping properties of the epoxy resinbonded material. The minimization of natural vibration in the machine significantly increases tool lifetime, workpiece surface measurability, as well as cutting speed and precision during the enlargement of the none-critical frequency range. “Especially due to its excellent damping properties, mineral casting has established itself as a competitive alternative to cast iron and welded constructions

for highly dynamic mechanical engineering applications and technologies,” Fabian Werner, Managing Director of RAMPF (Taicang), points out. The Chinese subsidiary of the international RAMPF Group has positioned itself as a leading end-to-end product and service provider for machine beds made of mineral casting in the Asian (including Japan) and North American markets, offering engineering, modeling, design, production, and assembly from a single source.

Excellent price-performance ratio EPUMENT mineral casting – specially-selected stones and minerals, and high-quality binding agents based on epoxy resin – is a high-tech material that is very well-suited for primary machine bed functions such as precisely securing the geometric position of the individual machine elements as well as the static, dynamic, thermal, and acoustic absorption of forces and moments. The superior damping compared to metal materials significantly improves the dynamic stability

of the machine bed structure in fast and accurate production machinery. Furthermore, processing and assembly times are appreciably reduced by optimum accuracies and the high level of finishing, as guides and other machine elements are already fitted with high precision. Together with the high availability and short delivery times, this makes EPUMENT a machine bed material with an outstanding price-performance ratio.

Professional and prompt service Customers in Japan can expect even more prompt service with regard to all aspects of innovative machine beds. The product and service portfolio of RAMPF Group Japan, the RAMPF Group’s subsidiary in Japan, now also includes high-precision machine beds made of mineral casting, hard stone, and metal shell constructions. “In the Japanese market, EPUMENT has high potential to be used for highly dynamic and precise machine tools in numerous applications, amongst others in machine tool engineering, medical technology, and the semiconductor industry,” says Yoshiaki Naganuma, Managing Director of RAMPF Group Japan. “We believe that the result of the damping test will further enhance the reputation of EPUMENT mineral casting as a highly competitive construction material in the Japanese market.”

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 â&#x20AC;&#x201C; for the most versatile machining possibilities.

www.grobgroup.com

17.03.2016 15:51:15

BUSINESS NEWS

F. Zimmermann Adds New Horizontal Machining Centre to its Product Range: Opening up New Horizons F. Zimmermann GmbH has brought its first horizontal machining centre onto the market. The new model range is particularly useful for efficient machining of standard components for the aircraft industry. It has two special patented features, applying to pallet handling and the travelling column. The new machining centre also stands out for its unbeatable value for money. The key element of the new FZH400 5-axis horizontal machining centre is a robust water-cooled travelling column. Common designs have the drawback that their deviation increases as the slide extends, owing to a lever effect. This is not the case with the patented column design of the new FZH400. With increasing penetration into the material the guide carriage distance increases, and that increases the rigidity – in contrast to commonly available solutions. The stepped drive guide ensures a perfectly constant geometry along the Z axis as well as maximum rigidity in sensitive areas of the workpiece.

Milling heads from Zimmermann For excellent results, Zimmermann offers an innovative family of milling heads that have proved their worth in gantry machines throughout the world. An outstanding example is the patented M3 ABC 3-axes milling head. It increases the efficiency of the horizontal machining centre even more because it has to perform only very small swivelling movements, especially when milling pockets in workpieces. This makes it possible to maintain a constant advance rate.

Minimal idle times as standard Already in the standard version, the FZH400 features an integral pallet handling system with pallet changing during machine time. The handling system, also patented, enables reliable transport of pallets without sagging. This makes it especially suitable for long pallets. Pallets are raised and lowered in such a way that the load is

balanced, thus almost eliminating bending and torsion forces. All of this applies to the standard version. The pallet system is extendable. If necessary, users can add a pallet station or equip the system with additional pallet changers. The standard automation system permits easy interfacing with the master computer and efficient linking of multiple systems.

The machine builder becomes a solution provider The machine has a configurable modular design and is extremely compact. No special foundation is necessary; a standard factory floor is sufficient for anchoring. Users can thus put the machine into operation more quickly and have much greater flexibility when setting it up. Turnkey solutions are available from Zimmermann on request. Its specialists configure the system, provide suitable clamping devices, handling solutions and tools, and write NC programs for the components that are to be

manufactured. Production can start immediately.

About the company F. Zimmermann GmbH is headquartered in Neuhausen a.d.F., Germany, and is one of the world’s leading suppliers of high-tech milling solutions. The machines have huge working areas, tremendous dynamic performance and enormous cutting capacity. Founded in 1933 by Friedrich Zimmermann, the company now has 200 employees, with subsidiaries in the USA and China. The innovative company has one primary goal for its range of products: being able to offer the right solution to its customers and so ensure high profitability: “Quality made in Germany”. Its specialized machines are in use throughout the world in the aerospace and automotive industries and find many special applications.

For more information, Web: www.f-zimmermann.com

Manufacturers of standard components can maximize their production times with the new FZH400 10

MACHINE TOOLS WORLD MAY 2016

PRECISION that speaks for itself

XKNC â&#x20AC;&#x201C; 20G XI'AN KITAMURA PRECISION MACHINE WORKS CO.,LTD. : Kenny Ruan : +86 029-88452325 / : +86 18710503635 : kenny@xknc.net : XKNC-kenny : Kenny1573 : http://www.xknc.com/eng/ /xkncEN : bit.ly/XKNC_Youtube

BUSINESS NEWS

FARO Announces New HDR Laser Scanners & Instant Rendering Software for BIM-CIM and Public Safety Customers FARO Technologies, Inc. (NASDAQ:FARO), the world’s most trusted source for 3D measurement, imaging, and realization technology in the BIM-CIM and Public Safety markets, announces the release of new 3D laser scanners with high dynamic range photography (HDR) that produce incredibly detailed images in bright and dark lighting conditions as well as increased resolution for superior color depth. Also launching is a major release, version 6, of FAROs well-known point cloud software, SCENE, which now provides instant rendering of scan data and simplified workflows. Historically, 3D laser scanning of scenes with large brightness contrast differences has been a challenge. The new Focus3D X 130/330 HDR models provide the solution to this challenge with performance that is comparable to the human eye. While typical digital images cover a contrast range of 255-to-1, the new FARO laser scanners capture brightness ranges of up to 4 billion-to-1. Together with its extended color resolution of up to 170 megapixels per scan, the new Focus3D models ensure the smallest details are captured with superior clarity. To unleash the capabilities of the FARO Focus3D HDR scanners, a new version of the popular FARO SCENE Software is now available. FARO SCENE Version 6.0 includes an incredible level of visualization due to a new solidsurface rendering technology that eliminates the need for further

MACHINE TOOLS WORLD MAY 2016

data processing in visualization applications. In addition, BIM-CIM customers using laser scanners for as-built documentation and Public Safety customers in crash, crime and fire investigations will benefit from a simplified interface that uses workflow-driven tools. Standard project workflows can be fully automated and when manual interaction is needed, the software provides support and guidance to ensure efficient and reproducible project results, all while keeping training efforts to a minimum. FARO SCENE 6.0 fully supports the new imaging capabilities of FARO’s latest laser scanners, as well as all previous models. With the two new Focus3D HDR models, FARO confirms its position as the innovation leader in documenting real-life scenes with easy-to-use 3D laser

scanners,” stated Dr. Simon Raab, FARO’s President and CEO. “In addition, the new SCENE 6.0 software extends this leadership into our customers’ offices by providing the best usability and productivity paired with unmatched visualization quality and performance. With these two product releases, we address the need of our BIM-CIM and Public Safety customers to efficiently capture and process all important on-site data.” Both products, the new HDR family of laser scanners and SCENE 6.0, are available for immediate order and shipment.

About FARO FARO is a global technology company that develops and markets computer-aided coordinate measurement devices and software. Portable equipment from FARO

permits high-precision 3D measurement and comparison of parts and compound structures within production and quality assurance processes. The devices are used for inspecting components and assemblies, production planning, inventory documentation, as well as for investigation and reconstruction of accident sites or crime scenes. They are also employed to generate digital scans of historic sites. With FARO, 3D measurement and documentation needs can be fulfilled confidently. As a pioneer and market leader in portable computer-aided measurement, FARO consistently applies the latest advances in technology to make its industry-leading product offerings more accurate, reliable, and easy to use. The focus is on simplifying workflow with tools that empower customers, thereby dramatically reducing the on-site measuring time and lowering overall costs. Worldwide, approximately 15,000 customers are operating more than 30,000 installations of FARO’s systems. The company’s global headquarters are located in Lake Mary, Florida, with its European head office in Stuttgart, Germany and its Asia-Pacific head office in Singapore. FARO has branch locations in Japan, China, India, South Korea, Thailand, Malaysia, Vietnam, Canada, Mexico, United Kingdom, France, Spain, Italy, Poland, and The Netherlands. For more information, Website: www.faro.com/india

BUSINESS NEWS www.mtwmag.com

Christian Thönes Appointed Chairman of the Executive Board

Christian Thönes (43) has already been a member of the Executive Board since January 2012 and headed the product development, production and technology areas. With immediate effect, Mr Thönes takes over responsibility for sales, product development, production, procurement, corporate public relations and audit. He joined the group in 1998 and continuously took over more responsibility. As the managing director of SAUER GmbH, Mr. Thönes built up today’s successful Advanced Technologies division (Ultrasonic and Lasertec). From 2009 to 2011, Christian Thönes was managing director of DECKEL MAHO Pfronten GmbH. In the past years, Christian Thönes has successfully driven the optimisation of production plants and product lines. Through innovative technology and software solutions, he has positioned DMG MORI for the future. Thönes: “I am pleased about the trust placed in me and look forward to the further global alignment of DMG MORI.”

Statements relating to the future This release contains statements relating to the future, which are based on current estimates by the management regarding future developments. Such statements are based on the

management’s current expectations and specific assumptions. They are subject to risks, uncertainties and other factors, which could lead to the actual future circumstances including the assets, liabilities, financial position and profit or loss of DMG MORI AKTIENGESELLSCHAFT differing materially from or being more negative than that those expressly or implicitly assumed or described in these statements. The business activities of DMG MORI AKTIENGESELLSCHAFT are subject to a series of risks and uncertainties, which may result in forward-looking statements estimates or forecasts becoming inaccurate. Should one of these factors of uncertainty or other unforeseeable event occur, or should the assumptions on which these statements are based prove incorrect, the actual results may differ materially from the results stated, expected, anticipated, intended, planned, aimed at, estimated or projected in these statements. Forward-looking statements must not be understood as a guarantee or assurance of future developments or events contained therein. There are two companies using the name “DMG MORI “: DMG MORI AKTIENGESELLSCHAFT with registered office in Bielefeld, Germany, and DMG MORI COMPANY LIMITED with registered office in Nagoya, Japan. This release refers exclusively to DMG MORI AKTIENGESELLSCHAFT. If reference is made in this release to the “DMG MORI group”, this refers exclusively to the DMG MORI AKTIENGESELLSCHAFT and its group companies.

Website: www.ag.dmgmori.com

MAY 2016

MACHINE TOOLS WORLD

BUSINESS NEWS

Open House 2016 - in the Region of the 10 Thousanders where the Swabian Alb is at its highest! The Region of the 10 Thousanders is where the Swabian Alb is at its highest and where Maschinenfabrik Berthold Hermle AG is holding its traditional Open House in Gosheim from 20-23 April 2016. More than 2000 visitors are expected to attend this event. To display the vast range of capabilities provided by Hermle machining centres and milling machines in many industrial sectors, over twenty machine models - from the compact C 12 to the large C 62 - will be on show in various configurations and with interesting equipment at the Technology and Training Centre. The event will also witness the unveiling of the newest machining centre - the C 250. A special show featuring over 50 exhibitors from the fields of tool technology, CAD/CAM, software and control technology will be staged as part of the event programme. Factory tours of the production and assembly facilities will give visitors the unique opportunity to experience the whole process of how Hermle machining centres are brought to life. The guided tours commence with an exclusive insight into the fascinating manufacturing workplace, where Hermle invested several million euros last year in new - in-house - machinery,

before moving on to the assembly lines; here the guests will see the assembly process for automation components, e.g. pallet changers and robot systems, which are developed and manufactured by Hermle-Leibinger Systemtechnik GmbH at the factory. In the area of generative manufacturing, an experienced team from our subsidiary Hermle Maschinenbau GmbH will be on hand with some brand new components, allowing attendees to discover further development of Hermle’s MPA technology.

Highlights of the Open House • The new 3, 4 or 5-axis C 250 machining centre, which provides easy access to the world of machining centres • C 60 becomes C 62 – complementing the second generation series from C 12 to C 62 • Over thirty machines, some automated at our Technology and Training Centre • Special show of tool technology – CAD/CAM software featuring over 50 well-known exhibitors • Hermle expert forum – with specialist machining lectures • Hermle user training with tips

•

and tricks for optimum milling & turning Hermle Maschinenbau GmbH with generatively manufactured components Live service competence – presentation and demonstration of our services The Hermle Apprentice Department with its own stand and presentation of Hermle’s training concept Tours of the company

key industries. The highest levels of precision combined with long-term accuracy and a competent and reliable service, the like of which cannot be found elsewhere, are characteristics which the market has come to expect from Hermle. We display these virtues and qualities every day with a highly motivated team and state-of-the-art facilities where the Swabian Alb is at its highest – in the Region of the 10 Thousanders.

Hermle machining centres – many people say they’re the best machines in the world As a pioneer of 5-axis technology, Hermle machining centres prove their worth on a daily basis in many

MACHINE TOOLS WORLD MAY 2016

For more information, Website: www.hermle.de

BUSINESS NEWS

EDM Productivity Forum (EPF) Launches the EDM Handbook – 2016

The recently concluded TAGMA Die Mould Exhibition saw the Launch of India’s first EDM Handbook published and released by EDM Productivity Forum (EPF). This is India’s first and most unique Technical EDM Handbook documenting some impressive Case Studies from more than 10 Tool Rooms across India. The Case Studies explain how these Tool Rooms have managed Breakthrough improvements in their EDM Section leading to improving Performance in their Machine Shops. The EDM Handbook was Launched by Mr A Dayananda Reddy, President TAGMA in presence of esteemed EC Members of TAGMA including Mr D K Sharma, Mr. D M Sheregar and others. Commenting on the event Mr Reddy said “I am delighted to introduce this unique initiative by Prime Industries. The current scenario demands continual Improvement on Productivity by all Tool Rooms and EPF is well poised to help the entire Indian market in this regard.” EDM Productivity Forum (EPF) is promoted by Prime Industries

MACHINE TOOLS WORLD MAY 2016

and supported by leading OEM’s like Makino and others. EPF envisions to promote Excellence and share Best Practices in the EDM Industry. The Flagship EDM Summit in November 2015 saw a huge response with almost 250 people from over 150 Tool Rooms visiting the event held in cities of Nasik-MumbaiPune-Aurangabad in 4 days. The Handbook is a compilation of case studies by clients like Godrej Tooling, Renata Precision, Endurance Technologies, Videocon

and others which were also showcased in the EDM Summits. The Handbook received a very positive response as a Technical Manual during the TAGMA Exhibition. Commenting on the occasion, Mr D K Sharma (VP, Godrej Tooling and Member EC, TAGMA) noted “It is the right time to bring a different energy to the market and this Technical Initiative from Prime Industries should not only help the Indian market but establish Prime Industries as an authority on EDM

Machining, something the EDM market will Welcome openly.” Summarizing the launch of India’s first Technical EDM Handbook Mr Ashish Varma of Prime Industries says “ We are really thankful to the clients who have kindly agreed to share their Best Practices and improvements which we have achieved jointly in their EDM Machine shops. This sharing of information supports the Government backed Make-InIndia initiative. The need to improve Productivity and Quality together is the burning need in the country and Prime Industries is proud to have played a small role for our clients in the EDM Sector. We are confident that many new initiatives in this year will strengthen the EPF activities and we should see much more interest and events from EPF in the coming Year.”

For more information, Website: www.primegraphite. com

BUSINESS NEWS

Kennametal’s Cheryl Bush Receives Women in Manufacturing STEP Award Kennametal Inc. (NYSE: KMT) announced that Director of Global Strategic Pricing Cheryl Bush received honors in the 4th Women in Manufacturing STEP (Science, Technology, Engineering and Production) Awards presented by The Manufacturing Institute. The STEP Awards recognize women at all levels, from the factory floor to the C-suite, who have demonstrated leadership excellence in modern manufacturing. The awards are part of the larger STEP Ahead Initiative, launched to examine and promote the role of women in the manufacturing industry through recognition, research and leadership for attracting, advancing and retaining strong female talent.

“My career in manufacturing has linked my enthusiasm for science and math to creating tangible products and services that make a difference in people’s lives,” said Ms. Bush. “Manufacturing offers vast opportunities for innovation and value creation in allaspects of product development through delivery. Having a career in manufacturing has been quite exciting and rewarding for me.” Ms. Bush joins three other women from Kennametal, Helen Patricia, Colleen Cordova and Martina Igel, who received the honor in 2013 and 2014. “We are thrilled to have Cheryl represent Kennametal at this year’s STEP Awards,” said Colleen Cordova, Kennametal

Vice President, Industrial North America and former STEP Award recipient. “Through her leadership and invaluable contributions to the company, particularly in process management, Cheryl serves as an inspiration to the next-generation of women in the industry and demonstrates the endless opportunities available to females in manufacturing.” The Manufacturing Institution will recognize Ms. Bush and 130 other honorees during a special STEP Awards reception on April 21 in Washington, D.C.

leader delivering productivity to customers through materials science, tooling and wearresistant solutions. Customers across aerospace, earthworks, energy, general engineering and transportation turn to Kennametal to help them manufacture with precision and efficiency. Every day nearly 12,000 employees are helping customers in more than 60 countries stay competitive. Kennametal generated more than $2.6 billion in revenues in fiscal 2015.

About Kennametal: At the forefront of advanced materials innovation for more than 75 years, Kennametal Inc. is a global industrial technology

For more information, Website: www.kennametal. com

TT7505 Chips Away at the Hard & Tough Recent trends in complex shaped component machining and high-speed cutting conditions for productivity improvement have proven to be a challenge for cast iron. To adapt to these trends including some of the more common challenges like flank and crater wear, notch wear and build-up-edges caused by abrasion, adhesion and diffusion, TaeguTec has introduced the TT7505 grade for high-speed grooving applications on cast iron. The Asian metalworking giant’s new coating grade is introduced to meet both the high hardness and strong toughness requirements demanded by cast iron machining. The TT7505 grade is optimized

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for high-speed cast iron machining – including continuous cutting applications – while guaranteeing stability and longer tool life. An additional advantage of the TT7505 grade is the application of a special CVD coating technology and a newly developed substrate for improved wear resistance and toughness for overall better performance. The new grade’s features offer

overall improved machining on a wide range of applications for all customers no matter the industry. During several case studies, TaeguTec’s TT7505 grade increased tool life by 25 percent while machining ductile cast iron GGG

40.3 and by 13 percent on the gray cast iron of GG 35 materials.

For more information, Website: www.taegutec.com

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BUSINESS NEWS

Global Release 2016 Brings Lantek Users Closer to Industry 4.0 Lantek, the leader in sheet metal software systems is launching the global release for 2016 of its Lantek Factory concept. The new version is inspired by sheet metal companies around the world producing parts for sheet metal, tubes and profiles for over 30 years. The new functionality takes producers closer to Industry 4.0 for advanced and agile manufacturing. Advanced automatic geometry recognition for multiple parts and dynamic lead in/out positioning reduces programing times, while the new Bevel 3D Designer allows interactive irregular bevel design in 2.5D. Part cost calculation has also been enhanced in compensation for head up/down times and sheet load/unload times. Cutting gains some improved strategies which optimize heat in the metal sheet during cutting, cut micro-joints at the end of machining, optimize hole destruction and, for punching, include specific strategies for special tools such as wheel or deburring. A new piercing strategy for thick materials, EcoPierce, saves both energy and time for thick parts. Lantek has introduced a complete new CAD toolbox for tube design to ease the design of tubes and the incorporation of machining features necessary for successful cutting. Capabilities include multiple shapes for tube ends and for text on tubes as well as enhanced machining features such as break holes, control of ordering and direction of cut, weld preparation and micro joints as well as verification and simulation of the process. Step by step, forward and rewind simulation give a true representation of the movement

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of the machine. To make this type of work easier, the software now supports 3D CAD formats from Autodesk Inventor, CATIA, SOLIDWORKS, Solid Edge, Parasolid, PTC Creo, Siemens NX and VDA. Additionally, it can also utilise Excel data presented in the correct format to define the tube. The extra CAD formats supported will make it possible to work with a 3D model adding any necessary machining features in the Lantek software. During the tube cutting process the system now has island management on common cuts to improve efficiency and, on 3-axis tube cutting machines, it has chuck avoidance and a triple contour cutting strategy. For 5-axis tube cutting machines the Lantek

software can now support the Mazak FabriGear and has extra features such as automatic vector correction, turret and drilling tools management and dynamic cutting for thick H section parts. In the Lantek Workshop family of software new configurations enable the lag time between work centers to be checked, the arrival of outsourced work monitored and the working capacity by time limit examined. New visual tools let users see the estimated time sum for an execution date and get reports on the available capacity by work center. Lantek has also introduced a new web based version of Lantek Workshop Capture specifically designed for use on a tablet. By making data capture mobile, it will

simplify and speed up the process and encouraging users to enter data reliably and make it easier for managers to review the current situation in the workshop from wherever they are. In Lantek Integra the company has improved the quotation stages of its ERP system with tools for calculating costs associated with operations and new dynamic pricing controls, which allow companies to apply different mark-ups according to commercial considerations or, if preferred, the capability for various methods of margin calculation. New quality assurance features keep track of returns including reasons for the return, replacement parts, credit notes and returnable packaging management. The traceability offered here helps to reduce the instance of returns and, for packaging, helps companies to maintain their obligations for recycling. Enhancements in REPLICA have improved system integration. The new Opentalk system makes it possible for a machine to send events in real time and transfer them to the management systems, while the Powersync system enables integration between Lantek software and the management systems already in place within a company, synchronising defined data sets to a specified schedule or on demand. The features in the latest Global Release will help companies improve efficiency, communication, cooperation and integration and give them some valuable tools for the implementation of Industry 4.0. For more information, Website: www.lanteksms.com

BUSINESS NEWS

High Quality Additive-Manufactured Components, Produced Faster The aerospace industry is in the vanguard when it comes to integrating Additive Manufacturing (AM) and 3D Printing into parts manufacturing and spare parts supply. Now, the sector is preparing to reach yet further heights by becoming even faster, more qualified and more industrialized using Additive Manufacturing. At Rapid.Tech, international trade show and conference for Additive Manufacturing, which takes place from 14–16 June 2016 in Erfurt, the Trade Forum “Aviation” is therefore discussing trends and new developments in this area. Whilst other branches still predominantly use Additive Manufacturing processes and 3D Printing in prototyping, the aerospace industry has been using them for years in the manufacture of series parts. AM also plays an important role in spare parts supply. “3D Printing is already an established manufacturing technology in various sectors of aviation. Now it’s a question of broadening the potential applications on the one hand and driving forward the industrialisation of AM processes on the other,” explains Dr. Eric Klemp, Managing Director of the voestalpine Additive Manufacturing Center and program coordinator of the Trade Forum “Aviation” (16 June 2016) at the 13th Rapid.Tech in Erfurt. A completely new approach to industrialisation of Additive Manufacturing is being presented by Daan A.J. Kersten, Managing Director of the Dutch company Additive Industries, in the form of MetalFAB1. The innovative, modular design of this system enables metal components to be manufactured

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in an integrated process chain – from the file all the way to the finished product – for the first time. Compared with tradional “mid-range” AM machines used in industry, it provides an increase in productivity of up to tenfold, and with greater reproducibility and flexibility. One of the features that makes this possible is the system’s high level of automation, which removes the need for manual labour. Matteo Levoni of CRP Technology SRL in Italy will reference various projects as he discusses the use of a carbon fibre-reinforced composite for AM-manufactured components for satellites such as KySAT-2 and 1U CubeSat. Rainer Sabisch of App Tital GmbH will consider in his talk how a combination of investment casting and AM can be used to design components with optimised topology. Christian Seidel from the

Fraunhofer Institute for Machine Tools and Forming Technology (IWU) will describe the road from design guidelines to rules that can be applied by design engineers. His talk will explain initial results, provide information on the ongoing work of standardisation bodies and finally illustrate the potential for transferring design rules into design software. By way of example, he will demonstrate software for mesoscopic lightweight design using honeycomb structures. The use of hybrid manufacturing to re-use as much material as possible in the repair of defective aerospace components is the subject of the session led by Christopher Stengel, SLM Solutions GmbH. Key requirements for this process are that the defect is recognised, that the component is suitable for 3D Printing and that the SLM

process can be used to prepare it for layered manufacturing of the original geometry. A methodology for making decisions about when to use additive processes in the manufacture and repair of aviation components will be explained by Gereon Deppe of the Direct Manufacturing Research Center (DMRC) at the University of Paderborn. He will also assess the costs of Additive Manufacturing processes, enabling a comparison with manufacturing and repair costs for conventional technologies. Finally, his session will look at quality criteria and the identification and evaluation of changes in the supply chain. For the first time this year’s Rapid.Tech, international trade show and conference for Additive Manufacturing, will include the trade forums on “3D Metal Printing”, “Additive Contract Manufacturing”, “Electronic Engineering” and “Automotive Industry”. In addition to the well-established trade forums on “Medical Technology”, “Dental Technology”, “Design”, “Tools” and “Science” and the User’s Conference, the new conference areas will provide opportunities for intensive professional discussion on specific AM topics. All Rapid. Tech conference presentations will be simultaneously translated (German<>English). “With the expanded conference programme and the extended, three-day duration of Rapid.Tech, we are keeping abreast of developments in Additive Manufacturing and 3D Printing,” explains Wieland Kniffka, CEO of Messe Erfurt. For more information, Website: www.rapidtech.de

BUSINESS NEWS www.mtwmag.com

Mobil SHC Gear Series Oils Meet New GE Gear Oil D50E35 Specification ExxonMobil has announced that its Mobil SHC™ Gear Series of synthetic industrial gear oils have been approved for use in General Electric (GE) off-highway vehicle motorized wheel gearbox applications requiring GE’s new gear oil specification, D50E35. Effective Jan. 1, 2016 the new GE D50E35 specification replaces the D50E27 specification for GE drives used in equipment such as construction vehicles and mining haul trucks. The new spec establishes micro pitting protection requirements in addition to scuffing wear resistance and other improvements. “Since their introduction, Mobil SHC Gear Series oils have been helping companies in the mining and construction sectors get more out of their equipment,” said Larry Mokan, senior equipment builder engineer at ExxonMobil Fuels & Lubricants. “Mobil SHC Gear Series synthetic oils meet the stringent new gear oil requirements for GE motorized gear drives with a formulation that delivers outstanding protection in extreme temperature and load conditions while combating micro pitting fatigue wear, rust and corrosion.” The Mobil SHC Gear Series represents the company’s continued commitment to developing

advanced, high-performance lubricant technologies that can help customers decrease costs and improve the productivity of their operations. These oils contain an advanced, proprietary additive system designed to protect gears from conventional wear modes, such as scuffing, while offering a highlevel of resistance against micro pitting fatigue. In addition, the oils offer the potential for improved lubrication of gearbox rolling element bearings as compared to conventional gear oils. “We began GE D50E35 qualification testing early and met the new requirements shortly after they were published in late 2014. We are confident that owners of GE OHV motorized gearbox drives who choose Mobil SHC Gear oils will also experience the same excellent field performance enjoyed by our customers over the past four years under the current GE specification,” said Mokan. The complete range of viscosities for the Mobil SHC Gear Series, ISO VG 150, 220, 320, 460 and 680, are approved for use under GE Material D50E35, categories A-E.

For more information, Web: www.mobilindustrial. com

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TECH PROFILE

Sparkonix Leads the Way in EDMs

parkonix (India) Pvt. Ltd. is one of the leading companies manufacturing Electric Discharge Machines in India. A pioneer in the Indian market, Sparkonix introduced the spark erosion technology back in 1968 with its indigenous development of Metal Arc Disintegrators. It was a key break-through for the technology starved Indian manufacturers heavily dependent on imports. Sparkonix’s EDM technology that was developed to be an import substitute for

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Indian market has continued to evolve and lead the market for the past four decades. “Sparkonix has always excelled at sensing the pulse of Indian customers.”, says Shailesh Patwardhan, Director Marketing at Sparkonix. To serve the evolving needs of Indian customers, Sparkonix has added over forty new features to its EDMs in the last two years. More importantly, all these valuable features come without any significant increase in price. Outlining the key shift in the EDM market, Shailesh highlights that “Today, EDMs are being categorized as a musthave technology in any tool room or large manufacturing set-up, as opposed to good-to-have machines in the past. This means, the needs of the customers have also changed significantly. At Sparkonix, we have developed cutting-edge features that enhance the performance, reliability and durability of the machine in view of the emerging needs of the customers.” Another emerging trend is that of customized EDMs. Sparkonix has been at

the forefront of developing customized EDMs for highly specific needs of the customers. “We see a lot of traction in areas like defense, where specialized component manufacturing has to be catered to by developing customized EDMs.”, says Ramesh Patwardhan, Director Technology at Sparkonix. The fact that more than one-fourth of Sparkonix’s business comes from customized EDMs speaks volumes on company’s capabilities. With over 3,000 customers, cutting edge R&D, state-of-the-art manufacturing facility and excellent service infrastructure, Sparkonix leads the way for EDMs in India. Sparkonix’s journey to develop world-class technology in EDMs has been a cornerstone in the importdependent machine tool market in India.

Solitaire No. 2 - 10" (250 mm) Precision Centerless Grinder

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AMERICAN RIGIDITY

ITALIAN INNOVATION

Combined to give you Customized Centerless Grinders Solitaire Machine Tools Ltd. 292, Dharamsinh Desai Marg, Chhani Road, Vadodara - 390002, Gujarat, India Tel.: +91-265-2761776, +91-265-2773585 Email: sales@smtgrinders.com www.smtgrinders.com

COVER STORY

Moving forward, we would focus more on high precision, high speed power transmission: Rajiv Moorthy Coimbatore-based Shanthi Gears Ltd. is now a part of the Rs.29,000 Crore Murugappa Group, one of the leading industrial houses in India. The company with a long history of manufacturing high quality, high precision gears, gearboxes, geared motors and gear assemblies, offering customized products and solutions for traction, cement, power, mining, aerospace, defence and other core sectors of the economy. The company, on the threshold of its Golden Jubilee, is strategizing its growth plans to almost double its turnover in the next three years. Mr. Rajiv Moorthy, the effervescent CEO unfolds some of the strategies aimed at achieving a sustainable, profitable growth of the company in a one-to-one with Mr. P.K. Balasubbramaniian of Machine Tools World. Excerpts:

Mr. Rajiv Moorthy, CEO, Shanthi Gears Ltd.

MACHINE TOOLS WORLD MAY 2016

COVER STORY www.mtwmag.com

Q. Whatâ&#x20AC;&#x2122;s the standing of Shanthi Gears, especially after becoming a part of the Murugappa Group? And whatâ&#x20AC;&#x2122;s your niche? We have a long history of 47 years, manufacturing high quality, high precision gears, gearboxes, geared motors and gear assemblies for a plethora of applications. The management teams between the two companies saw synergy through this acquisition. For the Murugappa Group it was a gateway to increase presence and tap opportunities in the engineering sector,foray into niche applications such as aerospace / defense and also increase presence in the non auto segment. The team at Shanthi clearly understood the culture, ethos and the corporate governance standards of the Murugappa Group before a decision was made. Tube Investments being in power transmission cemented the need to come together. At SGL we manufacture helical, spur and worm gears, gearboxes, gear couplings and geared motors. We have a diversified range and going forward we will focus on high precision and high speed power transmission.

Q. How big is the gear industry worldwide and where does Shanthi Gears figure in? The size of the gear industry worldwide is US $170 billion. Of this, 70% is automobile and 30% industrial. The size of the Indian market in terms of value is close to Rs.10000 crores. In this, the share of industrial gears is of the order of Rs.3000 crores.This also suggests the potential for growth. Almost 65% of our business comes from custom built products and the balance from our standard offerings. With infrastructure

poised for growth we expect to see a lot of traction in associated industries.

Q. You seem to thrive on home grown technology. What are the technological innovations you have showcased in recent years? Indigenous technology has helped our growth thus far. Tremendous knowledge has been acquired and built over the years, through our people. We have received prestigious orders from Defense and customers continue to repose faith in our capabilities. We are AS-9100C certified which qualifies us to supply components to the aerospace industry. We keep ourselves abreast of advancements in process and technology and capital plans for the next three years include investments in next generation equipment. In-house capabilities and competency enhancements are priority areas and we have a structured plan to bring out these through strategic alliances.

Q. Could you give some idea of your infrastructural facilities and wherewithal? We have the largest integrated manufacturing capability in India with latest machinery. Our ability to design, build and service gives us the added advantage to be considered as a partner to our customers. Our customers believe that we maintain high standards across various stages of our supply chain. The foundry, forging, and gear manufacturing line are well supported by a heat treatment facility.

Q. What are your core strengths and competencies? Superior design and engineering

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COVER STORY capability, best- in-class vendor base and process discipline have been core ingredients for SGL to be recognized as a ‘reliable’ partner. Our vast knowledge and experience in gear manufacturing is acknowledged and we are known in the industry as an organization which can provide ‘bespoke solutions’. As the old Indian adage goes, we believe that the fundamental principle of any economic activity is that no man you transact will lose, then you shall not. This is the Murugappa philosophy of doing business. With an involved and supportive Board, motivated team it is time we convert market opportunities to business.

Q. You seem to thrive on import substitution. What are your recent achievements? Do you have any firsts? Our recent achievements include product development for gear boxes in critical applications such as drives for merchant mills, raw material conveying, molten material transportation as well as gear components for various defense and aerospace applications. We have been working on developing gearing solutions for gas turbines and hydel power generation and our customers are happy with our offering. Customers prefer to work with us in areas of heavy duty gearing and we do

have a lot of firsts to our credit in this arena.

Q. What are the challenges involved in offering customized solutions? We first understand the customers’ exacting and implied needs to provide enduring solutions. Validation with regard to design, engineering and manufacturing needs tools, knowledge, expertise and know why. Our endeavor is to raise our own bar with regard to principles of First Time Right. Sometimes the biggest challenge is to make our prospects realize the importance of life cycle cost and not just at unit price.

Q. How do you identify the customer’s pain points and redress them? Our very approach to the customer is to solve their problems, to offer them a product which is superior in design and quality, and to give them value for the money spent. We take care of the entire chain – correct design, the best quality, the right price, delivery and after-sales support. There is surely a scope for improvement in all the areas mentioned.

Q. How do you educate your customer on the right selection and use of gears and gearboxes? Knowledge and experience are required

to educate and guide a discerning customer. At Shanthi Gears, we always guide the customer in the right selection of the product that meets his exacting requirement. We do not sell products, we provide solutions through our capabilities. We have a strong team of 12 Engineers at our R & D Center which is equipped with the latest software tools. Our R & D team is constantly working on product innovation and providing support to our Engineering Dept. We have a brigade of 45 Design Engineers who design products as per applications and life expectancy. Our reservoir of knowledge and resources are nurtured to help and enlighten our customer.

Q. How do you make your products more rugged and at the same time more energy efficient? We constantly improve our design and harness contemporary technology so that our products are robust and energy efficient. We have the talent within to imbibe the latest technology.

Q. Could you give some idea of your customer base and spread? Is Export a thrust area for you? We have a vast customer base spread across sectors like steel, cement, power, railways, defence and so on. The contribution of export to our turnover is marginal today. In the days to come, we will focus more to build products and solutions for the overseas markets.

Q. How do you plan to enhance your visibility and presence in the global market?

Shanthi Grears Core Team: L-R: Mr. Debashis Chattopadhyay, Head-Sales & Mktg; Mr. Rajiv Moorthy, CEO; Mr. Saurabh Jain, CFO and Mr. M. Karunakaran, Head-Operations

MACHINE TOOLS WORLD MAY 2016

We understand the importance and we are working on an approach in this area. We have launched customer connect programs recently and we have received good inputs and feedback for improvements. We will focus on going digital in many areas to make the process of gaining access a more pleasurable, friendly and easy one. We need to leverage on strengths and be clear of our ‘where to play and how to win’.

INDUSTRY FOCUS www.mtwmag.com

The Future of Metrology

“Measurement is the first step that leads to control and eventually to improvement. If you can’t measure something, you can’t understand it. If you can’t understand it, you can’t control it. If you can’t control it, you can’t improve it.” - H. James Harrington

Anshika Srivastava, THORS eLearning Solutions

roper knowledge of, and skills in, measurement techniques are required to properly construct engineering works and structures. Lack of knowledge and miscalculations can result in catastrophic events. Take, for example, the Great Kersten Blunder, in which software controlling a space probe on course for Venus used “24.5” instead of “25.4” to convert millimeters to inches. The error meant that the probe missed its target planet completely, losing $2 billion worth of technology. The eponymous Kersten was the programmer who made the error. Precise and reliable measurement is the foundation of all engineering works and structures. Without it, engineering machines will break down, buildings will collapse and vehicles will crash. It assures that all gears are fitted correctly to produce a continuous motion; it ensures that structures are balanced and properly supported by its foundation and it determines the correct distance needed to travel from one place to another. Proper knowledge and skills in measurement is required to properly construct engineering works and

structures. Metrology is defined by the International Bureau of Weights and Measures (BIPM) as the science of measurement, embracing both experimental and theoretical determinations at any level of uncertainty in any field of science and technology. Technological innovations have increased the measurable world to the molecular level. Year after year, metrology grows increasingly subtle, and metrological tools grow increasingly sensitive. And this is just the beginning. All of this directly affects the world of quality, which relies on increasingly sophisticated measurement tools and techniques as the lifeblood of quality assurance. For manufacturing applications in particular, the ability to properly measure materials and parts leads to fewer defects and higher levels of quality and customer satisfaction. In the future, we are likely to see significant advances in the following five key elements of metrology tools and equipment: • Increased speed • Improved accuracy • Reduced measurement size • Better environmental control • Lower costs. For metrology equipment manufacturers and the customers who buy from them, these are the five areas where technological advances lead to measurable results. For high-end users with the resources to afford it, the

next generation of CMMs (Coordinate Measuring Machines), articulated arms, optical scanners and the like will yield astonishing increases in speed and accuracy, with a corresponding reduction in size and greater portability. What does the future of metrology hold? To meet the anticipated industry needs, equipment manufacturers are looking for ways to optimize the functionality of measurement and inspection equipment—to measure all things in all ways —using a wide range of sensor and mechanical technologies to reduce inspection time and costs.

Multisensor technology Any measurement system uses at least one sensor technology. A sensor collects data points from a part to perform a measurement – it’s the probe or detector that “senses” the part. Sensor technologies are contact or non-contact. Combining two or more sensors on a single machine makes it multisensory. Smaller and varying feature sizes and tighter tolerances are good incentives for manufacturers to investigate multisensor data-gathering systems that incorporate tactile, vision, and laser-scanner systems. Multisensor technology offers high level of flexibility, accuracy, speed, and throughput, in addition the ability to measure forms and features, that may be impossible for a single-sensor machine

Software Another trend is the reuse of existing

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INDUSTRY FOCUS

equipment through the application of new, easier-to-use software and reconstruct CMMs with advanced sensors. This retrofitting of CMMs with new sensor technology significantly help manufacturers improve throughput with the degree of accuracy necessary to provide users with meaningful dimensional data. For example, large-scale metrology, too, will get a boost as indoor GPS technology is applied to more applications. The use of computer tomography (CT) inspection systems, particularly as applied to small components is also of significant interest in the metrology equipment industry.

Everybody wins when everybody measures It’s been said that the only constant is change. Nowhere does this aphorism ring truer than in the metrology industry. The constant evolution of tools and concepts forced by the

MACHINE TOOLS WORLD MAY 2016

demands of the marketplace lead to faster and more accurate measurement options for companies and organizations. Competition between makers of metrology equipment adds more fuel to the fire, spurring further advances. Manufacturers benefit by being able to offer their customers better-produced materials, and consumers gain when those materials are turned into better, safer and affordable products. The key is flexibility. With everincreasing options in terms of scanning speed, accuracy, measurement size, environmental control and cost, manufacturers and others who require measurement and inspection will be able to choose a solution that’s just right for their needs. As measurement becomes ubiquitous, quality will improve. Profitability and customer satisfaction will increase. It’s simple. By any measure, the future of metrology looks bright indeed.

About the author Anshika Srivastava is currently a blogger for THORS eLearning Solutions, an Ohio based company that provides eLearning content for the manufacturing industry. She has around 8 years of experience in digital marketing. As a part of the marketing function, she has helped companies in managing their digital footprint. Anshika is passionate about SEO, social media and web technologies. She holds a BE in Electronics and an MBA in IT & Marketing. She uses her varied experience to create refreshing content for the manufacturing audience.

INDUSTRY FOCUS

Innovation is a part of our culture: Satish Bhat Q. How was the year that went by for your company? The year FY2016 was good overall. In spite of GDP not growing as expected and manufacturing sectors growth was subdued, we have grown in volumes in both Consumables and Equipment. This is as a result of our reach to customer, value addition approach through technical support, strong after-sales service in higher customer satisfaction Index and many more activities. In case of consumables we have grown in spite of low business from key accounts of

FY2015. This means we have reached out to more number of end users and have successfully converted and retained them to Ador Welding. The year was good for Automation business as well as for Project Engineering Business due to launch of new products and successful commissioning of projects during the year.

Q. Any upheavals you had to surmount? The market was tough, Capex had dried out and thus market became fiercely competitive leading to price wars. No new projects launched, Margins were seriously under pressure. Thus the challenge was to acquire more customers by serving their specific needs with our technical expertise and support.

Q. What are the innovations you wish to display this year? Innovation has been a part of our culture with increased focus since last 3 years. We have established an Innovation Council

which is responsible for creating the culture of Innovation. Over 100 employees in the organization at various levels have undergone training in this regard. TM and OD activities are focused on Innovation. Innovation in Products and Services is indispensible in today’s competitive market. We have also done a lot of Innovation in our processes at support functions and manufacturing apart from our Products and Services. For example, in one of our manufacturing processes we have increased the efficiency of our Wet Drawing machine by changing the design of the pulley that was provided by the OEM manufacturer of the machine. A constant zeal of finding avenues to add value to the organization is the spirit of our employees, and this is what leads to such innovations at multiple levels. This year the Innovation focus will be on: • Ease of doing business. • Significant value addition to customers by enhancing their operational efficiency. • New Technology and Solutions for our customers.

Q. Did you ever feel there’s a better way? What would be your strategy and approach to make the most of this year and beyond?

Satish Bhat, Managing Director, Ador Welding Ltd.

MACHINE TOOLS WORLD MAY 2016

There is always a better way. The strategy going forward would be to sustain the initiatives taken in the last 3 years and capitalize on our Customer Relations, Technical and Manufacturing capabilities. Build synergies with our current capabilities and resources to offer new products to our customers.We would look at creating value through forward as well as backward integration. The focus would be on pursuing growth irrespective of the Economic or Market scenario.

INDUSTRY FOCUS www.mtwmag.com

Customization of process for higher productivity is the key to getting a bigger market share: Ashok Sheth level are becoming reality. A tooled up automated machine with higher cost is more preferred than a general purpose machine with low cost. The quality conscious customers are also finding out that low cost second hand machine no longer guarantees them business, as they are unable to meet quality parameters which are becoming stringent day by day.

Q. Any upheavals you had to surmount?

Ashok Sheth, Chairman Solitaire Machine Tools Ltd. Q. How was the year that went by for your company? The last financial year was slow to start with, but it picked up the speed of order receipt and execution. Domestic market is still a bit jittery for domestic consumption. Those who have good potential for Export of components / sub-assemblies are taking risk and procuring equipment and upgrading with automation. At SMT, we found the year quite good with healthy growth of about 40 %. The Export was made to various countries in North America, South America, Europe and China. The lesson learned was that customization of process for higher productivity was the key to getting bigger share of market. Customers are looking more for Solution than just a machine. The tolerances in sub-micron

The major change was the need to reduce the price of machines being sold in domestic market. The major vendors of Castings, CNC systems, Ball Screws and all other peripherals were not willing to reduce their prices, whereas customers are under tremendous pressure to bring down the price of their products. The Rupee also kept on getting depreciated affecting the import cost and cost of manufacturing. It was hard to keep two ends to meet and still continue profitable operations. The major issue with most customers is lack of skilled manpower availability at reasonable cost. Lack of manpower and higher turnover of employees is affecting the business all around. The skill imparted by Schools, Technical institutes, Engineering colleges are all too much of theory oriented and students graduate just by reading their books. Greater interaction with industry on shop floor level is a necessity of the day.

a year or two to come up with desired solution. The savings in manufacturing time would be really big for manufacturers of these products. We are also pursuing wider applications for New Micro Centerless Grinders. We would like to upgrade our machining capabilities for better accuracy and savings in machining time. New design tooling is being adapted for higher output. Several machines are being upgraded with CNC controls to ensure consistency in manufacturing. We would like to target full CNC machine shop by 2022.

Q. Did you ever feel thereâ&#x20AC;&#x2122;s a better way? What would be your strategy and approach to make the most of this year and beyond? Yes, there is always a better way to do whatever you are doing. You do not need rocket scientist brain to do better. All you need is common sense and open to new ideas coming from any source from where suggestions can be received. There is no limit to how much you can learn from your colleagues, employees, customers, vendors, competitors and even a layman, who has no clue on what you are doing. The simple strategy would be to listen more than speak. We have seen that new products, new processes have been evolved just by a stray idea on why this cannot be done by us. Close your eyes and you see it running like a movie with all the variables available to make the process productive and cost-effective.

Q. What are the innovations you wish to display this year? We would like to pursue grinding of Cam Shafts and Crank Shafts on Centerless grinders for higher productivity. The concept is being developed and may take

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MACHINE TOOLS WORLD

IND FOCUS

The most exciting thing at NRB is our focus on empowering the younger generation: Harshbeena Zaveri Harshbeena Zaveri, Managing Director & President, NRB Bearings Ltd. Q. How was the year that went by for your company? It was a challenging year for the automotive industry. However, we used the opportunity for focused product development and held our own on the financial front. Our strategy is to ensure that our progress does not stem purely from market growth; we develop new products for the future generation of mobile vehicles across applications. In the course of the year we concentrated on penetrating more deeply into emerging segments including defence, aerospace, marine, mining and offhighway along with a deeper engagement with our traditional segments such as two-wheelers, cars, trucks and farm equipment. We are very upbeat about the current year as we will get the benefit of all the operational improvements implemented through the year as growth numbers soar.

Q. Any upheavals you had to surmount? The culture we strive to build is one where difficulties are looked upon as

MACHINE TOOLS WORLD MAY 2016

Our company has been restructured over the last three years to give significant responsibility to young men and women under the age of 30, across functions. The average age of our workforce is one of the youngest in the industry and they hold significant positions and power to make the changes that are required to make us a market-leader. opportunities.Our approach is simplifying our strategy and attracting young men and women who enjoy engaging with the customers and are passionate about our products. Scaling up and yet being true to the essence of our goal,to be a customized friction solution provider is our differentiator. This year, we expanded our range and engineered cost effective, light weight friction solutions for a host of applications that resulted in increased fuel efficiency, noise reduction for engines and transmissions, and enhanced life. Size matters less to us than the impact and quality of the solutions we provide.

Q. What are the innovations you wish to display this year? What would be your strategy and approach to make the most of this year and beyond? We are leaders in light-weighting and the focus of our product and technology development has been the adoption of a disruptive approach which optimises material input and performance. Our true value lies not just in reducing the cost of

an existing process but in creating new and innovative bearing solutions to add value to our customers which include ZF, Bosch, Daimler and Getrag apart from the Indian auto majors.NRBâ&#x20AC;&#x2122;sResearch & Development centres focus on cutting edge product and process technologies. Our emphasis is to be pioneers not just in existing bearings but to create friction solutions using diverse materials, technologies and manufacturing processes. What is most exciting at NRB is our focus on empowering the younger generation. Our company has been restructured over the last three years to give significant responsibility to young men and women under the age of 30, across functions. The average age of our workforce is one of the youngest in the industry and they hold significant positions and power to make the changes that are required to make us a market-leader.

BE DYNAMIC!

THE FUTURE OF EFFICIENCY & SPEED IS HERE – MASTERCAM’S DYNAMIC MOTION TECHNOLOGY Since 2008, Mastercam has been building Dynamic Motion into our software. That means it has been shop-tested and proven in real-world environments. Dynamic Motion toolpaths carve out massive amounts of material quickly, reducing cycle times by up to 75% – while doubling and even tripling the tool life – immediately putting more money in your pocket. Sounds unbelievable, right? But as the market leader, we’ve had our Dynamic Motion toolpaths tested in most every conceivable work environment around the world. It works.

For more information, visit www.Mastercam.com 800-228-2877

INDUSTRY FOCUS

The field of robotics is in a massive growth phase similar to what IT was in late 90’s: Arjun Prakash Q. Effica is a name to reckon with in automation. What precisely is your niche? We started off in 2005 designing and manufacturing special purpose machines (SPMs) for a plethora of applications. We even developed robotized special plasma cutting systems for marking and precision cutting power transmission poles of 60 ft long. Way back in 2009 we executed a project worth Rs. 2 crores in Houston. This was a complex job involving different disciplines – mechanical, electrical, electronics, robotics, and industrial PCs. It involved handling, rotating, marking and cutting of poles where cost of error was very high. Over the years, we have changed our focus. Since 2011, to be precise, our focus is on material handling automation using robots which includes machine tending, palletizing & conveying.

Q. What are the automation solutions you offer for the manufacturing sector? We offer robot based component loading and unloading systems. The solutions are available for multiple CNCs, forging presses, sheet metal presses, plastic injection moulding and similar processes. Along with this we offer all the accessories required to complete the solution like conveyors – roller, belt, and slat, the end effectors for gripping various types of components, the safety systems, infeed and outfeed component stacking magazines. We also offer gantry machine tending to replace articulated machine tending projects for payloads from 2 kg to 100 kg. This is an economical solution, and with this the existing plant layout need not be disturbed. We also do bag conveying & palletiz-

MACHINE TOOLS WORLD MAY 2016

ing automation. This is a robot-based high speed palletizing system with a speed of 20 tonnes per hour. For the FMCG segments we offer pick and place solutions for the packing requirements. These are very high speed solutions for light weight products with a special emphasis on hygiene. We have made our systems modular and userfriendly so that in the event of a failure, the end-user can fix it themselves. This way we have removed the fear of breakdown and consequent downtime from the mind of the end-user.

Q. What are the challenges ahead for a company like you in today’s context? The field of Robotics is in a massive growth phase similar to what IT was in the late 90s. When this happens, we have to be ready to scale up our production to ride the growth wave. Side by side, we must educate the customer on the benefits of automation. They must be induced to adapt the manufacturing processes to make room for robots to take charge. We have to remove the fear from the minds of the customer that there won’t be any issues of breakdown and idle time since they themselves can address the snags if any and keep the machines humming.

Q. What’s the shape of things to come in factory automation and how do you envisage making a dent in this exciting field? Some 20 years ago a robotic solution cost Rs.30 lacs. Today it is in the vicinity of minimum Rs.15 lacs. The inflation adjusted prices are dropping down massively and will drop down further in the days to come. This will help manufacturers to go in for more and more robotic automation.

Arjun Prakash, Director, Effica Automation Ltd. There has not been any change in technology in Robotics for the past four decades. However, we are seeing significant changes in technology in the last 2-3 years. The next wave of robotic technology like collaborative robots which work side by side with humans and super easy programming and operation methods which are similar to your mobile devices and apps are already rolling out. The worldwide robotic sales for the year 2013 is said to be 179,000. This is nowhere near the potential demand for robots in the world. In the year 2014 China is the largest consumer of robots. Indian SMEs should think progressively and take path-breaking decisions to reap the benefits of productivity and flexibility offered by robots. We in India are on a growth trajectory. And robots will play a pivotal role in enhancing our quality, productivity and operational efficiency in the days to come.

REVOLUTION IN ALUMINIUM CASTING INDUSTRY Robotic Deflashing of AL Die Casting

Over 25 Proven Automation Solutions

THE GRIND MASTER ADVANTAGE ● ● ● ● ● ●

Optimized Process for Deburring/Grinding Automated Input/Output Devices High Quality Uniform Finish Result Eliminates Manpower & Health Hazards Compliance with Global Manufacturing Practices Modular and Flexible Solution for Variety of Components

Grind Master is a pioneer & leader in special purpose machines for Metal Finishing, Grinding, Deburring, Microfinishing & solutions including Robotic Automation and Abrasives. Our strong process knowledge makes us customers first choice when it comes for Grinding, Deburring Automation Solutions.

Grind Master Machines Pvt. Ltd. B-10/B-11/B-14, Railway Station MIDC, Aurangabad- 431005, Maharashtra (India). Tel. :+91 (240) 2374104 / 2374114 Email : sales@grindmaster.co.in Website : www.grindmaster.co.in

NANOFINISH I METAL FINISH I DEBURR I AUTOMATION I ABRASIVES

SUCCESS STORY

Garage to the Globe – The Saga of Grind Master

The winsome trio: Milind, Sameer and Mohini Kelkar

rind Master is a pioneer and leader in special purpose machines for Metal Finishing, Deburring, NanoFinish and solutions including Robotic automation and Abrasives. The company provides total solutions for surface finishing requirements With over 4000 machines across 6 continents, serving a wide range of industries, it brings a world of experience of over 30 years in machine technology & process knowledge. Grind Master competes with the best in the world. It constantly strives to exceed customer expectations with Innovative & Trustworthy solutions created with Passion and Expertise.Grind Master Accounts for 20-25% of All Indian Machine Tools Exports (data from IMTMA). 75% of Grind Master Exports are to China, where Grind Master competes with German and Japanese Machine Builders on Technology. Grind Master is the only established Indian Supplier to Global Automotive Companies such as SGM, SGMW, Great Wall and DPCA for Machinery with Turnover around INR 125 Crores. Garage to the Globe

Grind Master is a family owned business started by Entrepreneur couple Mrs. Mohini Kelkar and Mr. Milind Kelkar from VJTI in 1984.They began developing

MACHINE TOOLS WORLD MAY 2016

indigenous metal finishing machines from a rented garage in Aurangabad City. Until this time, all metal finishing operations were performed manually. These manual processes had limitations on time, accuracy and consistency of finish and resulted in an unhealthy work environment. Identifying this gap in efficiency of productivity, Mr & Mrs Kelkar focused their attention on developing and manufacturing automatic and semi-automatic metal finishing machines. Their passion for machine building, reinforced by their ‘Can and Will’ motto, resulted in the birth of Grind Master, a company based on innovation and efficiency in engineering, with a grounding in strong values. Over the past three decades, the company has grown exponentially, offering one of the widest ranges of Special Purpose Machines for the processes of deburring, grinding, polishing and microfinishing to suit every industry need. From making 2-3 machines a year, Grind Master now manufactures 450 machines in three state-of-the-art factories and additional manufacturing support units. Mr. Sameer Kelkar, IIT Bombay & UC Berkeley Graduate, has taken the organisation to next level with successful introduction of Robotic Technology. Grind Master offers a wide variety of Robotic solutions into its niche field of Surface Finishing.

The Grind Master plant in Aurangabad Widest range in the world

Today Grind Master offers the widest range of metal finishing machines in the world. The comprehensive solutions it offers for diverse industries like Automobile, Defence, Aerospace, Cookware, Foundry, Textile and Steel, comprise: • Robotic Automation for Fettling of Castings • Centreless Belt Grinding & Polishing of Tubes & Bars • Superfinishing of Cylinders, Engine & Transmission components • Gear Chamfering Deburring Machines • SPMs for Polishing, Grinding & Deburring applications • Cookware Polishing Machines • Sheet Metal Polishing & Deburring Machines • Coated Abrasives. The company rightly claims to be a ‘one stop shop’ for total solutions for metal finishing in the world. - P.K. Balasubbramaniian For more information Grind Master Machines Pvt. Ltd. B-10/B-11/B-14, Railway Station MIDC, Aurangabad- 431005 Maharashtra (India). Tel. +91 (240) 2374104, +91 (240) 2374114 Email :sales@grindmaster.co.in Website :www.grindmaster.co.in

COMPANY PROFILE www.mtwmag.com

Bright Roller Burnishing Tools for complete burnishing solutions

oimbatore-based Bright Roller Burnishing Tools Private Limited, incorporated in the year 1994, is an ISO 9001: 2008 certified company. With its sustained efforts, quality products and after-sales service, it is enjoying a reputation in the field of burnishing close to three decades. Clientele : The company has a very wide customer base in India covering MNCs, Corporate, Medium and Small Industries and Public sector undertakings. With a vast experience and an ever-expanding list of satisfied customers in India, the company has set its sight on the overseas market. It is exporting its quality products to countries like, USA, Iran, Australia, Thailand, Indonesia, UK, Singapore, etc. Applications: Bright Burnishing Tools are being used in sectors like automobile components manufacturing, motors and pump industry, textile machinery manufacturing, hydraulic and pneumatic parts, home and office appliances, machine tool manufacturing, earthmoving equipment manufacturing, railway parts, defense, aircraft parts and many more.

encountered in the day-to-day production process. Product range

Bright’s product range includes burnishing tools for Internal Diameter, External Diameter, Internal and External Tapers, Flat circular faces, Grooves, etc.

special purpose burnishing tools as per customer’s requirements. These include: • Single Roller Tool • Multi Surface Single Roller Tool • OD H Type tool • Face Burnishing Tool • Flat circular face burnishing tools • Groove Burnishing Tools • Burnishing Machine

Internal Diameter Burnishing Tools

• Tools for through and stepped bores • Min. Internal Dia 5mm and above • Designs available for Short bore length, Long bore length, Big internal dia. • Tools with machine feed / self feed design available • Tools available with different shank options Outer Diameter Burnishing Tools

• Tools for through and stepped bores • Min. External Dia. 2mm and above • Tools available with different shank options • Highly suitable for diameter less than 30mm & with short burnishing length

Apart from Burnishing tools, Bright also manufactures Burnishing machines like Hydraulic OD Burnishing Machine, Pneumatic ID Burnishing Machine, and Portable OD Burnishing Machine. Customer appreciation

“Customer appreciation is our source of strength and inspiration, and the same will help us to make our products better every time and in all ways. Many of our customers have sent letters appreciating the quality of our products and after-sales service. We always focus on continuous improvement and customer delight,” says the company – P.K. Balasubbramaniian

Taper Angle Burnishing Tools (Internal & The Process and its Advantage

External Angle / Taper)

Burnishing is a cold rolling process on ferrous and nonferrous machined components. Achieving superior surface finish (0.1 Ra to 0.3 Ra based on preburnishing condition) and close tolerance is easier with less cycle time and at negligible cost, thereby eliminating finishing and quality problem, which are

• Tools for Internal tapers and external tapers • Min. Minor Dia 5mm and above. • Highly suitable for mating taper assembly, like hydraulic end fittings • Can be burnished directly after CNC turning. • Tools available with different shank options. Special Roller Burnishing Tools

Apart from its standard product ranges, the company also manufactures

MAY 2016

MACHINE TOOLS WORLD

COMPANY PROFILE

Shavo Technologies offers high-tech tailor made solutions

S Rushil Shah, Managing Director, Shavo Technologies Pvt. Ltd.

havo Technologies Pvt. Ltd., a part of the Shavo Group founded by Mr. H.K Shah, a pioneer in the pneumatics field in 1960, is in the frontiers of niche high technologies cutting across diverse disciplines. The company headquartered in Pune and headed by Mr. Rushil Shah, Managing Director, represents some of the world leaders in their respective fields for technology solutions like static elimination, precision air movement, high quality instrumentation, high purity gas delivery, corrosive gas handling, energy absorption and so on. With a vast portfolio, the company serves over a thousand customers from diverse key sectors including semiconductor, aerospace, defense, chemical, oil & gas, automobile and so on. “Over the years, we have gone from

Applied gas delivery systems

MACHINE TOOLS WORLD MAY 2016

selling components to systems and solutions and turnkey capability in an effort to keep offering better value by leveraging the technologies we provide,” says Mr. Rushil Shah. All its principals have specific technologies that would be classified ‘cutting edge’ considering the fact that all of them are world leaders in their fields. Following are brief details of their principals and business areas: TESCOM is a recognized leader in the manufacture of high-pressure regulators up to 20,000 psig designed to work with all types of fluids, both corrosive. Tescom range covers over 70 standard models of high-pressure regulators to meet almost any requirement. HAM-LET specializes in the design, development and production of high quality instrumentation valves and fittings in a wide variety of materials for high, pressure, temperature and vacuum applications. These products are used in diverse industries like petrochemical, semiconductor, energy, food, biotechnology, pharmaceutical, defense, pulp & paper and mining. CLASSIC FILTERS brings you filter elements to filter housings to complete filter systems for almost any function. It delivers some of the most robust high quality, coalescing filters and particulate filters in the world. In order to manufacture high tech devices such as semiconductor devices, flat panel displays and even photo voltaic or solar cells, precise fluid control is a must. HORIBA is the established world leader in offering a full line-up of gas, liquid, and vapor delivery products. Applied Energy System Inc. is one

COMPANY PROFILE www.mtwmag.com

of the world leaders in the field of ultra high purity gas delivery systems like gas cabinets and panel for solar, semiconductor, nano technology and other high purity industries. Gas specializes in design and manufacture of air moving products including vacuum pumps, compressors, air motors, gear motors, vacuum generators and regenerative blowers. “As a matter of fact, our journey of working with high technology industries started with Gast which today remains one of the world leaders in air motors and fractional horse pumps,” reveals Mr. Shah. Meech’s forte is industrial electrostatics. With a standing of over 40 years, Meech has developed a wide range of products like ionizing bars, hand-held ionizing air curtains, etc. for effective static

neutralization and dust removal. With the experience gained from more than 200 successful web cleaning installations, Meech can offer both non-contact and contact web cleaning systems. ITT Enidine is again a world leader in energy absorption and vibration isolation products, providing solutions to a wide range of industrial markets. ITT Corporation is a hightechnology engineering and manufacturing company operating on all seven continents in three vital markets viz. water & fluid management, global defense & security, and motion & flow control. Shavo feels fortunate to work with some of India’s top companies and institutions like Reliance, Tata’s,, Biocon, GE, Department of Space, Ministry of Defense and many more. It has in excess of 1000 live accounts. The company has a full Electrostatics for effective static neutralization

High pressure regulators

High quality instrumentation valves

service capability at its Pune office and is in the process of building a worldclass service center in its Bangalore factory. “Our service support is the key pillar of the value we provide,” says Mr. Shah. – P.K. Balasubbramaniian

For more information Web: www.shavogroup.com

MAY 2016

MACHINE TOOLS WORLD

COMPANY PROFILE

MEPL - The Leader in Resistance Welding

“We introduce machines yielding high productivity at low power consumption.” - Gabin Kattukaran, Director, Mechelonic Engineers Pvt. Ltd

hen we talk of Mechelonic Engineers (MEPL for short), the first thing that conjures up in mind is the image of a Rail Welding Line it developed for the manufacture of continuous welded railway tracks for the Indian Railways. After long and rigorous R & D, Mechelonic Engineers developed the expertise to design and manufacture Rail Flash Butt Welders along with allied equipment like weld flash strippers, weld data recorders, rail straightening presses and rail grinding machines. It’s decades since the Railways have been using these robust equipment to make quality welds on which hinges the lives of millions who travel by rail. Flash Butt Welders is just one example of the early success of MEPL, the company founded by Mr. K.P. Antony who even today feels proud that he built not only machines but also relations with the giants in the industry. According to Mr. Gabin Kattukaran, the Director, the indomitable urge to provide dependable and cost effective solutions to the customer has culminated into the development of a number of special machines for the industry. The container line developed for the metal can making industry in India is a classic example. This machine designed

MACHINE TOOLS WORLD MAY 2016

MEPL’s state-of-the-art manufacturing facility for side seam welding can make 360 containers per minute. Productivity is paramount here. These cans are used for packaging processed mango pulps. No downtime is acceptable. During season, the machines have to work for 24 hours a day, non-stop! Engineering marvels

The special purpose flash butt welding machine it has developed for BHEL for welding tubes end-to-end for heat exchangers is truly an engineering marvel. MEPL was pitted against several others for developing this machine. The company worked for over three years to develop this SPM. The challenges involved were manifold. The testing criteria of the tube joint are critical. The tube is to be bent without cracking. The material build-up should be minimal. After the coils get assembled, a metal ball of 80-85% ID of the tube is passed from one end to the other to check free passage. MEPL met all these requirements and bagged the order against stiff competition. Subsequently it supplied three more machines to this power equipment giant. The machine is hydraulically operated, fully tropicalised and specially designed for heavy duty application where repeatability in performance is important. It is provided with a powered manual

adjustment facility for proper alignment of the fixed and moving tubes before welding. For accurate and consistent weld results, fully solid state electronic controls are provided. All electrical controls are housed in a separate cubicle with required protection. The machine operation does not require any skilled labour. The welding parameters are easily settable through a user-friendly interface to the control system. Quality is assured with a PC based welding monitor. MEPL has also come up with a Steel Grating Welding Machine with a rating of 1800 KVA for manufacturing steel gratings by electrical resistance welding. The application of high current and high forging pressure under precise control of a special welding controller and a PLC based sequence controller results in high quality electro-forged weld joints. The machine is used for manufacture of world-class gratings using round, square or twisted cross bars. The company also offers special machines for mesh welding. Its seam welding machine with 2-axis CNC controlled sheet handling is designed for continuous and roll spot seam welding of plate type and econocoil type heat exchangers. MEPL has exported such seam welding machines to handle sheets of 9 m length to China as well. Indeed, MEPL is a leader in resistance

COMPANY PROFILE www.mtwmag.com

welding. Though there are ‘n’ number of manufacturers in this category, no one has a comprehensive range that MEPL has. Its customers also represent wide ranging industry segments like automobiles, railways, aerospace, defence, power, steel mills, white goods, metal can making, electronics, switchgear and so on. “We specialize in handling difficult jobs which others cannot touch. We cater to specialized markets where customized design plays a pivotal role. That’s our niche”, elucidates Mr. Gabin. “And we do not depend on any one industry for our bread & butter. For instance, the automobile industry has not been doing well for quite some time now. So we had to change our gear and concentrate on other industries where our contribution was valued and realization was faster. We sell our equipment for a premium. And our customers do not mind paying a little extra for our quality, expertise and involvement in providing solutions based on our vast experience. They know once we take up a job, we shall accomplish it – no matter what amount of efforts go into it and how much time it takes. For instance, the equipment for tube welding for heat exchangers supplied to BHEL took over three years for us to develop.” Mr. Gabin is quite clear that MEPL is not in the commodity market. “We are in the niche market where our domain knowledge and vast experience are constantly put to test. Most of our products are import substitutes. We believe in indigenous technology and are proud of the made in India tag.” Mr. Gabin relates that in some cases the welding per se is hardly 10%. The rest is job handling, testing, assembly and allied operations. The customers prefer one company that is capable of handling everything. That is where MEPL scores over. Core strengths

“Our people are our core strength”, confides Mr. Gabin. There is a strong sense of belonging amongst them. Each employee has put in an average of 10-15 years of service in the company. This

stability, commitment, accumulated experience and process knowledge of our people is what is giving us the confidence to take up complex jobs.” The company has spearheaded several innovations in the field of resistance welding. It was one of the first to introduce microprocessor-based controls in its machines some two decades ago. It used solid state electronics in the controls and powerpacks. It introduced servobased systems in the machines depending on the dimensional accuracies and tolerances demanded. In keeping with the trend, it also automates its machines using CNC and other controls, linear guides, etc. “Today all components are available off-the-shelf. Hence, integration is easy provided you know the welding process, have the domain knowledge and know the components,” he adds. Pursuit of excellence

“Our aim is to provide more and more customized solutions to the customer. We introduce technologies relevant to the region in an energy starved country - machines yielding high productivity at low power consumption. There are some states where ample clean power is available. In some others there is acute shortage. So we have to make the necessary changes in our machine design to suit the power availability. It is universally known that with DG power the weld quality takes a beating. But we have now come up with machines which can make perfect welds even with DG sets,” reflects Mr. Gabin. “Resistance welding is a niche area. We cannot dictate changes. We have to follow change. We should be flexible. No matter what happens, we have to continue to be there,” declares the leader. MEPL has two manufacturing units now. One is in Mumbai and other in Vapi. These plants chisel out 120 machines a year on an average. The company has a highly motivated and dedicated workforce of 125 people. It has regional offices in Delhi, Kolkata, Bangalore, and Pune and resident engineers in Jamshedpur, Ahmedabad and Chennai to attend to service calls and stay closer to the customer. “Mechelonic

A special purpose boiler tube welding machine developed by Mechelonic Engineers machines hardly require any troubleshooting – so much so that a seam welder supplied to a customer in Mumbai some 36 years ago is still going stronger. If at all there is any wear & tear, it would be in the cooling system, pipes or cylinders.” Nevertheless, the company maintains a team of engineers and technicians specifically to service and maintain large welding plants. It currently provides such services to several Railway Flash Butt Welding Plants of the Indian Railways. Good spare parts inventory and management help in maximizing uptime of its machines at customers’ places. The pursuit of excellence has been a constant endeavour at MEPL. Its success is attributed to constant updating of technology, a firm commitment to continuous research and development, and a strong team that believes in itself and the company it belongs to. MEPL has every reason to boast of the widest range of products, systems & solutions in the Indian resistance welding market. Or as they would like to say: “Bigger, Better, Faster and More” welding solutions than anyone else in this part of the world. -P.K. Balasubbramaniian

For more information Web: www.mepl.co.in

MAY 2016

MACHINE TOOLS WORLD

CASE STUDY

Since using Equator we have not made a single bad part & have reduced part production cost by 27% The quality of the products a company produces, and their assurance of that quality, can mean all the difference to successfully acquiring contracts. Maintaining that quality also significantly increases the chances of repeat business. High-Tech Engineering, a precision engineering company based in Dunstable, Bedfordshire, UK, has always focused on the quality of the parts it produces. Now with its latest addition, a Renishaw Equator gauging system, it is reaching 100% part inspection and zero scrap whilst halving the operator requirements and reducing part production costs by 27%.

S Two parts produced by High-Tech engineering

MACHINE TOOLS WORLD MAY 2016

tarted in 1985 by Managing Director, Steve Tickner, High-Tech Engineering built a reputation in the motorsport industry for delivering high quality machined parts. The company has since moved into the aerospace sector and gained some key industry approvals, including becoming a preferred supplier to Rolls-Royce and BAE Systems. Recently High-Tech won a contract to produce precision milled titanium parts for a large aerospace customer. Due to the nature of the parts, High-Tech was instructed to carry out 100% part inspection. Steve Tickner explains, “We knew from the start that we would need to find an inspection method which could not only meet the cycle time requirements for the part, but would be a cost effective solution for us as well. Relying on the CMM we already had wasn’t going

to be an option. We couldn’t risk any bottlenecks. We knew that we would either need another CMM or something else which could give us the measuring capacity. That’s what led us to the Renishaw Equator.” Equator™ gauging system acquisition

It was through a simple internet search that Steve came to learn of the Equator gauging system. After some research and following meetings with representatives from Renishaw, High-Tech was impressed with what the Equator gauging system could offer, and was particularly pleased with the overall price of the system. Commenting on why High-Tech bought the Renishaw Equator gauging system, Steve says: “Space on our factory floor is at a premium. Within the space we set aside for this cell we had to include faster, more efficient technology. This meant that a co-

CASE STUDY www.mtwmag.com

ordinate measuring machine (CMM) with a temperature controlled environment was far too big to be practical. The Equator suited the space perfectly as it’s a compact machine. The added bonus is the fact it is thermally insensitive and doesn’t require any air supply, meaning we didn’t need to spend additional time, money and effort putting in another temperature controlled room or extra piping.” High-Tech is currently using the Renishaw Equator gauging system to perform 100% inspection of a complex aerospace part. It works by comparing the manufactured parts against a matching master part, gauging all the features in a single operation with an immediate pass/ fail decision, along with a report of the component dimensions. Comprehensive measurement in half the time of the existing CMM option

The Equator gauging system is used to gauge around 150 features including a number of bores, thicknesses and form measurements on the part with typical

tolerances of ±25 μm. The Equator gauging system does this within 10 minutes and well within the production requirements, far less than the machining time. This is almost a 50% reduction in cycle time compared to running the program on High-Tech’s CMMs.

operators, to “zero” the Equator gauging system and set its accuracy for subsequent measurements. This has allowed the same operator who machined the part to measure the part, halving the operator time required. Flexibility and future proofing

Process control, run by the machine tool operator

Production at High-Tech runs 24 hours per day, 5 days per week and is split into 2 overlapping shifts. During this time Equator is used by a number of operators with varying skill sets. Previously, HighTech Engineering would have relied on its CMMs, housed away from the machine tool in a temperature-controlled quality room. Using the CMM for the latest job would have involved two separate operators, firstly the operator machining the part and secondly the operator with the specialist skills to operate the CMM. By using an Equator instead, newly trained staff can use dimensions from a certified component, approved by the QC

The Equator™ gauging system is fully programmable and can be used on multiple parts, meaning HighTech Engineering can perform highly repeatable and rapid automated routines across numerous contracts resulting in significantly reduced labour costs. Ease of use – push-button simplicity

Commenting on this, Mr Tickner states, “All of the operators can use Equator. It really is easy; just load the part and push the button. It completely simplifies the process and frees up manpower, which in turn helps to deliver ROI very rapidly for the cell.” High-Tech has managed to reduce the cost of producing the aerospace part by 27% with the Equator gauging

Renishaw Equator gauging system at High-Tech engineering

MAY 2016

MACHINE TOOLS WORLD

CASE STUDY

The quality control room at High-Tech engineering system being a factor in that. This has had a real impact on the competitiveness of this sort of production, allowing the company to make the same precision quality parts, whilst also delivering better value to its customers. It is through implementing these types of solutions and continually striving to improve their processes that High-Tech has been awarded 6 consecutive SC21 silver awards, which is unrivalled in the UK. This award recognises excellence within the aerospace and defence industry, for the quality of the products a company produces, as well as its ability to supply them. To receive a silver award a company must consistently achieve at least 95% for delivery performance and at least 99.5% on quality of parts to all of its customers. Mr Tickner explains “Since we started using Equator we have not made a single bad part. The Equator is allowing the operators to operate complete process control. They all look at the Process Monitor screen, part of the Equator software, which lists all of the features being gauged. Next to the feature name there is a little bar which turns from green to amber to red as the size or location for each feature begins to drift. The operators know which tool on the machine is responsible for each feature and so can take corrective measures to occasionally tweak the process, to come back well

MACHINE TOOLS WORLD MAY 2016

The factory floor at High-Tech engineering within tolerance. As we carry out 100% inspection, it would be very hard to make a part wrong.” He continues, “We are also using the gauge data to trial different types of tool, to see which gives us the best level of efficiency – something which might save us more money in the future.” Outlook

Following the success of this manufacturing cell, Mr Tickner plans to use the Equator gauging system as part of future cells he will be commissioning for jobs in the pipeline. He concludes: “When you find something which helps you make a perfect part every time, reduces manpower commitments, reduces overall costs and doesn’t cost a fortune itself, it’s a winning solution. All of the benefits are passed on

to our customers who know they are getting the best quality at the best price”. About Renishaw

Renishaw is an established world leader in engineering technologies, with 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. For more information, Website: www.renishaw.com

CASE STUDY

Perfect Partners: Haas F1 Team calls on Haas dealer to manufacture & modify race car components

aas Automation Inc. is well known for supplying, supporting and servicing its CNC machine tools via a global network of independently owned and operated facilities, referred to as Haas Factory Outlets (HFOs). In late February, the HFO in Barcelona, Spain – part of HITEC Máquinas CNC SL, received a rather different request…from the Haas F1 Team, which, at the time, was testing its new, VF-16 F1 car at the local Circuit de Barcelona-Catalunya, ahead of the start of the 2016 Formula One world championship. To enable pit-stop practice to go ahead on February 25th, Haas F1 Team found some modifications were necessary to the wheel-gun sockets and other pit equipment. “Also necessary was some manufacturing of components related

MACHINE TOOLS WORLD MAY 2016

to the wheel nuts on the racecar,” said a team spokesperson. A quick call went out to the HFO in Barcelona, located about 30 minutes from the track, where Haas specialist programmers and operators used a Haas UMC-750 5-axis vertical machining center, a Haas ST-30 CNC lathe, and a Haas VF-2 vertical machining center, to modify and to make the required

components, which were then delivered to the race circuit, post-haste. “Haas Automation is more than just a sponsor,” said Guenther Steiner, team principal, Haas F1 Team: “They’re a true partner in building our organization. On very short notice, the local HFO here in Barcelona [the Haas distributor for Spain] was able to put skilled technicians to work and manufacture and modify the parts we needed. We’ve achieved a high level of efficiency by tapping into the resources of Haas Automation [and its partners], and it allowed us to make the most of our test.” Each Haas Factory Outlet (there are 170, worldwide) is built, equipped and staffed to the exacting standards laid down by the California-based company, so that customers receive the same, high level of service – including next day delivery of spare parts, wherever they’re located. Andreas Le Noir is joint owner of HITEC Máquinas CNC SL: ““It was a great pleasure for us to help Haas F1 Team during testing in Barcelona by making and modifying some critical parts for its car and its pit equipment. The challenge was to quickly source materials and tooling and deliver the parts ASAP,” he said. “We even delivered parts at 2 and 3 o’clock in the morning! F1 teams work 24 hours and, therefore, our applications engineers were challenged to manufacture parts in very quick time, working hard and long hours.” He continued: “The HFO concept is designed to provide customers with sales and technical support as if they were dealing directly with Haas, but with local and personal service. This was a great example of how closely we work with Haas, and how Haas also supports us to provide the very best service and support possible.”

For more information, Website: www.HaasCNC.com

CASE STUDY

Equipped with a C-axis & Y-axis plus powered tools the NLX 2500 from DMG MORI supports turning operations at Buchholz Hydraulic Founded as the handcraft enterprise Buchholz in Kiel in 1884, the Buchholz Hydraulik GmbH of today has concentrated on the solution-orientated development and production of valve controls for mobile hydraulics since 1959. The medium-sized enterprise now has over 300 employees and from its locations in three continents supplies customers from many different branches, including the construction and automotive engineering branches and the maritime industries. In its production, Buchholz Hydraulik trusts in high-quality and high-performance CNC technology in order to meet the high demands placed on productivity. In October 2014, DMG MORI installed an NLX 2500|700 in the turning division, which, with its C-axis and Y-axis, enables complete machining of the sophisticated workpieces. In addition the new DMG MORI design and the intuitive GUI CELOSÂŽ ensure work on the lathe is ergonomic and user friendly.

ork lifts and excavators are just two examples of the wide field of application of hydraulic solutions. Thanks to its consistent customer orientation Buchholz Hydraulik has established itself as a competent development partner that carries out a project from the concept phase right through to commissioning and optimisation in the vehicle. The core of the work is always the focus on individual product solutions that fulfil the requirements of the customers in respect of functionality and where the question of costs is concerned. For many years, Buchholz Hydraulik has stood for high product quality and customer-orientated order processing including short delivery times. This high standard is ensured by both well-trained specialists and innovative machine

MACHINE TOOLS WORLD MAY 2016

CASE STUDY

tool technology. Complete machining is an important keyword here, because this kind of production meets the high productivity requirements. In addition to diverse automated systems, Buchholz Hydraulik also upgraded recently in the area of turning where it replaced an old 2-axis lathe with an NLX 2500|700 from DMG MORI. Improved work ergonomics thanks to CELOS® and the new design

Produced for the European market at GILDEMEISTER Italiana, the NLX 2500|700 is available with very customer-specific expansion options so that it can ideally accommodate the specific application required. Buchholz Hydraulik uses a version equipped with a counter-spindle, C-axis and Y-axis as well as powered tools. “This enables us to both turn and mill the workpieces, and what is more, we can do this on the front and the back”, explains Heiko

MACHINE TOOLS WORLD MAY 2016

Neßler, the responsible machining technician. This is an enormous gain in productivity compared to the previous solution. “For the simple reason that we no longer need a second machine for milling.” Another new aspect for Buchholz Hydraulik is the user interface of the NLX 2500|700. Since last year, DMG MORI has been supplying the machine equipped with CELOS® and a 21.5” ERGOline touch display. Operation of the interface is carried out intuitively and DMG MORI achieves a high degree of functionality with this combination of advanced software and hardware. Heiko Neßler programs the job order directly on the underlying MAPPS V control – often parallel to primary machining. One great advantage of CELOS® is its 3D-simulation of the

program: “This warns us of potential collisions and also calculates the runtimes of the workpieces.” This option is used for calculations and other work scheduling. The new DMG MORI design rounds off the ergonomic operation of the NLX 2500|700 ab. “The large door provides good access to the work area”, says Heiko Neßler. Buchholz Hydraulik comes to a very positive conclusion with regard to the NLX 2500|700 and the new CELOS® user interface: it has been possible to integrate machine concept perfectly into everyday production. This verdict is clearly confirmed by the fact that another two NLX 2500|700 machines are to be installed in the coming months. For more information, Website: www.dmgmori.com

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TECH TRENDS

New Milestones in Microfinishing Precision engineered finish for automotive powertrain parts Preamble

Greenhouse emissions and Energy efficiency are the critical aspects pushing the limits of Powertrain Engineering in Automotive industry. ‘Lightweighting’ and ‘friction reduction’ are two key strategies in this aspect. Deploying both strategies makes designers of Engines resort to stringent surface finish parameters on Critical powertrain components such as Crankshafts, Camshafts, Transmission shafts etc. Microfinishing is a mission critical process required to achieve these specifications. Over the last few years microfinishing technology has crossed several milestones and made possible key advances in Engine Performance.

The Author – Sameer Kelkar, Silver Medallist & Graduate of IIT Bombay, and MS in Mechanical Engineering from University of California, Berkeley, is CEO of Grind Master Machines Pvt. Ltd. Sameer also leads the R&D team at Grind Master which has several Registered Designs and Technology Patents (Pending) in the field of Microfinishing and Superfinishing. This article is compiled with the experience of the past 6 years.

MACHINE TOOLS WORLD MAY 2016

New Milestones in Microfinishing

The Process of Microfinishing with film backed abrasives was developed to achieve consistently uniform finishes faster and more efficiently. Microfinishing generates Lubricating Characteristics at Surface Contact through a Highly Engineered Surface Finish so that the surface provides maximum bearing area to take up heavy loads and at the same time retain enough oil in the surface for adequate lubrication. Milestones in this technology in the past few years include the process capability of achieving highly precision Engineered Finishes, as well as advancements

to process more and more variety of components using Film backed abrasives. Major improvements in machine technology include flexible manufacturing systems capable of multi variants and compacter more energy efficient machines with ultra user friendly interfaces. What is Microfinishing?

Micro-Finishing is a method or process to remove the surface material of a dimensionally finished part to provide a precise fit to the mating part. An examination of the texture left on a metal surface as a result of machining operation will reveal tool marks, fragmented metal, chatter, etc. It is the micro-finishing operation that must be used to generate the final surface texture required for service life, performance and reliability of a product. A non-microfinished surface can be compared to a snow covered lake. A person’s weight will produce foot prints in the snow whereas, the ice will even provide support for the concentrated pressure of a person on ice skates. When a metal or steel part is machined, the surface becomes fragmented and also annealed if a heat generating grinding process is used. This type of surface will not support high bearing loads. Microfinishing is the process that removes the fragmented and annealed surface, leaving base metal for greater bearing loads.

TECH TRENDS www.mtwmag.com

Meeting Advanced Specifications of State-

Bearing ratio is illustrated in the figure

of-the-Art Crankshafts

below :

Crankshaft is the heart of an engine. This mission critical component transmits power from the combustion chamber to the powertrain. Specifications on a Crankshaft have undergone major advances globally in the past few years. While Friction Reduction has demanded finer and finer finishes, Lightweighting (and the resulting downscaling of engines to 2 and 3 cylinder engines instead of 4 cylinder engines) has led to more bearing loads on the crankshafts features. At the same time, user experience demands higher speeds, longer Engine Life and Lowest NVH (Noise, Vibration and Heat) have all led to tighter and tighter expectations from the crankshaft.

Microfinishing with Level II process with optimization for various process parameters led to achieving remarkable results with consistency as indicated below : Bearing Ratio 5-20% Htp : 0.15 microns Depth 5-80% Htp : 0.25 microns Depth 5-90% Htp : 0.35 microns Depth Surface Finish : Ra 0.1 microns

Reducing Friction requires the following features on the crankshaft :

1. Surface Finish Ra values to be lesser than typically Ra 0.1 microns on Main and Pin Journals, Finish Ra values to be lesser than typically Ra 0.15 microns on Thrust Walls, Tighter Oil Seal Finish requirements required to use thinner oils. 2. Bearing Area Htp requirements on all journals 3. Tighter geometrical tolerances including roundness, straightness, cylindricity. New specifications on profiles, crowning, lobing. 4. Consistent Stock Removal – Maintain-

ing Size tolerances. Most modern Automotive Crankshafts are microfinished using multiple Level processes, such as Level II or Level III Microfinish. Some of the case studies below will illustrate the results achieved on such crankshafts. Case Study : Achieving Parameters on Automotive Crankshafts for Passenger Car

Qualifying higher energy efficiency and emission norms had generated stringent requirement on journal surface so that engine NVH performance could improve. Tribology experts and engine designers came to a conclusion that to achieve the stringent requirements the bearing ratio parameters needed major enhancements, along with improvements in other specifications.

The above parameters were achieved with a consistency indicated by statistical process control parameters Cp (achieved Cp > 2.0 and Cpk > 1.67) Besides Finish, the corrections in geometry such as roundness correction by 50% below 3 microns, cylindricity controlled within 3 microns also indicate the process capability of Microfinishing. In one specific realization for Passenger Car Crankshafts, a special Size Control Feature with Online Gauging was deployed on a machine to achieve Diameter Tolerance ±3 µm with PP 2.19 and PPK 2.16. Case Study : Microfinishing Replaces Stone Finishing Technology for Camshafts

Stone Finishing is a traditional technology for finishing of shaft like components, including camshafts. Microfinishing with Film backed

MAY 2016

MACHINE TOOLS WORLD

TECH TRENDS

abrasives gives several advantages over stone such as consistency of results, lesser maintenance and adjustments, lower energy consumption etc. Due to the above reasons, Microfinishing has replaced conventional Stone lapping in majority of shaft type components. In one particular instance, a global leader in engine technology used combination of stone and film to achieve very stringent surface finish specifications, in plants including American facility. The earlier 3 level finish process was replaced with a 2 level process using film alone. The Surface finish achieved as below Ra < 0.067 microns with Cpm > 1.67 Rtm< 0.412 Wt < 0.45 Wc < 0.12 The resulting consistency and lowenergy operation as well as lower cycle time truly delighted the customer. Notes : Microfinishing Automotive Transmission Components

Automotive Transmission Components such as Geared Shafts (Input shaft, Output Shaft, Main Shaft) and Synchrocones, Differential Housings etc. were traditionally having only surface finish specifications such as Ra values. While not as critical as Engine Components, specifications on Transmission parts have also been upgrading over the years, necessitating the use of microfinishing technology instead of superfinishing. Apart from

MACHINE TOOLS WORLD MAY 2016

Ra values, many components are now specified with Rk, Tp, Rmr and Lead angle specifications. Geometry specifications such as roundness, cylindricity and size are also being tightened on such components. Microfinishing is distinguished from Superfinishing in the type of contact between the abrasive film and component as illustrated by the figures below. Microfinishing gives better consistency in surface finish, bearing ratios much quicker than superfinishing. Geometry correction is not possible with Superfinishing, whereas it is guaranteed in Microfinishing. Several successful projects including Microfinishing for Balancer Shafts, Differential Gear Housing, Main Shaft, etc. illustrate the benefits. Conclusion – Milestones in Microfinishing

Microfinishing is a Key Process Technology in Automotive Powertrain for achieving engine performance in terms of energy efficiency and emissions. Capability to achieve superior finishes enables reduced friction in the

powertrain and low NVH. In future specifications on finish for components such as Crankshafts, Camshafts and various powertrain parts are likely to get more and more stringent. Advances in Microfinishing Technology enable achieving these parameters with consistency. Grind Master NANOFINISH Microfinishing Machines

Grind Master NANOFINISH range of machines includes Microfinishing and Superfinishing Machines. A wide variety of Microfinishing machines covers the full range of crankshafts and camshafts, from 200mm to 3500mm. The Machines are based on a modular design concept, and can be optimized for specific applications with configurable stations including no. of arms, Arm positioning mechanisms and Automation Systems, Peripheral Systems. Optional additions include Deburring Units. The Machines are controlled with an Engineered Software – NANOFINISH Control System – built for finishing machines. The state-of-the-art range of machines NF Series are packed with several features that make them a market winner. Optimized Cycle times, Quick Setup Change, Quick Tooling Change Ease of Maintenance are some of these. Together with the Process Know-how gathered over microfinishing more than 20 million Engine Components, Grind Master provides complete Microfinishing Solution. With Over 150 machines worldwide, 5 Registered Designs and 4 Technology Patents (Pending) for Microfinishing series, Grind Master is a leader in Microfinishing Technology.

For more information Grind Master Machines Pvt. Ltd. B-10/B-11/B-14, Railway Station MIDC, Aurangabad- 431005 Maharashtra (India). Tel. +91 (240) 2374104, +91 (240) 2374114 Email :sales@grindmaster.co.in Website :www.grindmaster.co.in

TECH TRENDS

PICO generators from eldec: Mobile induction heating with maximum efficiency & precision Contactless, fast, accurate, and precision-controlled: These are the essential advantages of induction heating. The technology can be used whenever workpieces or components are heated to a predetermined temperature for further processing. The areas of application for induction heating are diverse, ranging from the automotive and machinery industries to power generation and electrical equipment. The experts at the eldec, an EMAG subsidiary based in Dornstetten, Germany, have a precise understanding of this wide array of applications. For over 30 years, eldec has been developing sturdy, high-quality energy sources for inductive heating. With the new PICO series, these specialists now offer their customers an extremely compact and cost-effective device with a very broad range of performance capabilities. It is extremely easy to handle — a crucial factor for portable use.

educe to the max was the slogan of an automobile manufacturer some years ago. The same could be said for the PICO series. This compact device is perfect for portable use andwas designed using the German company’s proven technology. The configuration of the machines central elements have been simplified to just the essentials—resulting in not only lower construction costs and but also a lower price to the customer. “Our goal was to develop a standardized and cost-effective energy source that covered virtually all known areas of application. PICO is very simple and extremely easy to operate, yet the generator is still able to meet any demand. Ultimately, all you need to do is unpack it, plug it in, and start heating,”

The Pico series from eldec.

MACHINE TOOLS WORLD MAY 2016

said Stefan Tzschupke, Head of Business Development Generators at eldec. Very diverse areas of application

The selection that the eldec experts offer their customers with PICO is very broad. The generator comes inthree sizes: PICO-S, PICO-M, and PICO-L. These can be configured as mid-frequency or high-frequency generators from 5 to 150 kW, depending on the model. They are equipped with a specially designed eldec control unit, proven inverter technology, and an intuitive operating interface. Where and how are these devices primarily used? “Due to the extensive basic configuration, they have a very broad range of application. Even customers who need a portable generator for use on a construction site turn to the compact PICO range,” Tzschupke noted. The device is used for example during inspection at power plants, to heat the tensioned bolts on turbine casings. Another typical application is the heating of components and parts for subsequent joining processes—

for example rotor caps, crankcases, or automotive powerplant components. The PICO series is also used for standard tasks such as induction brazing. Companies that install system integrators will likely find the PICO series to be a highly affordable way of integrating precision heating functions. Turnover expected to grow

The smaller PICO-S model has been on the market since the beginning of 2015. The larger M and L models followed at the start of this year. They are produced primarily from pre-assembled components, so customers can expect delivery of their device within a few weeks of ordering. With an expected turnover of up to 100 devices per year, the series occupies an important position in the company’s overall planning. Why is the market outlook for PICO so good? “PICO is a cost-effective, standardized series covering a wide range of applications. It essentially has no limitations,” explained Tzschupke. “The customers also benefit from short delivery times when making their investment decision. In light of that, we see major sales opportunities in the growing Asian markets, for example, where full functionality, high product quality, & low cost play a vital role.”

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TECH TRENDS

Design Tools For All: The 35-Year Evolution of CAD By Jon Hirschtick

Jon Hirschtick, Onshape founder

Jon Hirschtick is the founder of Onshape, the first professional 3D CAD system to run on a web browser, phone or tablet. He previously founded SolidWorks, was the director of engineering at Computervision, and began his career as an intern at the MIT CADLab. His hobbies include magic, golf, blackjack, 3D printing, tennis and yoga.

MACHINE TOOLS WORLD MAY 2016

ver the last four decades, I’ve watched CAD grow to become a vital part of the way virtually all products are designed and manufactured. In 1981, when I was a student at MIT’s CAD research lab, there were probably only thousands of CAD users in the world. Now there are millions. It’s understandable why CAD began as a tool for the elite few. Back then, one seat of CAD cost hundreds of thousands of dollars – you ordered the computer, the software, the monitor, the table and even the chair all from the CAD company. It was sold as a “turnkey system.” The notion that you’d buy software and run it on an independent computer was considered wacky. At the same time, engineers were paid a fraction of what they are paid today. You had one super expensive computer surrounded by a lot of “cheap” engineers. Now, it’s the exact opposite: Each highly-paid engineer can easily be surrounded by many relatively cheap computers – laptops, desktops, tablets, and their phones. Then two very significant things happened in the 1990s. First, CAD technology evolved from simple “wireframe” and 2D drafting to 3D solid modeling. Equally important, the computing platform migrated from mainframes and proprietary terminals (the CAD companies made the hardware) to UNIX workstations and Windows PCs. Moving to desktop personal computers was truly transformational: It was the democratization of CAD, making the tool accessible to millions of engineers whose companies previously

could not afford the technology. With 3D professional CAD, every company could make design improvements faster and dramatically speed up their production cycle. Having been personally involved in some of these changes, it’s been gratifying to see 3D solid modeling go from a curiosity in a lab to eclipsing 2D and becoming the way products are routinely designed. But the story isn’t over. The computing platform is evolving yet again. Cloud, web and mobile technologies are making CAD available on any computer, tablet and phone. Running CAD in a web browser means engineers can work on any Mac or Windows PC or even on inexpensive Chromebooks, lowering the financial barrier for entrepreneurs and startups to turn their ideas into successful products. With cloud-based CAD, design tools are also finally adapting to the way people really work today. Many products are no longer designed and manufactured under one roof. Design teams are often distributed in offices around the world. For the first time, multiple engineers can simultaneously work on the same CAD model. With mobile CAD fully running on phones and tablets, design teams no longer are chained to their offices; work can happen whenever and wherever inspiration strikes. Engineers aren’t so “cheap” anymore. Increasing their productivity is vital for a company to survive and thrive. As CAD technology continues to rapidly evolve with the times, I’m thrilled to still have a front row seat.

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PROJECTS www.mtwmag.com

Automobile Tata Motors Ltd.

Automobile Airport / Aviation Defence Industrial Cluster Iron & Steel Manufacturing

PROJECT

Material Handling R&D Centre Railways Power

UPDATE

Transport

Indiaâ&#x20AC;&#x2122;s largest commercial vehicle manufacturer, has signed a contract to supply 25 Tata Starbus Diesel Series Hybrid Electric Bus with Full Low floor configuration with the Mumbai Metropolitan Region Development Authority (MMRDA).

Place: Maharashtra Contact: Minari Shah, Head (Corporate Communications), 1st Floor, Bombay House, Homi Mody Street, Fort, Mumbai-400001, Maharashtra. T: 022-66658282, 66657824, E: minari@tatamotors.com Mahindra & Mahindra As part of its expansion plan, the company plans investment to the tune 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

Airport / Aviation Airports Authority of India (AAI) Plans to construct new integrated terminal building at Guwahati Airport.

Place: Guwahati Assam Contact: Anil Kumar Sharma, Regional Airport Director, LGBI Airport, Guwahati-781015 Assam, T: 0361-2840223, M: 9435546068, E: redner@aai.aero Delhi International Airport (P) Ltd DIAL is contemplating plans to construct the fourth runway at the IGI Airport. The completion is targeted by 2020. The draft expansion plan is submitted to the Aviation Secretary.

Place: Delhi Contact: â&#x20AC;&#x153;Kshitiz Singhal, Manager (Corp Comm), New Udaan Bhawan, Opp. Terminal-3, Indira Gandhi International Airport, New Delhi-110037. T: 0124-3376000, M: 9999017344, kshitiz.singhal@gmrgroup.in Delhi International Airport (P) Ltd. DIAL is currently working on a plan to expand Terminal 1 passenger handling capacity from the current 18 million to 30 million per annum. The completion is targeted in

MAY 2016

MACHINE TOOLS WORLD

PROJECTS

four years.

Place: Delhi Contact: Kshitiz Singhal, Manager (Corp Comm), New Udaan Bhawan, Opp. Terminal-3, Indira Gandhi International Airport, New Delhi-110037. T: 0124-3376000, M: 9999017344, kshitiz.singhal@gmrgroup. in Textron India Pvt Ltd Plans to build its singlelargest selling helicopter model — Bell 407 — in India. The company is undertaking feasibility study. The facility will be set up by 2018-19. Textron has a development centre in Bengaluru.

T: 022-26146211, 26261700, F: 26146926, 26261704, M: 9811311382, E: gm_wr@pawanhans.co.in

Defence Gujarat Cooperative Milk Marketing Federation (GCMMF) Dairy products producer under the Amul brand is setting up two processing units in Kanpur and Lucknow. This would be ready in 6 months.

Place: Uttar Pradesh

Place: Karnataka

Contact: Ashish Mathew, Senior Executive (Projects), PO Box 10, Amul Dairy Road, Anand 388 001, Gujarat. T: 02692-258506, 258507, 258508, 258509, 02742-253881, E: ashish.mathew@amul.coop

Contact: Arneeta Vasudeva,

Reliance Group

Head (Business Development AND Communications), 3rd Floor, Corporate One, District Centre, Jasola, New Delhi-110025, Delhi. T: 011-49343100, F: 49343125, E: avasudeva@textron.com

Reliance Group company Reliance Defence plans to set up a centre for research, development and innovation in aerospace technolog at Rambilli near Vizag.

Industrial Cluster Navayuga group The group plans to set up an industrial smart city spread across 6000 acre adjacent to Krishnapatnam port in Nellore district. SPV is likely to be created with the state government and the Japan International Cooperation Agency (JICA) for this project.

Place: Andhra Pradesh Contact: Chinta Sasidhar, MD, Plot No. 379, Road No. 10, Jubilee Hills, Hyderabad 500033, Andhra Pradesh, T: 040-23339990, F: 040-23337789, E: nec@navayuga.com

Iron & Steel SAIL

Pawan Hans Ltd Pawan Hans is in talks with Airbus to develop a maintenance repair and overhaul unit at its Juhu base.

Place: Maharashtra Contact: Sanjay Kumar, General Manager, Juhu Aerodrome, S.V. Road, Vile Parle (West), Mumbai-400056.

MACHINE TOOLS WORLD MAY 2016

The company is undertaking expansion of Bhilai Steel Plant targeting a capacity of 7 MTPA capacity after expansion. The completion is targeted by December, 2016.

(IDCO) The state government has sought final approval for the proposed National Investment and Manufacturing Zone (NIMZ) at Kalinga Nagar in Jajpur district.

Place: Odisha Contact: Susanta Kumar Mohanty, CGM (Land), IDCO Tower, Janpath, Bhubaneswar-22, Odisha. T: 0674-2540820, 2543506, Ext509, F: 2542956, M: 9437153773, E: cgmland@idco.in, cmd@idco.in Rotolok India UK-based Rotolok Holdings Ltd subsidiary in India 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.

Place: Andhra Pradesh Place: Chhattisgarh

Place: Andhra Pradesh Contact: Vijay Mairal, 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

DGM (PR), Bhilai Steel Plant, Bhilai - 490001, Chhattisgarh. T: 0788-2223587, E: vijaymairal@sail-bhilaisteel. com,

Manufacturing Odisha Industrial Infrastructure Development Corporation

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

Material Handling L&T Construction The Metallurgical & Material

PROJECTS www.mtwmag.com

Handling business of L&T has bagged an order to execute an Ash Handling Plant (AHP) covering high concentration slurry disposal systems on an engineering, procurement and construction basis from NTPC Ltd for the Tanda Thermal Power Project in Uttar Pradesh.

Place: Uttar Pradesh Contact: Debojyoti Chatterjee, Corporate Communications, L&T House, Second Floor, N.M. Marg, Ballard Estate, Mumbai-400001, Maharashtra. T: 022-66965232, 67525656 E: debojyoti.chatterjee@ larsentoubro.com

R&D Centre Cummins India Ltd. Plans investment for the expansion of its research and development centre in India. The completion is targeted by end of 2016.

Place: Maharashtra Contact: Anu Soman, Sr Manager (Corp Comm), Campus Tower A, Level-5, Survey No. 21, Balewadi, Pune- 411045, Maharashtra T: 020-67067000, E: anu.soman@cummins.com

Railways Public Works Department, Indore Plans to construct of Railway

over bridge near Burhanpur Lalbag Railway station on Itarsi Bhusawal broad gauge track dist Burhanpur.

Power Kalpataru Power Transmission Ltd

Contact: Sunil Malvi, Executive Engineer, Old Palasia, Indore-452001, M: 09826829286, 9424392336, E: eepwdbriind@gmail.com

Bagged an order from Powergrid Southern Interconnector Transmission System Ltd (A wholly owned subsidiary of PGCIL) for turnkey transmission line project of 765 KV D/C Vemagiri - Chilakaluripeta.

Ministry of Railways

Place: Andhra Pradesh

Place: Madhya Pradesh

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

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

Contact: Rahul Shah, Company Secretary, Plot No 101, Part III, G.I.D.C Estate, Sector-28, Gandhinagar-382028, Gujarat. T: 079-23214000, E: rahul.shah@ kalpatarupower.com, Kalpataru Power Transmission Ltd Bagged an order from PGCIL for Transmission line supply project for Ultra Mega Solar Park transmission system in Andhra Pradesh.

Place: Andhra Pradesh Contact: Rahul Shah, Company Secretary, Plot No 101, Part III, G.I.D.C Estate, Sector-28, Gandhinagar-382028, Gujarat. T: 079-23214000, E: rahul.shah@ kalpatarupower.com

from PowerGrid Southern Interconnector Transmission System Ltd (a subsidiary of PGCIL) for the construction of a 400 kV double circuit transmission line linking Cuddapah to Madhugiri.

Place: Andhra Pradesh Contact: T Madhavadas, Executive VP & Head Power Transmission and Distribution, Post Box No979, Mount Poonamallee Road, Manapakkam, Chennai-600089, Tamil Nadu. T: 044-22705306, 22705000, E: madhavadas@lntecc.com L&T Construction The Power Transmission & Distribu- tion business has bagged a contract from Power Grid Corporation of India Ltd (PGCIL) for the construction of a 765kV double circuit transmission line at Cuddapah.

L&T Construction

IL&FS Engineering and Construction Company Ltd

The Power Transmission & Distribu- tion business has bagged a major turnkey order has been received

The company in JV with Unitech Power Transmission Ltd has received LoA from Power Grid for the works of

MAY 2016

MACHINE TOOLS WORLD

PROJECTS

765 kV transmission line in the state of Gujarat. The scope of work includes supply contract for tower package - TW02 for 765kV D/C Bhujbanaskanta Transmission Line (Part - II) associated with Green Energy Corridors: ISTS - Part C along with contract for construction work line in Gujarat.

Place: Gujarat Contact: Abdul Majeed, Head Business Development, Door No. 8-2- 120/113/3/4F, Sanali Info Park, Cyber Towers, Road No. 2, Banjara Hills, Hyderabad-500033, Telangana. T: 040-40409333, abdul_majeed@ ilfsengg.com, W: www.ilfsengg.com, Chhattisgarh Surguja Power Ltd. Plans to set up 4x135/150 MW thermal power plant based on coal washery rejects. 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.

UP Rajya Vidyut Utpadan Nigam Ltd 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 Neyveli Uttar Pradesh Power Ltd 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.

Place: Uttar Pradesh

Place: Chhattisgarh

Contact: K Chandran,

Contact: S Verma, Manager,

CEO, AE 55,Officer Colony, Panki Power Plant, Kanpur-208020,

First Floor, Urjanidhi,

1, Barakhamba Lane, Connaught Place, New Delhi-110001, Delhi. T: 011-23456123, 23456102, 23456000, E: cspfccl@gmail.com

MACHINE TOOLS WORLD MAY 2016

Uttar Pradesh. T: 0512-2260030, E: ceo.nuppl@nlcindia.com

Transport Nagpur Metro Rail Corporation Ltd. The metro rail corporation plans to allow a renewable energy service company to generate about 14 MW of solar power. Solar power can be generated by placing the solar panels on the rooftops, boundary walls, viaducts and vacant lands of the metro project.

Place: Maharashtra Contact: R. Anand Kumar, GM (Procurement), Metro House, 28/2, CK Naidu Marg, Anand Nagar, Civil Lines, Nagpur-440001. T: 0712-2554217, E: anand.kumar@ metrorailnagpur.com, www.metrorailnagpur.com Bangalore Airport Rail Link Ltd Plans to implement 42-km of Light Rail Transit System (LRTS) under public-private partnership in Bengalu- ru. 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.

Place: Karnataka 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 MP Group The Group has received contract from Noida Metro Rail Corporation (NMRC) for plying buses within Noida and Greater Noida. The bus network will traverse prominent areas with 13 different route plans. The company has developed a Special Purpose Vehicle (SPV) to implement its NMRC project for City Bus Service operation. The buses will be procured by the MP Group whereas infrastructural support in the form of ticket revenue collection and more will be provided by the NMRC.

Place: Noida Uttar Pradesh Contact: Ganesh Sumbhe, Accounts Manager, MP Group, 2nd Floor, Chiranjeev Apartments, Karve Road, Erand- wana, Deccan, Pune-411038, Maharashtra. T: 020-25442780, M: 8380021657 E: ganesh@etsl.co.in

MGM-Pubblicità(210x297)_Layout 1 08/04/13 10.33 Pagina 1

HIGH QUALITY FOR YOUR MACHINERY

MGM brake motor main features

VARVEL production lines

• TEFC 3-ph asynchronous brake motor (0.09kW-130kW) • AC 3-ph brake (no rectifier) or DC brake on request • Oversized brake disc for higher brake torque, longer life and reduced maintenance • Fine and easy brake torque adjustment (as standard) • Very quick brake reaction time • Frequent START/STOP cycle applications • Manual brake release (as standard) • Hexagonal hole on non drive end of the shaft for manual rotation • Single speed or two speeds motors • All motors designed for inverter duty

• RS-RT worm gearboxes: 28 to 150 mm centres. One stage worm, helical/worm and double worm. • RD helical gearboxes: 50 to 2300 Nm. Two and three stages. • RN parallel shaft gearboxes: 180 to 3300 Nm. Two and three stages. • RO-RV bevel/helical gearboxes: 180 to 3300 Nm. Three stages. • RG precision planetary gearboxes: 10 to 230 Nm. One and two stages. • VR dry friction speed variators: IEC63 to IEC90 1 to 5 stepless speed range, 300 to 1500 rpm. • VS planetary speed variators: IEC71 to IEC112 1 to 5 stepless speed range, 200 to 1000 rpm.

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A new generation of electric motors and gearboxes for power transmission quality from the alliance of two dynamic italian companies. For those who want quality.

MGM-VARVEL Power Transmission Pvt Ltd Ware House No. G3 and G4 • Ground Floor • Indus Valley's Logistic Park • Unit 3 • Mel Ayanambakkam • Vellala Street Chennai - 600 095 • Tamil Nadu, INDIA • Phone: +91 44 64627008 • info@mgmvarvelindia.com • www.mgmvarvelindia.com REGIONAL OFFICE: KOHLI TOWERS • 4th Floor, Dapodi • Near Bharat Petrol Pump • Pune - 411012

PRODUCTS

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

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

The CNC Controller – Phantom:

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

MACHINE TOOLS WORLD MAY 2016

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

PRODUCTS www.mtwmag.com

Grinding Oil 1- Straight Grinding Oil for Gear Grinding Features of Grinding Oil No.1 • • • • • • • •

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

Translucent and low odor Superior cooling properties Non irritating / Non corrosive Produces excellent surface finishes Excellent filter-ability All grinding wheel compatible Superior lubricity package Excellent oxidation Stability / Long sump life

Grinding Oil 1 is compatible with all types of grinding wheels. It can be used for grinding high-speed steel, cobalt, carbide, ceramics and hardened steel. Grinding Oil 1 can also be used in grinders that require the same oil for both lubricating the machine and the wheel / work-piece interface. Unique advanced synthetic and natural lubricity additives in Grinding Oil 1 help keep the grinding wheels clean and free cutting allowing them to function properly. Conventional oils can allow build-up and packing of the wheel. This can lead to burned parts, smoke and scrap parts. Grinding Oil 1 helps maintain part integrity, surface finish and an overall great working environment.

Grinding Application: Primary Creep feed

Secondary Gear Grinding -Profile & Warm Blanchard

Crush

ID and OD

Center-less

Cylindrical

Production

Milling Small Tooling

Diamond and CBN Wheel

Tool & Cutter

Dual-Purpose Grinding/Hydraulic

500CB Cutter Build Inspection Machine

For Product Enquiry Contact Gleason Corporation 1000 University Avenue, P.O. Box 22970 Rochester, NY 14692-2970 USA Email: calbrecht@gleason.com Web : www.gleason.com

Gleason Corporation introduces its latest innovation, the 500CB Cutter Build Inspection Machine. The 500CB delivers more accurate and highly automated build, truing and inspection of all types of stick-blade bevel gear cutters. The 500CB features automated closed-loop blade positioning creating a highly accurate and repeatable build quality. An accurately built cutter head is a critical factor in achieving precise gear quality and maximum tool life. In addition, the 500CB also automatically controls the tightening of the blade clamp screws, consistently applying the correct torque. These features require greatly reduced operator involvement to build highly accurate and repeatable cutter heads, while freeing personnel to perform other functions. This advanced machine has an intuitive operator interface including “wizard” functions to guide an operator through the build process. The software has many smart features, making recommendations to the operator while continually displaying key data as the head is being built. The 500CB is supported by the Gleason Global Service network with strategically located spare parts centers and over 250 service professionals in all major markets worldwide.

MAY 2016

MACHINE TOOLS WORLD

PRODUCTS

Guarding Tool Life with New Grade

For Product Enquiry Contact TaeguTec Ltd. 304 Yonggye-ri Gachang-myeon Dalsung-gun, Daegu, 711-860, South Korea Tel : +82-53-760-7589 Fax : +82-53-760-7621 E-Mail: yoav@taegutec.co.kr, Website: www.taegutec.com

The machining of cast iron material has a tendency to generate deviation during operation due to the nature of the material. Moreover, the usage of ductile cast iron has grown as a trend and has become more pervasive as a material of choice in every industry. In order to respond to these two simultaneous machining conditions, TaeguTec has launched the improved TT7015 Life+ CVD grade which is geared towards turning operations. The advanced coating and substrate design of TaeguTec’s new TT7015 Life+ enables improved wear resistance and toughness during the machining of parts made from cast iron. The improved grade provides higher stability on a wide range of applications and generates longer tool life due to the grade’s anti-chipping capability. The Asian metalworking giant’s new TT7015 Life+ grade is specifically geared towards general purpose machining of gray cast iron and ductile cast iron materials. Furthermore, the TT7015 Life+ grade minimizes unexpected insert failure even under interrupted cutting conditions while offering excellent surface roughness during machining due to its fine coating layer. During the testing phase of the TT7015 Life+, the new grade increased tool life by as much as 117 percent. While working on disk brakes made from gray cast iron, the TT7015 Life+ increased tool life by 100 percent while performing facing operations. On a front hub made from ductile cast iron, the new grade increased tool life by 100 percent. But the big eye opening test came with the internal roughing operation of a differential case cover made from ductile cast iron which increased tool life by an amazing 117 percent.

Tough Grade on High Temperature Alloys

MACHINE TOOLS WORLD MAY 2016

TaeguTec has unveiled the TT8080, an excellent PVD coated grade for superior performance in turning of stainless steel and high temperature alloys. The TT8080 grade has been adapted to turning applications and is particularly well suited for stainless steel and the machining of high temperature alloys under low cutting speeds and interrupted cutting conditions. Characterized by excellent toughness and high anti-chipping capability, the TT8080 grade is the perfect choice for interrupted and rough machining. Compared to the existing TT8020 grade, the TT8080 grade guarantees longer tool life and higher machining stability due to improved wear resistance. The strong coating adhesion that envelopes TaeguTec’s TT8080 is not only is crack resistant but also eliminates delamination. Product testing on different forms of machining resulted in incredible increases of tool life over the competition. Most notably, while conducting an interrupted facing operation on a valve body, TaeguTec’s TT8080 PVD coating increased tool life by a whopping 160 percent. On another test, but this time on a pipe fitting made from the same material, the new coating increased tool life by 71 percent on an external interrupted operation. For external continuous machining of a ring on SUS 316, TaeguTec’s TT8080 PVD coating increased tool life by 33 percent over the competition.

PRODUCTS

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

Following are some of its unique features: • • • • • • •

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

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

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

Standard Machine Elements

For Product Enquiry Contact Elesa and Ganter India Pvt. Ltd. A-54, Sector -83, Noida - 201305 (U.P.) INDIA Tel. +91 120 472 6666, Fax +91 120 472 6600 E-Mail: info@elesaganter-india.com, Website: www.elesa-ganter.com

Elesa+Ganter wide range of standard machine elements has for many years offered locking mechanism operating along the “latch-frame” prefriction principle. But to keep a sliding door shut, you’ll need a different principle: the hook-type latch GN 115.8 acting in radial direction. Not all doors, flaps or even manhole covers have frames which may be used as an abutment for locking mechanisms with clasp impeder. With hook-type latches, these locking challenges are no problem at all. Hook-type latches essentially consist of two elements, namely the fixed closing bolt and the hook including the rotating setup. The assembly locks in radial direction to the axis of rotation, the angle of rotation is normally 90 degrees to the left or right – depending on the installation of the hook and the associated stop pin. Without this pin, the hook can be turned by as much as 360 degrees.

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

MACHINE TOOLS WORLD MAY 2016

ADVERTISERS INDEX COMPANY NAME

PG. NO.

COMPANY NAME

PG. NO.

EMAG INDIA PVT. LTD.

PUNE MACHINE TOOL EXPO - 2016

ACE DESIGNERS LTD.

BACK PAGE

ENGIMACH - 2017

ACMEE - 2016

ADOR WELDING LIMITED

GRIND MASTER MACHINES PVT. LTD.

AMTEX - 2016

ANCA MACHINE TOOLS PRIVATE LTD

GROB MACHINE TOOLS INDIA PVT. LTD.

ASIAMOLD - 2016

H HARTING (INDIA) PVT. LTD.

BRIGHT BURNISHING TOOLS PRIVATE LIMITED

INDIA MACHINE TOOLS SHOW - 2017

CNC SERVICING & SOLUTIONS (I) PVT. LTD.

INSIDE FRONT COVER

CNC SOFTWARE, INC.

LAPP INDIA PVT. LTD.

INSIDE BACK COVER

44-45

MECHELONIC ENGINEERS PVT. LTD.

EFFICA AUTOMATION LIMITED

MGM-VARVEL POWER TRANSMISSION PVT LTD

RAJKOT MACHINE TOOLS SHOW - 2016

S SANJAY TOOLS & ADHESIVES

13 & 23

SHANTHI GEARS LIMITED

SHAVO TECHNOLOGIES PVT. LTD.

SOLITAIRE MACHINE TOOLS LTD.

SPARKONIX (INDIA) PVT LTD

UNITY CONTROLS PVT. LTD.

MARPOSS INDIA PVT. LTD.

D DOWEL ENGINEERING WORKS

J JYOTI CNC AUTOMATION LTD.

PG. NO.

BIRLA PRECISION TECHNOLOGIES LIMITED

COMPANY NAME

WIN INDIA - 2016

X XI'AN KITAMURA PRECISION MACHINE WORKS CO., LTD.

MAY 2016

MACHINE TOOLS WORLD

Mr.

Inside Story

Rajiv

Moorthy CEO, Shanthi Gears Ltd.

My Life’s Goals

Aim & Ambition: Leadership is about one life influencing another and taking people with you. I would like to constantly create high performance teams with an insatiable urge to excel. I believe that robust processes, innovation and a mindset to embrace change lead the way to exponential results. I would like to always be a part of such teams which help create value for others and self.

Vision: I am fully sold out on the ‘Swatch Bharat Abhyan’ of the Prime Minister. We have no doubt that a clean and conducive work atmosphere would enhance productivity considerably. I have experienced the positive effect within the Murugappa group. A neat, clean and visit ready plant reflects the culture of the organization and paves the way for operational excellence.

Social Goal: The Murugappa Group runs hospitals, schools and is involved in various social activities through the AMM foundation. One percent of the PAT of every company is kept aside for such social causes. At Shanthi Gears we are currently working on enhancing the literacy level of children across various parts of the country.

Business Goal: Our current distinctive competencies center around our abilities to provide custom built solutions for our customers. We will work on enhancing our capability in areas of design and engineering to cater to the futuristic demands of high speed and high precision power transmission technology. It would be our endeavor to work on innovative business models to reach our customers and provide a variety of solutions through enhanced levels of service and delivery.

My Leisure Choices I love jogging whenever I find time. It helps me to be physically fit. I read a lot and watch good movies- Tamil, Hindi and English Favorite holiday spot: I love the backwaters of the God’s Own Country, Kerala. Music I like : I enjoy old Tamil Film Songs: Also some English music. Sports I Love : Cricket & Tennis

Ask my Taste Buds Favorite food: I love good vegetarian food. Favorite Drink: South Indian Filter Coffee.

In Awe of My recent favorites include Prime Minister, Mr. Tshering Tobgay, who has done some commendable work in green revolution and increasing the carbon credits.

MACHINE TOOLS WORLD MAY 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