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

www.mtwmag.com

Executive Publisher

Contents

Vol 2 Issue 01 | JUNE 2016

Shirish D.

INDUSTRY TREND

CEO Shekhar D.

Editor Shilpa Dongre

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

The budget seems to be a positive step....

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

Online Division

Ganesh M., Pradeep M. Pillalamarri

Circulation Executive

Servo Application in Machine-Tool Industry

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

Technology Transformation will drive the machine tools..

COVER STORY

Machine Tools World turns one year! TECH UPDATE

INNOVATOR

(Maharashtra & Gujarat) Pune S.Kadam - 09833373371

Gujarat Dinesh Shah - 09327344559 Rajkot (Saurashtra) Swapnil Bhatia: 09227909005

The real game changer

Houghton at a 1.5 ton landmark & still counting!

INTERFACE 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 JUNE 2016

Nickunj Eximp: The legacy of excellence

122

PROJECTS

140

PRODUCTS

Auto Industry continues to drive the Machine Tool Industry

The future: High precision, high speed power transmission

Garage to the Globe â&#x20AC;&#x201C; The Saga of Grind Master

Processed cooling & drying come of age

Spraymet Surface Technologies helps in conservation of resources

ROBOTICS: The flexibility factor

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

Contents COMPANY SPOTLIGHT

Vol 2 Issue 01 | JUNE 2016

CASE STUDY

Electrotherm (India) Limited: Sustained Technology leadership

Partnering the manufacturing & automation industry HEIDENHAIN INDIA

Haas Automation Improves Competiveness for Lange CNC

TECH TRENDS

WILâ&#x20AC;&#x2122;s Leadership in High-Tech Manufacturing

BUSINESS NEWS

Mastercam Sponsors ORACLE TEAM USA

Ziehl-Abegg Investing 28 Million Euros

Vollmer shows tool grinding in a new dimension

106

DMG MORI Confirms Annual Forecast for 2016

Sparkonix - from the first to make EDMs in India...

100

The power of Power Tools

Hermle Open House More Popular Than Ever

Renishaw Reels Out New RTLA Scale Length Options to 21 Metres 8

MACHINE TOOLS WORLD JUNE 2016

108

The all-rounder for Highly Flexible Shaft Machining

110

Editorial Board

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

Mr. Arjun Prakash Managing Director Effica Automation Ltd.

Mr. GK Pillai Managing Director & CEO

Mrs. Mohini Kelkar Managing Director

Ms.Samina Khalid Marketing Manager

Mr. MIHIR Baxi President – Global Sales

Walchandnagar Industries Ltd.

Renishaw Metrology Systems Ltd.

Grind Master Machines Pvt. Ltd

Jyoti CNC Automation LTD

Editorial Index A Ador Welding 88, 140 Autodesk 36 B Birla Precision 142 C Centraline 141 Concept Laser 34 Cyient 110 D Delcam 42 Delta Electronics 44 DMG MORI 16 Dormer Pramet 143 E Effica Automation 54 Electrotherm 62 EMAG INDIA 46, 108 F Fatty Tuna 118 G Gem Equipments 52 Graebert 22 Grind Master 58 GROB Machine Tools 46 H Haas Automation 72, 94 Hangsterfer’s 143 Heidenhain 64, 82 Hermle 18 Houghton 56 Hypertherm 24 K Kasto 114 Kennametal 70

L Lakshmi Machine Works 141 Lantek 96 M Mastercam 10 Mitsubishi 10 N Nickunj 40 NORD DRIVESYSTEMS 20 P Pesmel 24 Phillips Corporation 28 R Rapid.Tech 102 Renishaw 20, 74 S Shanthi Gears 50 Shavo Technologies 106 Shell Lubricants 26 Solitaire 86 Sparkonix 80 Spraymet 60 T TaeguTec 30, 98 Taipei World Trade Center 30 Totem 84 U UCAM 48 Unity Controls 142 V Vollmer 78 W Walchandnagar 66 Z Ziehl-Abegg 12

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

JUNE 2016

MACHINE TOOLS WORLD

BUSINESS NEWS

Mastercam Sponsors ORACLE TEAM USA CNC Software, Inc., developers of Mastercam® CAD/CAM software, is pleased to announce that it has entered into a preferred supplier agreement with ORACLE TEAM USA, the sailing team that represented the Golden Gate Yacht Club in its successful defense of the 34th Louis Vuitton America’s Cup Match and will again defend the 34th America’s Cup and the current defending champion. ORACLE TEAM USA will defend its title in Bermuda in June 2017. “We are very excited to be designated as a preferred supplier of ORACLE TEAM USA,” says Meghan S. West, president of CNC Software, Inc. “Our software is being used by Core Builders Composites (CBC) in New Zealand in the production of the carbon-fiber composite components for ORACLE TEAM USA yachts. It delights us

to take our association further and help support the team, while having the good fortune to promote our relationship with a celebrated organization and an absolutely thrilling, world-renowned event.” Established in Ventura, California in 2001, CBC – the Mastercam customer Mrs. West references – has built all of ORACLE TEAM USA’s racing yachts, including USA 17, the 90 ft. x 90 ft. (approx. 27m x 27m) trimaran that won the 33rd

After the 2010 victory, CBC relocated to New Zealand

movements necessary to produce a part. In addition to providing seats of Mastercam Mill, Solids, and Multiaxis, CNC Software also provides all training, support, postprocessors, and machine simulation models for CBC’s composite fabrication and metal cutting machine tools. Its composite manufacturing system, a Poseidon 5-axis machining center, has a workpiece capacity of 59 ft. x 20 ft. x 10 ft. (approx. 18m x 6m x 3m) and has been used extensively to produce large composite tooling and components for ORACLE TEAM USA’s AC72 America’s Cup racing yachts.

Part designs originate with ORACLE TEAM USA and are sent to CBC. Mastercam software is the bridge between the CAD file of a part and the CNC machine, directing the machine and cutting tool

For more information, Website: www.mastercam.com

America’s Cup in February 2010, and components for the AC72 wingsail catamaran that retained the America’s Cup in 2013.

Mitsubishi Electric Inaugurates CNC Technical Center in India Mitsubishi Electric India Pvt. Ltd. announced that it has opened a technical centre for CNC Business in Peenya, Bengaluru, India. Mitsubishi Electric’s CNC business has seen a remarkable growth of 50% in sales units in last financial year. Considering the huge growth potential of Indian market, this new facility aims to contribute for expansion of Indian Machine tool market. As of now the Mitsubishi Electric CNC sales & service network comprises of 4 regional offices and 11 satellite offices. In addition to this network, the Mitsubishi CNC Technical Centre will help strengthen business in India with centralized management and support. The Facility is on a site measuring 15,700 square feet. With this CNC head office in India, the sales and support will be enhanced as assembly of CNC package for machine tool builders, repair centre and training center for customers will be under one roof. The technical center also has a state-of-the-

MACHINE TOOLS WORLD JUNE 2016

art showroom with all Mitsubishi Electric CNC equipment. The showroom is open for customers to walk-in and enquire. The technical centre is a small support to “Make in India” initiative where, the local assembly and repair will decrease downtime thus supporting manufacturers to have responsive and robust production. Mitsubishi Electric Group Companies in India have been manufacturing in India since 1998 and the CNC Technical Centre in Peenya is the newest manufacturing facility apart from manufacturing of Transportation Systems, Automotive Equipment and Factory Automation

products from Bidadi near Bengaluru, Gurgaon and Pune respectively. As per a public announcement by Mitsubishi Electric Corporation last year, they have started Commissioning of manufacturing facility for Elevators in Vemagal, Kolar District which is planned to start operation in FY2016. Mr. Makoto Kitai, Managing Director of MEI, said: “By setting up this CNC Technical Centre in India, we have demonstrated our commitment to invest, foster innovation, enhance skill development, and support the ‘Make in India’ initiative. CNC Machines are the future of our industries which uses precisely programmed commands aimed at accuracy and productivity. This CNC technical centre will enable expansion of manufacturing capacity and reduced delivery time. ” For more information www.in.mitsubishielectric.com

BUSINESS NEWS

Ziehl-Abegg Investing 28 Million Euros “We are equipping ourselves for the future”, that is the commitment from Peter Fenkl, Chairman of the Board of ZiehlAbegg. Since worldwide demand for energy-saving fans and motors is on the increase, the Künzelsaubased company is constructing a new building for EC production in the Hohenlohe Business Park (Baden-Württemberg). Over the next two years Ziehl-Abegg will be investing a total of around 28 million euros in Hohenlohe. “By doing this we are strengthening the position of Germany and Hohenlohe in particular as a production location” says Fenkl. Up to now, the energy-saving motors and fans have primarily been manufactured in the Würzburger Straße facilities in Künzelsau. In order to almost double the production area to nearly 8,000 square metres there is a need for a new building in the Hohenlohe Business Park. The new building, with an initial estimate for construction costs of 11 million euros, will be ‘docked’ on to an existing building. This will not only enable use of the existing loading ramps but also incorporate existing surfaces. Building work is in fact expected to start in the summer of 2016. The construction of new manufacturing facilities, as well as the relocation of the existing production facilities will then take place mid-2017. This will involve the relocation of 140 jobs from Künzelsau (Würzburger Straße) to the new building. “Relocating to a new place of work is of course often not easy for those affected” says CEO Fenkl. Therefore, the company did not take this decision

MACHINE TOOLS WORLD JUNE 2016

lightly. However, the existing site is already operating at full capacity and further growth at this facility is not possible. “It is also clearly evident that this is a growing sector” says Fenkl as the targets demanded by the European Union for energy consumption by electric drives in fans will be further tightened by no later than 2020, according to the so-called ErP Directive (energyrelated products). “We have been noticing the trend towards our highly efficient products for a number of years now”, says the CEO, commenting on the positive development of sales which is also continuing in the current year 2016. Ziehl-Abegg has been producing fans in the Hohenlohe Business Park since 2003. In 2008 this facility, which is used for the manufacture of centrifugal fans, was expanded to cover an area

of around 19,000 square metres. The entire Ziehl-Abegg site in the Business Park extends to 230,000 square metres. The most recent building with the distinctive ZA Tower has become a real eye-catcher. This is where the company has been developing and producing elevator motors and motors for use in both medical technology as well as underwater vehicles since 2014 on a site which covers a good 12,000 square metres and also houses the Ziehl-Abegg Automotive Division and gearless, where the ZAwheel in wheel hub drive for electric city buses is produced. The number of Ziehl-Abegg employees in the Hohenlohe Business Park will therefore rise in the coming year from the existing 480 to more than 620. It is currently not yet possible to give a realistic estimate of how many additional jobs will be created in what period of time at the ZA branch factory in Kupferzell.

Keyword EC drives EC stands for “electronically commutated”. This type of drive requires less energy when it’s operating but has a higher procurement cost as a result of the more complex electronics.

First Haas Mumbai Demo Day 2016 held in Mumbai

The 1st of the year HAAS Mumbai Demo Day 2016, was inaugurated by Mr. Nishikant Ahire, CMD – AMT Group in the midst of several industry professionals who graced the occasion with their presence at Haas Factory Outlet, Mumbai. The Haas Demo Day attracted roughly 800 visitors from 500 companies. Other than Maharashtra, delegations came from Gujarat & Delhi. Visitors were able to witness the latest generation Haas CNC machines: VF-2 & ST-35. Premiering for the 1st time was the New Generation Control from Haas. The new generation control packs even more innovation into what was already the industry’s greatest overall CNC control. With 5 exhibitors displaying their latest products and technical experts in attendance from major Tooling, Work holding, Accessories, CAD/CAM, Measurement and Probing manufacturers the Mumbai Demo Day truly lived up to its expectation. Like all Haas CNC machines, the VF-2 and the ST-35 are built at the company’s one and only 1-million square foot factory in California, US. Haas Factory Outlet has a network of local HFOs in India that support all Haas products, each one employing factory-trained engineers and stocking official Haas spare parts.

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

BUSINESS NEWS

DMG MORI Confirms Annual Forecast for 2016 The year started off according to plan for DMG MORI AKTIENGESELLSCHAFT: In the first quarter, order intake amounted to € 591.6 million and was thus at about the previous year’s level (€ 587.2 million). Sales revenues amounted to € 541.4 million (previous year: € 538.4 million). As in the previous year, EBITDA amounted to € 42.4 million, EBIT reached € 28.0 million (previous year: € 30.0 million) and EBT was € 25.8 million (previous year: € 27.9 million). As of 31 March 2016, the group reported earnings after taxes of € 18.1 million (previous year: € 19.5 million). Sales revenues in the first quarter were € 541.4 million and thus exceeded the previous year’s figure (+ 1%; € 538.4 million). Domestic group sales revenues were € 184.6 million (previous year: € 184.7 million), international sales increased by 1% to € 356.8 million. As in the previous year, the export share amounted to 66%. In the first quarter, order intake reached € 591.6 million and was thus at about the previous year’s level (€ 587.2 million). Domestic orders amounted to € 199.0 million (previous year: € 207.7 million). International orders amounted to € 392.6 million (previous year: € 379.5 million). Thus the share of foreign business rose to 66% (previous year: 65%). As of 31 March 2016, the key income figures of the DMG MORI group developed as follows: As in the previous year, EBITDA amounted to € 42.4 million, EBIT was € 28.0 million (previous year: € 30.0 million) and EBT reached € 25.8 million (previous year: € 27.9 million). As of 31 March 2016, the group reports earnings after taxes of € 18.1 million (previous year: € 19.5 million). Investments in property, plant and

MACHINE TOOLS WORLD JUNE 2016

equipment and intangible assets in the first three months amounted to € 10.8 million (previous year’s value: € 25.4 million). Here, particularly the already started projects to strengthen our worldwide sales and service presence were a priority. Expenses for research and development amounted to € 10.9 million in the first quarter (previous year: € 11.1 million). In financial year 2016, we are presenting a total of 12 new developments together with our Japanese partner. In the era of Industrie 4.0, we place particular focus on integrated technology and software solutions. Our app-based control and operating software, CELOS, allows us to currently offer our customers the key factor for an intelligent, networked production. On 31 March 2016, the group had 7,491 employees of whom 275 were trainees. The number of employees remained almost constant compared to the end of 2015 (31 Dec. 2015: 7,462). At the end of the first quarter, there were 4,074 domestic employees (54%) and 3,417 employees (46%) working for the international com-panies. Personnel costs amounted to € 139.3 million (previous year: € 135.8 million). The share price of DMG MORI AKTIENGESELLSCHAFT at the start of the year was quoted at € 37.05 (04 January 2016). At the end of the first quarter, the share closed at a price of € 40.92 (31 March 2016).

Current On 6 April 2016, DMG MORI COMPANY LIMITED announced that it had increased its direct and indirect shareholding in DMG MORI AKTIENGESELLSCHAFT to 76.03%. Moreover, at a Supervisory Board meeting, it announced its intention to conclude a domination and profit

transfer agreement. Against this background, the Executive Board of DMG MORI AKTIENGESELLSCHAFT has decided in coordination with the Supervisory Board to postpone the Annual General Meeting convened for 6 May 2016 to a later date.

Forecast The global machine tool market is expected to grow only modestly in 2016. The German Machine Tool Builders’ Association (VDW) and the British economic research institute Oxford Economics expect in their latest forecast (status: April 2016) a growth of global consumption by only 1.9% to reach € 68.6 billion. As in the previous years, the autumn forecast (2015: +4.1%) was significantly corrected downward; currently, this year by 2.2 percentage points. In the financial year 2016, we continue to expect a volatile economic development. Influence factors for the cyclical development and thus, also for the investment tendency of companies are further declining growth dynamics in Asia and persisting exchange rate fluctuations between the international currencies. We confirm our forecast for financial year 2016. We are expecting a slightly better order intake than in the previous year and are planning again sales revenues of around € 2.3 billion. EBT will be significantly below the high level of the record year 2015. We are also expecting a slightly improved positive free cash flow. As a result of DMG MORI COMPANY LIMITED intending to conclude a domination and profit transfer agreement, we are unable, at present, to make any comments on a dividend payment for financial year 2016.

SNIPPETS

75%

of the Indian machine tool producers are ISO certified.

66%

revenue for the Indian machine tool industry comes from metal cutting, CNC machines

$3-4 bn growth to be expected in Indian Machine Tools Industry by FY 2020

40%

of Machine Tools Consumption accounted from The automotive and auto components industry.

160

The Indian machine tools industry comprises of around 160 players in the organised sector.

13%

The production of machine tools in India to grow at a CAGR of 13% during the forecast period

BUSINESS NEWS

Hermle Open House More Popular Than Ever The number of visitors to this year’s Open House in Gosheim was overwhelming. On Friday alone, Hermle AG welcomed more than 1000 visitors to Gosheim. In total, roughly 2800 visitors from 1200 companies came to learn about the latest development trends in milling, turning and generative production. The event also attracted an increased number of guests from overseas. Hermle AG welcomed more than 800 international visitors during the four-day Open House event. The largest delegations came from the Czech Republic, Italy, Spain, Russia, the Netherlands, Denmark and Turkey. Good interest was also shown by attendees from Japan, India, the USA and many other European countries who used the Open House to discover more information about Hermle’s latest innovations. More than 20 interesting components from various sectors illustrated quite clearly the outstanding performance of the German company’s products. For example, a ship’s propeller, motorcycle rims, engine components and various tool and mould making dies were milled. Visitors were also able to marvel at traditional show highlights such

MACHINE TOOLS WORLD JUNE 2016

as a sink machined precisely from a 260 kg block of aluminium and weighing just 40 kg once finished, the machining of a titanium blisk from an aeroplane engine measuring 800 mm in diameter and an intricate fan impeller which was re-manufactured for a 1959 Porsche Junior tractor. “The new C 250 machine model, which has found its place in Hermle’s extensive portfolio, generated a lot of interest among visitors. Hermle will play a major role for Government’s Make in India initiative. The 3 and 5-axis machining centre offers the highest levels of precision, speed and reliability, and will definitely become a firm favourite with Indian customers.” says Mr. Swapnil Patil – Product Manager for Hermle in India.

The largest machining centre in the Hermle portfolio, the C 62 U / C 62 U MT (mill/turn version), which can machine workpieces weighing up to 2500 kg and cuts an imposing figure in the Technology and Training Centre, was showcased as a re-engineered version. The guided factory tours gave visitors the unique opportunity to experience first-hand the state-of-the-art production and assembly facilities, the Hermle training department and Hermle’s automation subsidiary Hermle-Leibinger Systemtechnik. Numerous lectures dealt with various issues from the world of milling and offered attendees very useful and practical information about the latest trends. A special show featuring over 60 exhibitors from the fields of tool

making, CAD/CAM, measurement engineering, software and control engineering was also well received. Within the context of Industry 4.0, Hermle setups for machine tuning according to the cutting task, Hermle control functions for increasing precision and productivity through intelligent setting of the machine dynamics and Hermle control tools for operator assistance and transparency were presented live at both the machining centres and in the Hermle User College. Hermle subsidiary Hermle Maschinenbau GmbH was presented in an exhibit featuring components generatively manufactured using MPA technology (Metal Powder Application process). Hermle service competence was demonstrated in a separate area at two machining centres. Extensive diagnostic and service tools showed users how quickly and competently Hermle Service can be on the scene to solve the problem at hand. The Hermle training department’s presentation of training concepts was also a very popular exhibit.

BUSINESS NEWS

Renishaw Reels Out New RTLA Scale Length Options to 21 Metres Renishaw, the global metrology specialist, has more than doubled the maximum length of its RTLA linear stainless steel ribbon scale. It is now available in lengths up to 21 metres and can be used with or without the FASTRACK™ scale carrier system. The longer RTLA scales, used with Renishaw’s RESOLUTE™ absolute optical encoders, are now suitable for applications with very long axes. These include large aerospace trimming and drilling systems, wing structure drilling systems, milling machines for power turbine manufacturing and the manufacturing of outsized components. Renishaw’s RESOLUTE is the world’s most advanced singletrack true-absolute optical encoder system delivering up to 1 nanometre resolution, superior long-

term reliability, instant operation after power-up without reference return, high speed performance to 100 m/s, smooth velocity control with interpolation errors (SDE) of ±40 nm and excellent positional stability with jitter (noise) of 10 nm RMS. RESOLUTE is also compatible with a range of ‘open’ and ‘proprietary’ serial protocols including Siemens DRIVE CLiQ, BiSS®, FANUC, Mitsubishi and Panasonic for connection to a wide range of industry-standard motor drives and controllers. Furthermore,

combining RESOLUTE’s easy installation, thanks to its generous set-up tolerances and integral setup LED, with its excellent dirt immunity gives outstanding performance even on the very long axes typical of heavy industrial applications. RTLA scales are mounted to the substrate using either their own self-adhesive backing or the FASTRACK scale carrier system. Comprising two miniature guide rails, FASTRACK securely retains Renishaw’s low-profile stainless steel scales and allows them to expand at their own coefficient of thermal expansion. RTLA with FASTRACK is ideal for environments requiring frequent removal and replacement of damaged scales even when access is limited, thus

reducing machine downtime. Installation of RESOLUTE and RTLA scale on machine axes translates into increased up-time, greater reliability and reduced cost of ownership for the end-user. Renishaw is one of the world’s leading engineering and scientific technology companies, with expertise in precision measurement and healthcare. Since its formation in 1973 it has won numerous awards, including a Queen’s Award for Enterprise 2015 for its RESOLUTE true-absolute encoder system. For more information, Website: www.renishaw.com

Industrial gear units with 190 kNm output torque NORD DRIVESYSTEMS extends the successful industrial gear unit range by adding a new size with 190 kNm output torque. The series now comprises nine sizes and covers torques from 25 kNm to 250 kNm. The addition of the new size 14 units allows for configurations tailored even more precisely to individual applications. Featuring a single-piece UNICASE housing as is standard for all NORD gear units, they achieve a longer bearing life than gear casings manufactured from jointed parts and ensure efficient power transmission and high tolerance for load peaks and jolts. They can be assembled as two or three-stage helical inline or helical bevel gearboxes with

MACHINE TOOLS WORLD JUNE 2016

nominal transmission ratios from 7.1:1 to 400:1, or even up to 30,000:1 with an auxiliary primary stage. The input and output direction can be freely selected. NORD industrial gear units can be mounted on any of the six sides. The manufacturer configures industrial geared motors for a diverse range of uses from steel works to process plants. Application-specific features and options include reinforced bearings and shafts, extra-large

bearing distance, extended output shafts, and Drywell designs with an additional oil drip disc and a leakage oil display or oil sensor. Disc and drum brakes, dual-gear setups, auxiliary motors, IEC motor adapters, turbo couplings, axial fans, motor swing bases, torque limiting backstops, and cooling and heating systems are available as well. NORD DRIVESYSTEMS develops, produces and sells drive technologies with around 3.200 employees, and is one of the international leaders in the industry. In addition to standard drives, NORD supplies application-specific concepts and solutions, even for special applications, for example with energy-saving drives or

explosion-protected systems. Gross sales amounted to approx. EUR 540 mn in the 2015 business year. The company founded in 1965 now has over 36 subsidiaries worldwide. The closely meshed sales and service network ensures optimum availability for short delivery times and customer-oriented services. NORD produces a wide variety of drive units for torques from 10 to 200,000 Nm, electric motors with powers from 0.12 kW to 1,000 kW as well as the necessary power electronics in the form of frequency inverters and servo controllers. Inverter solutions are available for classical installations in the switch cabinet and for decentralised and fully integrated drive units.

MODULAR GEAR CUTTING MACHINE FOR GEAR PRODUCTION PRODUCTIVE

FAST

USER FRIENDLY

HIGHLIGHTS

High speed pick-up gear hobbing machine for milling chucked parts with a tailstock

xcellent chip flow – ideal for highperformance dry gear E hobbing

robe to measure gears and sensor system for aligning P with boreholes or grooves

+ + +

Easily integrated into manufacturing systems Integrated automation: no additional costs Time-tested KOEPFER gear hobbing technology

EMAG India Private Limited “Technology Centre” I No. 17/G/46-3 · Industrial Suburb I 2nd Stage · Yeshwanthpur I Bangalore · 560022 I Karnataka · India Phone: +91-80-42544400 I Fax: +91-80-42544440 I E-mail: sales.India@emag.com I Website: www.emag.com

COMPACT

BUSINESS NEWS

Graebert Launches ARES Commander 2016 & ARES Touch Graebert– the pioneer in highperformance Computer-AidedDesign (CAD) solutions across desktop and mobile devices – has announced the availability of the 2016 version of its acclaimed ARES Commander 2D/3D CAD package in India. ARES Commander 2016, which runs on 32- and 64-bit Windows, Mac and Linux operating systems, is an advanced DWG-based CAD software with several pathbreaking features and tools. Graebert also announced the launch of ARES Touch, world’s only true CAD solution for Android and iOS mobile devices. Far more than a simple viewer or editor, ARES Touch is a complete professional CAD solution, using the same acclaimed CAD engine powering ARES Commander. “ARES Commander 2016 is a modern CAD solution, with unique features focused on both productivity and ease-of-use,” said Surya Sarda, Director, Marketing, Graebert India. “We believe that CAD users should not be tied down to just one computer at the office. When you buy ARES Commander, you pay only once to work on PCs running any OS – Windows, Mac and Linux – as well as from a smartphone or tablet with ARES Touch and, in the near future, through the Cloud with ARES Kudo.” The core product development of ARES Commander 2016 and ARES Touch has been done at Graebert’s India Development Center (IDC) in Noida. Set-up in 2012, the stateof-the-art IDC is the company’s largest development center globally and is instrumental in developing Graebert’s core CAD technologies. During the product launch, Graebert India also announced major

MACHINE TOOLS WORLD JUNE 2016

investment plans, to expand the Indian operations. “India is important for Graebert’s future growth, both, in terms of developing new pathbreaking products, and business opportunities. Graebert has already invested $4 million in India and plans to further invest $5 million in order to expand the capacity of the India business to meet growth needs,” informed Sarda. Graebert India has devised a four-pronged strategy to sustain 100 percent CAGR growth over the next five years, which includes— winning competitors’ customers, expanding sales and distribution network, launching new products and services, and targeting large opportunities emerging from flagship government programs like Smart Cities, Make in India, and Digital India. “Our biggest competitor is moving away from perpetual licensing to a subscription-only model. This has not augured well with Indian companies as it significantly raises the cost of the CAD software. As a result, we are witnessing a trend where several customers are migrating from competing platform to our CAD solution. We expect such migrations to gather momentum as the final date for moving to subscription-only model approaches,” Sarda said. Graebert plans to increase the footprint of its sales and distribution network through distributor Ingram. It already has a set of 45 strong partners. With new opportunities arising out of Smart City, Make in India and Digital India projects, Graebert plans to expand the partner network to smaller cities. Further, Graebert India will soon launch ARES Map, which will

provide a major boost to its government business. ARES Map is a hybrid solution that bridges the intelligence of GIS contents and a fullfeatured CAD system. In the near future, Graebert India also plans to introduce its globally acclaimed surveying solution, SiteMaster, and iSurvey surveying services to expand its addressable market. Graebert has a set of offerings that are important for government’s flagship projects—Smart City and Digital India—for creation of geospatial information systems which can be integrated with digitized land record maintenance system and are integral for planning

and implementation of smart cities. Graebert India is making available a 30-day free trial of the fullfeatured ARES Commander 2016 and ARES Touch on its website. The company has launched a Review & Win contest for CAD professionals, who can evaluate the free-trial version and submit their in-depth review. The best three product reviews submitted by users stand a chance to win exciting prizes.

Mr Surya Sarda is heading the Marketing, Business Development and Sales organization of Graebert for the SAARC region. Surya’s responsibility is to spearhead Graebert’s initiatives, which includes relationships with distributors, partners, system integrators and enterprise customers. He has built and Mr. Surya Sarda nurtured the entire India team Director, Marketing and from scratch, and has enabled Business Development over 100 percent CAGR for Graebert India Graebert in India. An IIT Kharagpur alumnus, he completed his post-graduation in Mechanical Engineering from Mississippi State University, United States. He began his career with Autodesk and has tremendous experience in business incubation, business strategy, product management and product marketing with companies like Visio Corporation (now Microsoft), GeoTouch Inc., CADopia and IntelliCAD Technology Consortium. During his 10-year stint at Autodesk, Surya worked on various assignments including a NASA-funded project at Autodesk Atlanta, $500 million NAVFAC project bid for US Navy, and has been a key contributor in the Autodesk re-engineering team. He also headed Intellicad Technology Consortium and contributed to the growth and establishment of the IntelliCAD brand.

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BUSINESS NEWS

Hypertherm Announces Winning Five Trademark Enforcement Court Cases Hypertherm, a manufacturer of plasma, laser, and waterjet cutting systems, is pleased to announce the winning of five unique court cases against five Russian companies during the last few months. All five companies were found guilty of violating Hypertherm’s trademark rights by importing a variety of counterfeit consumables and Powermax air plasma systems. As a result of the judgement against them, the defendants are prohibited from importing any products in Russia with the Hypertherm name, and are also required to reimburse Hypertherm for damages and court fees. Critical business challenges for any original equipment manufacturer (OEM) include quality control, efficiency levels, budgeting, and inventory management. However, with the advent of technology and globalization, modern OEMs are now faced with yet another area of concern – the proliferation of counterfeit. Counterfeits are products made in exact imitation of something valuable or important, with the intention to deceive or

defraud a customer into thinking that the product is an original. Often the price is less than the original. As counterfeits are usually close copies of the genuine product in appearance, at times, end users may actually be unaware of their counterfeit purchase, and are misled to think that they are getting a good bargain instead. Counterfeiting has evolved over the years, from being largely localized operations into highly profitable global businesses with mass production facilities, international sales, and complex global distribution networks. According to the International Chamber of Commerce (ICC), the value of global counterfeit goods is expected to exceed USD 1.7 trillion by 2015. Examples of protected Hypertherm trademarks include Hypertherm, Powermax, Hypertherm HPR, and ProNest. Hypertherm and their partners will continue their efforts to protect the market from counterfeit products and to eliminate counterfeit goods. “Hypertherm devotes an enormous amount

of resources to the development and engineering of technologically advanced cutting systems and consumables,” said Theo Cornielje, Regional Director Hypertherm Europe B.V. “We decided to pursue these legal actions because we are concerned about our customers and their business. These counterfeit consumables do not include the advanced manufacturing characteristics of genuine Hypertherm consumables and do not perform as well or last as long. As a result, our customers are paying more for an inferior product. We are pleased to see that our efforts are recognized by the legal system.”

Pesmel Supplies Packing Lines to Baosteel Group Pesmel has signed a contract of two coil packing lines and logistic system to Baosteel Zhanjiang Iron & Steel Industry. Automated lines will be delivered to Baosteel’s mill situated in Zhanjiang City, Guangdong Province in China. The start-up of the lines will be in summer 2017. Baosteel is building a new cold rolling mill to Zhanjiang City. The mill will produce 1.65 million tons of medium and high-end sheets. “Baosteel is widely known as high grade steel producer emphasizing efficiency, energy savings and environmental friendliness in their production.” points Pesmel’s China Area Manager, Liu. Following these values Pesmel and Baosteel have

MACHINE TOOLS WORLD JUNE 2016

been researching coil packing materials and technologies together. While Pesmel has been focusing on technology, Baosteel developed the packing materials and operations. In packing technology

Pesmel concentrated on two things, moisture protection and packing cost savings without compromising in packing quality. “For moisture protection we use TEW (through-eye wrapping)

technology. In this method crepe paper and PE film are wrapped to the coil simultaneously. The crepe paper absorbs the moisture inside the coil, as stretched PE film forms an airtight package that protects the coil from outside moisture.” explains Sami Koivuluoma, Product Manager in Pesmel. The coils arriving to the packing line are measured and all packing materials are individually cut according to coil size. This kind of optimization can easily reduce packing material costs 20-30%. That brings big annual savings to steel mills, and on top of all it also improves the packing quality For more information, Website: www.pesmel.com

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BUSINESS NEWS

Shell Lubricants Launches Shell Knowledge Webinar Series Shell Lubricants, the global market share leader in finished lubricants, announces the launch of Shell Knowledge Webinar Series 2016. Launched in 2014, this webinar series is aimed at engaging Shell Lubricants’ customers, OEMs, partners and industry analysts, among others under the theme of ‘Energy Efficiency and Technology Leadership’. As a part of this initiative, the company plans to organise 25 sector- specific webinars led by technical, business and marketing experts from Shell, along with eminent speakers from industry bodies like Confederation of Indian Industry (CII). The idea behind this Knowledge Webinar series is to enable knowledge sharing with various customers across geographies. The series is designed to help the participants understand the importance of lubricants with respect to the technical and business functions of various industries. This stems from Shell Lubricants’ continued investment in research and development to produce market leading lubricant products and its efforts at collaborating with OEMs and companies to overcome most exciting technology challenges. As part of this year’s edition, Shell Lubricants has hosted three webinars till date, which were attended by over a 100 participants. These webinars elaborated upon dynamics of energy efficiency for: manufacturing sector and cement sector; and in stationary power engines. Speaking about the initiative, Mr. Akhil Jha, Vice President – Technical, Shell Lubricants India said, “The energy landscape today

MACHINE TOOLS WORLD JUNE 2016

is marked with numerous challenges. Depleting resources, increased energy demand and inefficient use of fuel are some of the key concerns affecting the output of our industries. Keeping this in mind, the Shell Knowledge Webinar Series 2016 has been conceptualised to keep our valuable patrons abreast with the latest energy efficient solutions that ensure optimum use of resources. Ever since its launch in 2014, we have received an overwhelming response from the participants and look forward to developing more such engagement platforms in the future.” The first webinar in the series was held in March to discuss the trends in energy efficiency for the manufacturing sector. This was led by Mr. Kuldeep Saxena, Technical Team Leader – Shell India and Mr P. V. Kiran Ananth, Senior Counsellor, Confederation of Indian Industry (CII). The webinar threw light upon a plethora of topics including the energy efficiency scenario in Indian industries; approach and methodologies adopted by industries for financial matters and use of renewable energy, amongst others. The month of March also saw a webinar on ‘Energy Efficiency in the Cement sector’. The agenda focussed on energy benchmarking for the cement industry; role of equipment design in energy efficiency, and how lubricants help in enhancing the same. Mr. K Muralikrishnan, Senior Counsellor, Confederation of Indian Industry (CII) and Mr. Umesh Dwivedi, Business Development

Manager Grease, Shell Lubricants India were the key speakers for this webinar. ‘Improving Operational Efficiency of Stationary Power Engines’ was the topic of the third webinar in the series. Led by Mr. Praveen Nagpal, Global Product Application Specialist at Shell Global Solution, the webinar deliberated upon the trends in stationary power engines; challenges facing stationary heavy fuel oil engine operators; and the benefits of oil condition monitoring amongst others. The webinar received positive feedback and Mr. R Sarathy – DGM Technical Service – Wartsila India Pvt Ltd. said, “The webinar series is a unique initiative started by Shell Lubricants and was well organised. The discussions revolved around the day-to-day industry challenges and highlighted the role of lubricants in providing energy efficient solutions. This also helped us to understand both present and future requirements of the sector. We would like this to be a regular platform as it adds lot of value for the customers.” Some of the other industry experts who participated in the webinars and shared similar feedback are Mr. Gautam Banerjee, General Manager, Bhushan Steel; Mr. Ravindra Varma, O&M Incharge, Wartsila India Pvt. Ltd.; Mr. Sanjay Singh, Energy Manager, Shree Cement Limited; and Mr. Karunakar Avuram, Manager – Sustainability, Godrej Consumer Products Ltd. Shell Lubricants plans to organise a series of Knowledge Webinars in due course. Some of

the topics that will be discussed in the upcoming webinars are: future of lubricants technology, changing energy scenario, sector-specific challenges and best practices, role of lubricants in maximizing customer output and case studies highlighting Shell Lubricants’ work with OEMs.

About Shell Lubricants The term ‘Shell Lubricants’ collectively refers to Shell Group companies engaged in the lubricants business. Shell sells a wide variety of lubricants to meet customer needs across a range of applications. These include consumer motoring, heavy-duty transport, mining, power generation and general engineering. Shell’s portfolio of lubricant brands includes Shell Helix, Shell Rimula, and Shell Spirax. We are active across the full lubricant supply chain. We manufacture base oils in eight plants, we blend base oils with additives to make finished lubricants in almost 70 plants, and we distribute, market and sell lubricants in over 100 countries. We have more experts talking to more customers than any other lubricants supplier. We have over 350 technical support specialists and 1,000 sales professionals working with customers every day. We offer a wide range of services in addition to our products, including Shell LubeMatch, a market leading online tool that matches lubricants to vehicles and equipment, and Shell LubeAnalyst, an early warning system that enables our business customers to monitor the condition of their equipment and lubricant, helping to save money on maintenance.

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BUSINESS NEWS

Renishaw opens new Additive Manufacturing Solutions Centre in India Renishaw, the global engineering technologies company, is opening a new Additive Manufacturing Solutions Centre on 15th June in Pune, India. The new facility will provide a secure development environment in which customers can expand their knowledge and confidence using additive manufacturing (AM) technology. The Solutions Centre will be equipped with the latest AM systems and staffed by knowledgeable engineers to allow fast access to deploying the technology, all at fixed predictable costs. Additive manufacturing, often referred to as metal 3D printing, is widely recognised as a transformational manufacturing technology that will impact on everything from components in aircraft engines and satellites, to dental restorations and surgery for facial reconstruction. Renishaw, which is the UK’s only supplier of metal AM machines, sees the new Indian centre as a cornerstone in its ambition to be a major

contributor to the adoption of AM in the established and fast growing high technology Indian manufacturing sector. Rhydian Pountney, Renishaw’s Director responsible for Indian Sales and Marketing Operations mentions, “We are delighted to be opening the first Solutions Centre in India. The thrust of the additive manufacturing centres is to create a platform on which to work in close partnership with our customers to help them realise the benefits of AM in their products and manufacturing processes.” “Renishaw’s vision is to make AM a mainstream manufacturing technology, used in series production of high performance parts for aerospace, medical, automotive, oil & gas, mould & die and consumer products. The technology will enable companies to design and make innovative products with spectacular gains in performance and efficiency,” says Clive Martell, Head of Global Additive Manufacturing.

When adopting any disruptive new manufacturing technology, companies will go through a rigorous assessment process to understand the potential benefits, and to prove the reliability and capability of the production process. The investment in time, resources and equipment to achieve this can be significant. Renishaw Solutions Centres will lower this entry barrier by providing cost-effective access to machinery, facilities and AM expertise. Solutions Centres will provide a confidential development environment in which firms can explore the benefits that AM can bring to their products, and quickly build their knowledge and confidence in AM as a production technology. Marc Saunders, Director – Global Solutions Centres comments, “Whilst AM can create complex geometries in a single process step, some level of finishing is generally required to produce functional products. Renishaw’s knowledge

of metrology, machining and finishing processes can help customers to develop an integrated manufacturing solution for their innovative new product.” Whilst the new Pune Solutions Centre highlights Renishaw’s continuing investment in the development, manufacture and application of AM technologies, it also maintains the company’s long term commitment to the Indian market. It will sit alongside Renishaw’s existing key strategic additive manufacturing development locations in the UK, USA, Canada, Germany & China, with additional centres also planned for other key markets.

For more information, Website: www.renishaw.com

First Phillips CNC Open House 2016 conducted in Mumbai First PhillipsCNC Open House concluded on 7th May 2016 at Phillips CNC Technical Center in

MACHINE TOOLS WORLD JUNE 2016

Navi Mumbai. The Multi-Brand Open House was inaugurated by the Industry expert Mr. Nishikant Ahire, CMD – AMT Group. In India Phillips Corporation through its subsidiary CNC Servicing and Solutions India Pvt Ltd represents industry leading global brands such as Haas, Hermle, SHW, Zeiss, Sunnen, Tsugami, Maple, Kent etc in India. The ‘PhillipsCNC

Open House’ in India - the first of its kind was hosted at the Phillips CNC Technical Center in Navi Mumbai from May 5-7, 2016. The event witnessed approximately 800 visitors & 500 companies over 3 days of the Open House. The Machines on display were: 1. Kent KGS-84AHD Precision Surface Grinder 2. Tsugami M08J CNC Lathe 3. Tsugami B0205 Sliding Head Turning Center with Bar Feeder

4. Maple Taiwan ME- 850 Vertical Machining Center 5. Sunnen USA SV-2015 Vertical Honing Machine 6. Zeiss Comet L3D Optical scanning machine This event showcased the latest technologies in Milling, Turning, Honing, Grinding and Measuring with experts on hand to provide solutions helping manufacturers enhance their quality and productivity.

BUSINESS NEWS

Taiwan brings together TaeguTec Launches Two Taiwan Machine Tool New Five-Cutting Edge Industry to ACMEE 2016 Insert Lines Taipei World Trade Center (TWTC) brings together Taiwan Machine Tool Industry, Ambattur Industrial Estate Manufacturers Association (AIEMA) and National Small Industries Corporation (NSIC) at ACMEE 2016 from June16, 2016 to June 20, 2016to be held at Chennai Trade Centre, Chennai, India. This is the 12th edition of the International Machine Tools Exhibition that will serve as a great bilateral trade platform for Automobile, Aerospace, Automation Engineering, Ancillaries, Consultancy and Services, Machinery, Machine Tools, Electrical, Electronics, Energy and Environment. The representatives of 6 world’s leading machine tools and accessories brands from Taiwan – YCM, FFG, EXCETEK, TONGTAI, HIWIN and CHAIN HEADWAY will present their high-quality innovations and total manufacturing solutions for India’s aerospace and automotive industries at the Taiwan machine tools product launch at seminar venue, Chennai Trade Center on June 17,2016,11:00 to 13.00. The event will see various Technical Sessions, Product Presentations, Launches, and Social Networking Evenings. Mr. George Lin, Director of Taipei World Trade Center, Chennai (TWTC) said, “In the recent years, the Indian Government has implemented several schemes to nurture human capacity for advanced research and technological development in the country. Such initiatives make India a lucrative market and catering to this dynamic market, we have been bringing advanced technology and unique business solutions to India and will continue to excel our offerings. Through our

MACHINE TOOLS WORLD JUNE 2016

contribution to the ACMEE 2016 event, TWTC intends to stand true to its commitment of building bilateral ties between India and Taiwan that is mutually lucrative”. Bringing the best machine tool cluster in the world, Taiwan Machine Tool Industry is the 3rd largest supplier for machine tools parts and components in the world. It is also the 5th largest machine tool exporter in the world long with being the 7th largest machine tool manufacturer in the world. The 16 Taiwanese companies exhibiting in India under the aegis of TWTC are HannKuen Machinery & Hardware Co., Ltd., Kilews Industrial Co.,Ltd., Sesame Motor Corp, Echain Tool Industry Co.,Ltd, Brainchild ElectronicCo.,Ltd,Cose nMachinery Industrial Co,Illinois Enterprises co,Shan Hua Plastic Industrial Co., Ltd.,Kolowa Ventilation Co., Ltd.,Chain Headway Machine Tools Co Ltd,Yeong Chin Machinery Industries Co., Ltd.,Hiwin Technologies Corp.,Excetek Technologies Co., Ltd.,Fair Friend Ent.,Co., Ltd,Tongtai Machine & Tool Co., Ltd and Precision Motion Industries. Covering the five pavilions of ACMEE, these companies will showcase and launch products in categories like Drilling, Tapping, Boring, Milling Spindle Heads, Servo and Hydraulic Slide Units, Tool holders, Boring bars, End mills, Rapid drills, Carbide end mills, Lathes and Turning Machines, Milling and Boring Machines, Machining Centers, etc.

TaeguTec has launched two new five-cutting edge insert lines - RTMX and RTHX - with related cutters specifically dedicated for the stainless steel and difficult-to-cut materials used, but not exclusive, in the aerospace, oil and gas and power generation industries. ChaseMold’s RTMX and RTHX inserts including the line’s optimal cutter design were born through rigorous trial and error as well as performance testing in order to attain excellent performance in stainless steel, difficult-tocut materials and turbine blade machining under severe machining conditions and in unstable fixtures. The RTMX is a press-to-size type line for economy while the RTHX ground type is dedicated towards high precision machining with both line’s offering a high positive rake angle for low cutting resistance. Both inserts come in 10 and 12 millimeter sizes and their chip formers are available in three types: MM, ML and MLL. The MM chip former is recommended for unstable conditions, the MLL for stable conditions and the ML covers the middle range between the MM and MLL types. Furthermore, both lines are available in standard and special grades; the special grades are made for any machining environment, even under harsh conditions due to their high wear resistance and toughness capabilities. Cutters are available in end mills (ø32 mm), modular types (ø25-40 mm) as well as face mills (ø40-80 mm) and all are coolant capable for easy chip evacuation. During the product testing

simulating real-world conditions, TaeguTec’s new ChaseMold lines achieved higher tool life and productivity than the competitors’ similar offering. For tool life during the roughing operation of the airfoil, shroud and the root part of the blade component made from martensitic stainless steel (X20Cr13, AISI 420), TaeguTec’s new 5-teeth RTMX line outlasted a leading competitor’s tool by 65 percent, while on a blade shroud and root roughing operation made from stainless steel (1.4923), the same RTMX line increased tool life by almost 30 percent. In another test that emulated real-world machining conditions, TaeguTec’s RTMX completely annihilated the competition by increasing tool life by 100 percent while performing a spiral roughing operation on the blade’s airfoil part of the component made from alloy special martensitic creep-resisting steel (1.4938 + QT, X12CrNiMoV12-3). Concerning productivity, TaeguTec’s tests using the ChaseMold RTMX line on an aerospace engine case made from Waspaloy and Inconel 718 increased productivity by 65 percent on a leading competitor’s similar offering. For more information, Website: www.taegutec.com

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BUSINESS NEWS

Premium Aerotec Relies on Concept Laser as Premium Supplier Premium Aerotec is starting the series production of 3D-printed metal parts for the Airbus Group at its Varel site (Friesland). To do this, the Airbus subsidiary constructed a new production hall for the additive manufacturing of titanium parts in Varel. At the same time, the company concluded a cooperation agreement with Concept Laser as premium supplier for the machinery and plant technology.The industrial series production is gathering pace. With its investment, Premium Aerotec is following the plans of Airbus. According to Peter Sander (Airbus, Head of Emerging Technologies & Concepts), Airbus is planning to print one tonne of metal powder a month in 2018. Accordingly, AM production and AM processes should be consistently promoted and expanded through to 2018.

Achieving series production with a new production hall and Concept Laser Premium Aerotec’s new production hall for 3D metal printing commenced operation on January 20, 2016. The opening ceremony was attended by 250 employees and guests, including for example Brigitte Zypries, Parliamentary

MACHINE TOOLS WORLD JUNE 2016

Secretary of State at the Federal Ministry for Economic Affairs and aerospace coordinator for the German Government. This heralded the start of the industrial series production of a double-walled pipe elbow in the fuel system of the A400M transport aircraft. These complex parts were previously produced from individual cast parts which were then welded together to form one assembly. In the hall, two M2 cusing Multilaser machines and one X line 1000R machine from Concept Laser produce 3D parts in the LaserCUSING process. “By the middle of 2016, another X line 2000R will be added. It features what is currently the world’s largest build envelope (800 x 400 x 500 mm3) in the field of powder-bed-based laser melting and is also equipped with 2 x 1,000 W lasers,” says Gerd Weber, site manager in Varel. Frank Herzog, CEO &

President of Concept Laser GmbH, is also delighted at the trust placed in his company: “The fact that we have been chosen as premium supplier to Premium Aerotec fills us with pride and demonstrates to us that we are on the right path.”

Cooperation agreement sets the course for the future For the aviation industry, additive manufacturing methods present both an opportunity and a challenge. This is because additive manufacturing technology produces entirely new components and also creates new supply chains. Premium Aerotec is at the focal point of an extensive network of a wide range of different companies. In order to shape a successful

future in partnership, the working relationship with certain partners has been stepped up. For example, on January 20, 2016 a delegation from Premium Aerotec signed a cooperation agreement with Concept Laser as the premium supplier for machinery and plant technology. The core aspects of the working relationship are also the further industrialization of the laser melting process for applications in aviation, the further development of the plant and process technology and the QA systems, as well as the qualification of new powder alloys. Frank Herzog says: “This cooperation marks an important milestone for the industrialization of 3D metal printing in aircraft construction and undoubtedly also sends a signal to other industries. The network will work together to improve the value chain. We are already working today on the solutions of tomorrow to make laser melting with metals even more attractive for commercial series production. The implementation of the Industry 4.0 concept in the form of digitization, automation and the interlinking of any number of machines are an integral part of our AM Factory of Tomorrow, which was presented at the end of last year.”

TECH UPDATE

The real

game changer A

MSME in Maharashtra would now get latest of Autodesk CAD-CAM-CAE software just for 1999/-*

utodesk, a leading CAD/ CAM software provider announced that it will provide advanced design technology to local MSMEs from the manufacturing sector as per a Memorandum of Understanding (MoU) with Maharashtra government in the launch commenced at Hotel Trident in Mumbai on 5th May, 2016.

Chief Minister Devendra Fadnavis said, “This will enable our MSMEs to uniquely design and manufacture their products as per international standards. This partnership of Government of Maharashtra and Autodesk will create a potential for Maharashtra MSMEs to become globally competitive and locally productive.” Mr. Apurva Chandra, Principal Secretary (Industries) of the Government of Maharashtra was the chief guest for the event & being welcomed by Autodesk Team along with Pradeep Nair, Managing Director,

MACHINE TOOLS WORLD JUNE 2016

Autodesk, India and SAARC. As per the agreement Autodesk will be offering 2 years subscription of Fusion 360 software just for the price of Rs.1999 only which is discounted by around 90% of its offer price, further it will be offered free of cost to the MSMEs of Maharashtra with the annual turnover less than 1 crore who are registered with the Department of Industries, Government of Maharashtra. Autodesk also launched the customer showcase portal www.bharatfusion360.com which will help promote the work of MSMEs who derive greater business success by using Fusion 360. Further, the company will help the MSMEs to showcase their work at national and international platforms. Autodesk would also be training around 8,000 franchisees in the state on the optimum usage of Fusion 360 design platform. Commenting on the occasion, Apurva Chandra, Principal Secretary (Industries) of the Government of Maharashtra said, “We are glad to see global technology leaders like Autodesk coming to the forefront in helping the growth of MSMEs in Maharashtra. Our government will leave no stone unturned in ensuring that we provide the most congenial growth environment to the businesses in the manufacturing sector. With the cutting-edge design technology

from Autodesk, we are confident to witness many innovative products being churned out by the MSMEs of Maharashtra.” “Today, with Cloud technology, it’s possible to democratise design. As the pioneer in delivering the entire product development process on a cloudbased platform, Autodesk is uniquely positioned to enable Indian MSMEs to leapfrog to world class manufacturing capability,” said Pradeep Nair, Managing Director, Autodesk, India and SAARC. The event included the real-time experience of various users of Autodesk Fusion 360 from Nashik,

TECH UPDATE www.mtwmag.com

Pune and Thane. They shared their most exciting experience of using this software by achieving cost and production efficiencies. Fusion 360 is a complete CAD, CAM and completely integrated product development platform available on the cloud. It helps move easily between industrial design and mechanical engineering with direct, freeform and parametric modeling. It saves the extra cost for data management, simulation and visualisation. It enables you to work online, offline, Mac, PC or mobile.

lntegrated CAD CAM You can forget expensive, disjointed tools to design, engineer and generate CAM output. Take your product development from design to engineering to fabrication, including integrated CAM for a cost far less than the maintenance on other CAM systems. The CAM capabilities of Fusion 360 enable you to quickly generate toolpaths that cut cycle times, reduce machine and tool wear, and produce the highest-quality finished parts. When manufacturing, Roughing operations often consume the most time, and always remove the most material. Fusion 360 contains the same proven HSM family of cutterpaths, including Adapative Clearing the leading strategy for faster machining, constant loads and reduced tool wear. 2D strategies include drilling, contouring, pocketing, facing, and adaptive clearing. 3-axis CAM offers parallel toolpaths, horizontal clearing, penciling, scallop/constant stopover strategies, and spiral/ morphed spiral for more organic designs. Avoid file translation frustration Fusion 360â&#x20AC;&#x2122;s accurate design file import and translation functions mean communication issues with partners, suppliers and customers are a thing of the past. Fusion 360 gives you the ability to work with customers using various popular CAD systems, resulting in improved collaboration and design processes, allowing you to save more time and win more business. With fully integrated CAD/CAM functionality, you can also make necessary CAD edits quickly and professionally without costly rework. lmport file formats such as SLDPRT, SAT, STEP, IGES STL and OBJ

and many more. Export back data in the formats such as IGES, STP, SMT, DXF, DWG and lnventor. Work anywhere from any device, share with anyone Just Login with your user name on any device and get access to your data anywhere. Invite unlimited team members to your projects. Keep track of versions, and view the work others have done within the project through a live activity feed. You also can keep track of progress and team activities via the A360 Team application in your web browser. Securely share your designs with specific individuals using the public sharing link from your data panel. The link will allow the recipient(s) to view and download the design within their web browser with our free 3D viewer-even if they donâ&#x20AC;&#x2122;t have an Autodesk Account.

JUNE 2016

MACHINE TOOLS WORLD

COVER STORY

turns one year!

MACHINE TOOLS WORLD JUNE 2016

Machine Tools World has turned one year so fast, in the thick of events. It was in June last that we brought out the maiden issue in response to a demand from a section of our readers and patrons to bring out a monthly dedicated to the metalworking & machine tool industry. In 12 issues, MTW proved its pedigree and commitment. It’s today the throb of the industry, reporting and reflecting the latest trends in technology and portraying the innovations showcased by our industry stalwarts. “The proof of the pudding is in the eating”, they say. We are getting appreciation from opinion leaders on the technical content, quality and presentation of the journal.

COVER STORY www.mtwmag.com

On the happy occasion of our 1st Anniversary, we recount with gratitude the contribution of our editorial members, industry experts, advertisers, readers and patrons, and of course the Team Divya for their unwavering commitment and dedication to make MTW the best-in-class and a truly international industry journal. The conceptual cover we have designed this time shows a galaxy of CEOs and industry experts who have figured in Machine Tools World in one issue or the other. They continue to be our guiding lights. We are grateful to them. ‘Anubandh’, the ancient Indian word meaning ‘interdependence’, is once again getting redefined. The progress and sustainability of our industry too depends on networking, co-operation, sharing of

knowledge, experiences and resources for mutual benefit. We can no longer work in isolation. We cannot hitch our fortune to one industry segment. The same way, we cannot castigate someone as competitor and keep aloof. In the eco-system we envisage, let us see everyone as partners in progress. This doesn’t mean we should not maintain our individuality or hone our competitive edge. India stands 14th in production and 10th in consumption of machine tools in the world, as per the Gardner Business Media Survey. The country is set to become a key player in the global machine tools industry and is likely to see a substantial high-end machine tool manufacturing at home. With emphasis on ‘Make in India’ and high-tech

manufacturing, the country should also be able to bring down progressively the import of machine tools in to the country. All this would mean hectic business activities in a burgeoning economy. In the days to come, Machine Tools World hopes to play a pivotal role in bringing meaningful and responsible industrial journalism that would help all concerned in the metalworking and manufacturing sector. – P.K. Balasubbramaniian

JUNE 2016

MACHINE TOOLS WORLD

INTERFACE

Nickunj Eximp: The legacy of excellence

EDM Graphite, Resin, EDM Machine spares, Electrolytic Copper, Polishing Stones, etc. We are one stop solution for anything under the sun when it comes to EDM.

Q2. What are the market opportunities for your products in India? How do you plan to position these products?

Mr. Nickunj Shah, Chairman & Managing Director, Nickunj Eximp Entp P Ltd.

Q1. Please brief us about recent initiatives undertaken in EDM Space? Which are your focus areas? We are proud to have developed a series of new High-End Zinc Coated, Diffused and Specially treated EDM Wires. What makes us stand apart is the fact that we have the widest range of high end wires manufactured in India as well as sourced from Bedra, Germany being their sole distributors in India for the past 25 years. Our focus areas are mainly in the Coated and High end segment. Since there are over 35 plain wire suppliers in the Indian market, we prefer to stay away from this RatRace and our strategy is to deliver value to our customers through High-end coated wires. We also provide the complete EDM Consumables program viz. Filters, Tungsten Copper Rods and Tubes,

MACHINE TOOLS WORLD JUNE 2016

The market opportunities for our products are enormous. With the increase in the number of high end to extremely high end EDM Wire cut machines entering the Indian market, our High-end coated wires are a perfect fit. We have specifically developed wires based on individual machines that work best on the respective makes and models.

Q3. What is your marketing strategy for India? Our core strategy is to keep it simple & focus on quality conscious customers who focus on productivity and time saving solutions along with superior surface finish as opposed to those who operate purely on price based model. We, as a philosophy, lay lot of importance on Relationship Marketing with customer & customized business solutions being most important for us while emphasis on purely price selling is minimal.

Q4. According to you what are the factors affecting your business? The fact that there is currently no other player in Indian market who has such a vast offering of wires, tailored to specific machines & requirements of the customer gives us an upper hand over our competitors. We have been

ruling the industry for more than three decades now & the kind of expertise & in-depth industry knowledge we have developed along the journey is outstanding & incomparable with any other local player. Our PAN-India Sales & Technical support team helps us to outreach each & every nook & corner of the nation which strengthens our backbone further.

Q5. What are the key technological trends that are driving EDM industry? High Precision, Stupendous quality finish & Lightning fast completion of jobs. Today the industry has adopted the Japanese methodology of Just-in-time manufacturing aimed primarily at reducing flow times within production as well as response times from suppliers and to customers. Right balance between faster wire cutting speeds & excellent surface finish of Ra factor in range of 0.2 to 0.3 is being desired with 0 being ideal.

Q6. What is your vision for your company? We aim to be the largest manufacturers of high-end specialized EDM wires in the country. Our vision is to produce 1000 MT annually by 2018/19 and exponentially increase the production there by Year on Year basis. Our name is synonymous with Quality so we envision to be regarded as the best in the country.

INDUSTRY TREND

The budget seems to be a

positive step in the right direction

Q. What trend will drive CAD/CAM Industry in near future? Optimal integration between CAD and CAM as well as a highly reliable Design/ Model for Manufacture methodology is what will drive the CAD/CAM industry in the future. It is evident that what is being designed will one day be manufactured; however – inspite of new age technology like 3D printing, there are various aspects regarding volumes, material, resource availability that a manufacturer (usually small & medium businesses) need to consider. Often, there is a disconnect between both these processes which results in inefficient manufacturing. CAD/CAM tools have the ability to tie these loose ends together by providing a system that connects the dots and provides an optimal guideline or options that the manufacturing planning department can consider. Price is always a key driver, and therefore offering the above at an economical price, backed by quality support will also be critical in driving this trend.

Q. What is the impact of Union budget on the industry? The budget seems to be a positive step in the right direction, with tax benefits to start-ups in manufacturing for the immediate short term period of about 2-3 years. Revision in Customs & Excise Duty rates would also be beneficial in sectors such as Defence Production, IT Hardware & Capital Goods. The MRO Sector in Aerospace is likely to gain through complete exemption on customs duty on spares imported for undertaking repairs. With the push in Aerospace Sector that the industry has been eyeing for a while now, this should

MACHINE TOOLS WORLD JUNE 2016

increase potential for business. Duty benefits in renewable energy is also a very positive step. Finally, duty exemptions have been reduced on several military equipment. This shall provide a fillip to Make-in-India initiatives as well as provide a level playing field for Indian Manufacturers. The budget’s focus on Infrastructure Development is another very important and positive feature. All in all I am pleased with the budget. The devil however lies in successful execution; I for one have immense faith in our system as it stands today, to propel India on the path of economic progress, strength & growth.

discourage the use of pirated software, encourage the adoption of new age technology, encourage continued education, invest in R&D – both as individual companies (micro-scale) as well as on the consortia levels (macro-scales) and most importantly pay due respect to customer requirement and resulting quality thereof.

Q. What are the remedies do you suggest to improve the positioning of the industry you are into? We are suppliers to the manufacturing industry and the success of this industry is critical to our success. The manufacturing industry faces many challenges – most of which can be addressed by diligently applying best practices and proven formulae – in the short term. In the longer term, innovation and competitive differentiation are key to the collective success of the entire supply chain in the business. The manufacturing industry should also regulate &

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INDUSTRY TREND

Servo Application in

Machine-Tool

Industry

Mr. Manish Walia VP-Industrial Automation Delta Electronics India Pvt. Ltd.

machine tool is a machine for shaping or machining metal or other rigid materials, usually by cutting, boring, grinding, shearing, or other forms of deformation. Machine tools employ some sort of tool that does the cutting or shaping. All machine tools have some means of constraining the work piece and provide a guided movement of the parts of the machine. Thus the relative movement between the work piece and the cutting tool (which is called the tool path) is controlled or constrained by the machine to at least some extent, rather than being

MACHINE TOOLS WORLD JUNE 2016

entirely “offhand” or “freehand”. According to a report, analysts forecast the global machine tool market to grow at a rate of 6.33% over the period 20132018. The machine tools market in the US is forecast to grow at a rate of 2.32% over the period 2013-2018. The Global Machine Tool Market 20142018 research report covers the present scenario and the growth prospects of the global industry for the period 2014-2018. In terms of product, the market can be segmented into three: Metal Cutting Machine Tool, Metal Forming Machine Tool, and Machine Tool Accessories.

Machine tools, such as metal cutting tools, metal forming tools, and machine tools accessories, are used to cut and shape metals and other materials during the manufacturing of a product based on its specifications. These tools provide an effective and efficient method of manufacturing critical components with the utmost ease and accuracy. Machine tools are used extensively by companies across several sectors such as Automotive, General Machinery, Precision Engineering, Transport, Aerospace, and Dies and Mould. The report Machine Tools Market

INDUSTRY TREND www.mtwmag.com

“

According to a report, analysts forecast the global machine tool market to grow at a rate of 6.33% over the period 2013-2018.

in the US 2014-2018 says one of the key factors contributing to this market growth is the increase in private non-residential fixed investment. The Machine Tools market in the US has also been witnessing the increase in technological advancement in machine tools. However, the increasing use of plastic products across industries could pose a challenge to the growth of this market. This research has been prepared based on an in-depth market analysis with inputs from industry experts. The report focuses on the US; it also covers the Machine Tools market landscape and its growth prospects in the coming years. The report also includes a discussion of the key vendors operating in this market. The Machine Tools Markets in China 2014 research report says China’s demand for machine tools has grown at a fast pace in the past decade. In the next five years, both production and demand will continue to grow. This new study examines China’s economic trends, investment environment, industry development, supply and demand, industry capacity, industry structure, marketing channels and major industry participants. Coming to servo systems, they can be used in CNC machining, factory automation, and robotics, among other uses. Their main advantage over traditional DC or AC motors is the addition of motor feedback. This feedback can be used to detect unwanted motion, or to ensure the accuracy of the commanded motion. The feedback is generally provided by an encoder of some sort. Servos, in constant speed changing use, have a better life cycle than typical AC wound motors.

Servo motors can also act as a brake by shunting off generated electricity from the motor itself. A machine tool, also known as a “machine centre”, is used to cut and fabricate precision metal components for machinery. Its main applications are in industries such as automotive, aircraft, aerospace, military, machinery, moulding, electronics, and power stations. Machine tools, also called “mother machines” for giving birth to new mechanical products, are used for manufacturing the metal components of various mechanical devices and equipment. Machine tools are divided into three types: manual metalcutting, numerical control (NC) and computerized numerical control (CNC). Based on customer demands and market trends, Delta Industrial Automation provides CNC controllers, spindle motors and drives, and AC servo motors and drives which offer constant speed, constant torque and the accurate position control required for machine tools. Through continued research and innovation, Delta Industrial Automation has launched the new high performance NC300 series CNC controller. It supports the standard ISO G-code format. Connected to Delta’s ASDA-A2-F series servo systems, permanent magnet spindle systems and next-generation DMCNET communications network, it can process high-speed data transmission and achieve high-speed motion control easily. Equipped with 3 servo axes and 1 spindle machine, this controller provides a complete output and input interface sufficient for carving and milling processing. The NC300 control

system is particularly suitable for mould processing, milling, cutting and drilling applications. Delta continues to work closely with industry to develop extensive and specialized products and automated control systems. These offer the high efficiency and high precision required for mechanical manufacturing and CNC machining that help customer’s gain a competitive advantage in the international market. At Delta, as the technology of microprocessor unit becomes more advanced and much further, the development and cost affectivity of permanent magnet manufacturing technology for servo motor and high power and high performance semiconductor power devices is improved continuously. Therefore, AC servo motor and AC servo control system have become the basic techniques for accomplishing automation control technology in current industry field. Delta servo system is an omnibearing integrated servo system which is based on Delta’s strength in industrial and electronic technology and developed for different customers’ requirements of various application machine tools. All ASDA series servo drives are provided with a superior digital signal processor (DSP) which represents a high-speed performance of the control circuit loop. Besides, the other features of Delta ASDA series, including gain tuning, smooth motor operation and software analysis / monitor function, also provide highspeed and high-precision motion control for a wide range of industrial automation applications.

JUNE 2016

MACHINE TOOLS WORLD

INDUSTRY TREND

Technology

Transformation will drive the machine tools industry in future Q. What trend will drive MACHINE TOOLS industry in near future ? L.J. Naidu Multi-tasking machines capable of handling complex processes, Additive manufacturing, Cost efficient Automation solutions, Highly Intelligent cnc control systems for digitalization of manufacturing processes, Ultra precision machine tools will be few major trends in near future. Mr Andreas Zieger Efficiency, flexibility and the interaction of machines. The globalisation is pushing the price fight, the scale effect is one solution to reduce the cost, but with high demand on quality. On the other side we see that optimised processes and integration of best technologies will bring additional benefits. Flexibility, is another challenge, the product cycle time becomes shorter and thus the invest needs to be flexible too. Machines need to be able to get adapted fast and easy to the new task. Finally the interaction of machines, on one side the mechanical connection to optimise a complete process and on the other side the data connection, here chaotic machine usage, shorter shut down time, tool life optimisation and finally quality information leads to higher usage of the capacity. The OEM try to outsource not only parts but also design and process development and by that the machine tool builders take over a more important role in the partnership. EMAG has here

MACHINE TOOLS WORLD JUNE 2016

Mr. Andreas Zieger, Director, EMAG INDIA Pvt. Ltd.

a good technology portfolio, a new modular machine concept to integrate that technologies and for all machines a build in automation to integrate machines to line and that we bring in the partnership.

Q. What is the impact of Union budget on the industry ? L.J. Naidu FY 16-17 budget has projected significant investment towards Infrastructure projects like Road/ Railways/Port, this will drive investment into related Industry. At the same time, introduction of infrastructure cess & luxury tax on certain categories of passenger car vehicles is likely to have noxious effect on Automobile Industry. Mr Andreas Zieger By focusing on education, infrastructure and defence it can be seen as initiator to set further development.

Mr. L. J. Naidu, Managing Director, GROB Machine Tools India Pvt. Ltd.

Q. What are the remedies do you suggest to improve the positioning of the industry you are into ? L.J. Naidu Rationalization of various taxes & cess for certain period, tax benefits for vehicles using alternate fuel technologies like Electric, Bio diesel etcâ&#x20AC;Ś will help vehicle manufacturers plan their strategies on long term and will benefit overall depending industries to larger extent. Mr Andreas Zieger To build up a multi technology industry with high quality standards to be recognized a partner in global industry world.

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Learn how Gleason’s latest gear production, inspection and service technologies are taking India’s gear applications to the next level.

www.gleason.com/GWI

INDUSTRY TREND

Auto Industry continues to drive the

Machine Tool Industry Q1. According to you what is current Scenario of Machine Tool Industry? In my view the industry is in heighten state of anticipation for the demand to go up at steeply. The Machine Tool industry by and large is active but higher growth results are not yet visible. But the mood is positive. Funds and cash flow remains tight and somewhat difficult. Not visible are expansions or new investments. Planned expansion plans are yet to take off. General engineering is active. Of course the main stay is the Auto. Here to we see some ups and downs depending on sectors and regions.

Q2. What is latest trends that are driving the Machine Tool Industry? Once again in opinion the Auto Industry continues to drive the Machine Tool Industry. Defense, railways & aerospace are really strong drivers at this moment comparatively more particularly the Ordnance factories and railways. Milling machines producers (VMCs & HMCs) are the gainers at this time with more positive growth. This is a clear demonstration of the user industry maturing gradually. The Grinding Machine industry is still sluggish. I wonder when the market will mature for better consumption of these machines in tune with our GDP.

Q3. How does UCAM is seeing the future for its Products? UCAM’S products have always enjoyed an excellent patronage from its customers who are both OEMs and end

MACHINE TOOLS WORLD JUNE 2016

Mr. Indradev Babu, Managing Director UCAM Private Limited

users. UCAM’s focus on providing the best engineered solution to its customers is amply evident from its tag line “Engineering Excellence. Exactly” The future is very exciting for UCAM and its products. The company has clear plans in place and poised to bring to its customers a new range of products underlying the importance of efficiency, reliability and aesthetics. Products from the stables of Nimble Electric and Nimble Machines divisions will be making a significant impact in industry segments other than

machine tool industry. The products like torque motors and Gear Hobbers from UCAM will be contributing meaningfully to the MAKE IN INDIA slogan that is redefining the boundaries of the Machine Tools and Allied Industry

INDUSTRY TREND

The future: High precision, high speed power

transmission 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?

Mr. Rajiv Moorthy, CEO, Shanthi Gears Ltd.

MACHINE TOOLS WORLD JUNE 2016

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

INDUSTRY TREND www.mtwmag.com

Armed with sophisticated production & QC equipment, Shanthi Gears comes out with products of unmatched quality and reliability

Shanthi Gears has an integrated gear manufacturing facility – one of the largest in India 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. Inhouse capabilities and competency enhancements are priority areas and we have a structured plan to bring out these through strategic alliances.

Q. What are your core strengths and competencies? Superior design and engineering 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. 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 plan to enhance your visibility and presence in the global market? 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’.

JUNE 2016

MACHINE TOOLS WORLD

INDUSTRY TREND

Processed cooling & drying come of age “Comprehensive range of products & solutions, presence in air and water, patronage from OEMs, contemporary technologies and back-up from our Japanese partners are our major strengths,” says Mr. K.P. Manoharan, Managing Director, Gem Equipments Pvt. Ltd. Q. You are known for your capabilities in designing customized systems. What’s the latest in your compressed air dryers? Our Nexgen Refrigerated Air Dryer is an embodiment of engineering excellence, innovation and reliability. The heat exchangers are designed to provide highly efficient heat transfer. It features honeycomb construction of aluminium fins giving true cross-flow for greater effective temperature differences, nonclogging larger cross-sectional area for air flow, integral air-air and air-refrigerant exchanges, with stainless steel demister moisture separator, robust non-corrosive grade aluminium, and larger heat transfer area for higher efficiency. The rugged electronic panel displays inlet,ambient and dew point temperatures in single display on demand. The tripper module gives alarm for compressed high discharge pressure, compressed low suction pressure, expansion valve malfunction, auto drain valve function and fan motor cycling. The VFD compressor with speed control proposed to manufacture in future is one of the major developments towards optimization of refrigeration systems

MACHINE TOOLS WORLD JUNE 2016

based on average load under R&D now. For periods of high cooling demand, the compressor speed can be increased, and vice versa for low cooling demand. In short, it is PLC based, operating on conventional gas, using optimized power, and demonstrates better dew point capacity and reliability.

Q. What are your innovations in cooling towers? Our bottle type FRP cooling towers with a capacity range 100 to 4500 lpm are really innovative. They require no sprinklers to be maintained, and operate for lower pressure return water. They are ideal for multiple inlets and outlets. These FRP towers also come in square type with stationary non-clog nozzle for easy maintenance, and PVC fills for larger contact surface area. Inevaporative cooling, we offer both coil type and modular type. In the coil type, the cooling water moves in a closed loop; hence no contamination. In the modular type, aerodynamically designed FRP fan blades are used for better efficiency and walkway is provided for access and service Our Dry Cooling Towers are in a class apart. The DCT type has a capacity range

of 120 to 3,000 kVA generator ideal for 1-10 MW power plants. The DGAS type comes in horizontal configuration, suitable for gas generators and adaptable for heat recovery. The capacity range is 500 to 3000 kVA Power generator. Our Aqua Saver( GAS) is designed to suit 100 to 5000 kW induction furnaces and 30 to 1000 HP air compressors. All these models reduce water consumption and conserve water. Moreover, in the absence of scaling, they hardly require any maintenance. We have recently bagged an order from Jordon (through ISGEC) for a dry cooling system valued at Rs.1.8 crore. Similarly we have also received an order valued at Rs.2.3 crores for a dry cooling system from Suzuki for their Gujarat Plant. We would also soon execute an order for large size evaporative cooling towers from a customer in Philippines.

Q. Your Bottle type FRP Cooling Tower is said to be a revolutionary product. What are its special features? Our Nexgen Bottle type FRP Cooling Tower features superior extended shaft flange mounted frame, waterproof with aluminium body, S.S. shaft and EPDM

INDUSTRY TREND www.mtwmag.com

sealing. The body is UV protected with a glossy finish. The FRP louver profile reduces water spillage. It has a high efficiency aerodynamic fan with axial flow and low noise. It is made of corrosionfree aluminium which is computerized balanced and wind tunnel tested in Germany. The spiral fills made of rigid PVC are clogg-free resulting in long life. This revolutionary product manufactured using the RTM (Revrse Transfer Mould) technology goes with a 5-year warranty for FRP body and structure.

Q. Anything new in your chillers? Well, we offer Industrial Chillers up to 100TR capacity. These factory assembled packaged unites go with a 2-year warranty which is industry’s first. The Mini series Industrial chiller uses a coaxial type heat exchanger. The design maximizes exchanger efficiency by using copper tubes in a coiled tube-in-tube arrangement. It promotes turbulence break-up boundary and maximizes the heat transfer rate with minimum pressure drop. A counter flow pattern is used to achieve maximum temperature difference. A series of Nexgen Chillers from 5 to 15 tr capacity under development has a high power efficiency and low footprint.

Q. So what’s your expanded portfolio today? We are primarily into Refrigerated Air

Dryers, Cooling Towers and Industrial Cooling Systems – all utility products essential for every industry. You can add to these the compressed air accessories we make like the After Coolers, Moisture Separators, Compressed Air Dryers, Air Filters and other contamination removing equipment, you get a complete picture of our product spectrum.

Q. Could you throw some light on your manufacturing facilities? We have a sprawling, well equipped manufacturing facility in a 5-acre verdant land. We have a workforce comprising 200 dedicated employees. A good number of them are professionally qualified managers and engineers involved in Engineering, Planning, Procurement, Production, Quality Assurance and other allied functions. They are assisted by a select few consultants and specialists in specific domains. We are following the state-of-the-art manufacturing process and the Japanese methodology for chiseling out products of impeccable quality and enduring value. We have a technology tieup with Orion, Japan for manufacturing Desiccant dryers as per their design in India and for marketing them under Gem brand in India and abroad. We have vast experience in designing, manufacturing and supplying Air Cooled Heat Exchangers for various process applications.

GEM has its modern, well equipped manufacturing facility in Coimbatore. Seen here is its Testing & QC Section.

Q. What’s your R & D set-up? With an unwavering commitment toquality and excellence, we have set up and nurtured our in-house R & D with the best of talents and in-depth knowledge of international codes which facilitate designing products to ISO standards. We have ISO-2001-2008 accreditation from DNV. We are also a member of CTI. We work in close co-ordination with research institutes and the user industries which help in developing new products and improving existing ones to meet the exacting requirements of our customers spread across the world.

Q. What are your growth strategies? We are opening a Warehouse-cum-Assembly Unit at Bhiwandi, near Mumbai shortly. The unit will stock all our standard products and accessories. The end product can be assembled here and supplied to the customer. We shall have a dedicated team attached to the unit. We shall be working in tandem with our channel partner to make this business model a success. This would ensure availability of our products and services to the local customers at a short notice. Once this is a success, we shall replicate the model and set up such warehouses-cum-assembly units in key industrial hubs like Delhi, Ahmedabad, Hyderabad, Calcutta etc. Our OEM business for cooling systems is expected to grow steadily. The off-take of compressor manufacturers like ELGI, Atlas Copco, etc. will increase substantially. This would help our business to grow at least at 15%. The business with Powericais expected to double next year. We can also expect increased business from St. Gobain, Nissan and Maruti Suzuki. Our order booking for radiator cooling for gensetsin marine containers is also growing at a fast pace. Last year we sold approx. 10 units, this year 110 units and next year it should touch 200 sets. At our plant we have introduced the bin system for all fast moving items. At any given time we shall maintain sufficient numbers in stock. Thesestock model would improve our delivery time and enhance the delivery rating with our esteemed OEM’s.

JUNE 2016

MACHINE TOOLS WORLD

INDUSTRY TREND

ROBOTICS: The flexibility factor Q. Effica is a well-known name in Robotic automation. 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 â&#x20AC;&#x201C; 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 & palletizing automation. This is a robotbased 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

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a special emphasis on hygiene. We have made our systems modular and user-friendly 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 enduser.

Q. Productivity enhancement is understandable. How do you increase efficiency and flexibility? Robots help enhance flexibility. Special purpose machines need retooling but robots need only reprogramming. The changeover is minimal and not timeconsuming. Practically we observe that our customers have seen an increase in machine utilization by up to 35% while using our solutions. This is because people are prone to fatigue and night shift efficiencies are very low. This is not there when robots are at work. Naturally efficiency levels are high.

Q. Could you elaborate on the cost saving aspects? To begin with there is a form of instant savings from the increased machine utilization. In the case of CNC machines,

Mr. Arjun Prakash, Managfing Director, Effica Automation Ltd.

if we are able to tend to 3 machines and increase their machine utilization by a factor of 35%, then it is the equivalent of having the fourth machine which may be priced similar to our robotic solutions. This is even more pronounced in the case of forging presses where the cost of a single press can run up to multiple crores and the savings are massive in terms of capital investments when robotic machine tending is used. Added to this the unavailability of skilled labour and the attrition turnover of trained people is a bugbear. This disrupts production and uptime of machines. When you switchover to robotic automation, the breakeven is achieved in less than 18 months in most cases and in some cases even instantly as mentioned above. The risk factor is less and no recurring costs. All these bring enormous savings to be accrued to the bottom-line. Today we see even very small scale machine shops and businesses breaking even with robotic automation. As the prices of robots keep dropping in the future we are only likely to see more and more of this trend.

INNOVATOR

Houghton at a 1.5 ton landmark & still counting! Houghton International (HI) celebrates a landmark one & a half century of product innovation, customer satisfaction & global growth. “Since 1865, the mission and values established by founder Edwin F. Houghton have made it possible to reach this note worthy milestone. From our early roots in Valley Forge, Pennsylvania, to becoming the largest metalworking fluids company in the world, we have come a long way.” - Sanjay Hinduja, Chairman

elebrations of success ring across the 6 continents that Houghton operates in. The company has reached a 150-year landmark and is bringing to gether its key stake holders for the occasion. Amid the festoons, the Open Houses and other events that mark the date, the heart of every Houghtonite swells with pride.

The pioneering spirit lives long

A pioneer of metalworking fluids, Houghton International was born in 1865 in Valley Forge, Pennsylvania USA. This brain child of Edwin F. Houghton, a manufacturer of rust preventives, began to spread its wings and launch new metalworking products for key applications with turnkey fluid management services. HI’s prestigious customers comprise reputed global companies from key industries including Aerospace, Automotive, Bearings, Construction, Food& Beverage, Forging & Stamping, Heat Treatment, Machine & Job Shop, Machinery, Mining, Non-Ferrous, Offshore Energy, Spring & Wire, Steel and Wind Energy. From a regional US-based supplier, to a global market leader, HI has come a long way. Leaders do things differently

This leader in the metalworking fluid space believes in doing things differently, yet consistently. Houghton has never wavered from its pioneering vision to be the most successful and respected specialty chemical company in the world. Its dedication to resolving customer problems by actively partnering with them to provide innovative and sustainable technical process-fluid solutions, and improve their production efficiency through increased productivity, reduced

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cost, minimized risk and minimized environmental impact, still runs asstrong as it was when the company was founded. The 7 core values that hold Houghton strong

Despite phenomenal growth, Houghton International is committed to its core valuessuch as Environmental Health and Safety (EHS) focus, results-drive, customer-focus, innovative spirit, integrity, openness to change, and a singular global “It is so rare for a company to reach this milestone. We want our employees to feel proud of this great achievement and we want to thank our customers for their continued support. We are and will remain committed to innovation, improvements and compliance in the metalworking industry.” Michael J. Shannon Chief Executive Officer “The fast-growing economies are increasing their share of output in the industrialized world. India has made a commitment to that trend with its recent “Made in India” campaign. Houghton is making investments to support our global and domestic customers in India and partner with them to achieve their goals by providing our leading technology and solutions” Jeewat Bijlani, President, Americas & Global Strategic Business “A crucial part of a company’s sustainability over the century and more, has been the strength and flexibility of its operations. As we innovated, launched new product lines and entered new markets, we kept our operations focused on our customers. With customer service offices and manufacturing now in six continents, our focus remains.” Marcello Boldrini President, Asia and Global Metals & Mining

vision. These remain at the center of its practices, processes, policies & products. The future is Innovation

Houghton is reputed to be a company that stands for product innovation. Our experienced global research team works closely with our customers to better understand their needs. Solutions to customer problems are developed at the laboratory before being tested at our customers’ facilities. In addition, our scientists are part of customer improvement teams and are actively involved in the design of our customers’ next generation products. The future has in store new solutions and platforms including “green chemistry” to improve performance and effectiveness from metal working fluids to our customer’s operational requirement. Come join us in this innovation journey and partner with us to achieve your fluid management goals! “Befriending the ASIAN TIGER was a challenge, but not an impossible one. Houghton’s rich 15O-year old business history, expertise and wealth of knowledge helped us in our Mission India and we are happy that India is today one of our key markets in the APAC region.” Melvin Gay Managing Director, South Asia Pacific “India is an integral part of our business and has earned a place of pride in our global business. We have successfully adapted global vision to Indian business culture and customers, and have been fulfilling our promise to the Indian market with competent and energetic team members.” Santosh Charkraborty Managing Director, India

INNOVATOR

Garage to the Globe – The Saga of Grind Master

Machines for the processes of deburring, grinding, polishing and micro-finishing 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. Widest range in the world

The winsome trio: Milind, Sameer & 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.

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

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

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The Grind Master plant in Aurangabad

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

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

INNOVATOR

Spraymet Surface Technologies helps in conservation of resources

hat does it take a metallurgist to become an entrepreneur? Besides a good academic background and industry exposure, you also need self-confidence and courage to leave a cushy job and enter business. That’s precisely what Bindagi did.

the Divisional Manager of Metco Thermal Hard facing Div. In 1987. Bindagi received special training in tribology at Metco, Australia as well as Sulzer Metco, USA. Back home he presented several papers on the nuances of ‘thermal spraying’ in conferences organised by IIW, BARC, VSSC and other organisations.

A scholastic career

P.T. Bindagi, the Technical Director of Spraymet Surface Technologies P. Ltd., headquartered in Bengaluru. Bindagi took his degree in metallurgical engineering from the Bellary Govt. College. He was state first. After this scholastic career, he took up a job with Precision Fasteners as a metallurgist in their R&D lab. After a short tenure of two years, He joined Ador (erstwhile Advani-Oerlikon) in 1984 and took the onus of product marketing in the newly set up Powder Division. At Ador, he stayed for long 10 years. He had his career progression and soon became

The turning point

The year 1994 was a turning point for

Proprietary coatings

Mr. P.T. Bindagi, Technical Director, Spraymet Surface Technologies Pvt. Ltd.

Waste into wealth: Spraymet harnesses the best of surfacing technologies to reclaim machinery components & parts and conserve resources 60

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Bindagi. That was the year when he bid adieu to service and decided to be on his own, doing the same thing closer to his heart : propagating the art and science of tribology, harnessing the proven technologies of thermal spray, plasma spray and HVOF. Subsequently, It took hardly a few months for him to give shape to his passion: establishing his own company in the name and style of Spraymet Technologies Pvt. Ltd. Today Spraymet is engaged in thermal spray, ENP plating and weld surfacing. While the main plant is in Bangalore, Bindagi set up the second plant in Pune to stay closer to its customers especially from the automobile sector which is demanding technical excellence, proximity and service all at the same time. Spraymet has the distinction of having pioneered the carbide coatings in the steel mills and galvanizing line roll coating.

The company owns a few proprietary coatings like moly blend (Spraymet MoB) for metal to metal wear and Ductile matrix carbide (Spraymet DMC) for plastic processing feed screws. Bindagi is keenly interested and is working towards expanding applications in turbine industry, medical implants and other new frontiers. In his quest, to spread knowledge, Bindagi also picks up students from universities for project work related to tribology and wear metallurgy. “Today when I look back, I have the satisfaction of having chosen a business line which is not only winning bread for me but also butter for the industry at large,” states Bindagi. There is substance in what he says. He has helped the industry save a lot of money and helped conserve its scarce resources. May his tribe increase! P.K. Balasubbramaniian

COMPANY SPOTLIGHT

Electrotherm (India) Limited :

Sustained Technology leadership

Mr. Shailesh Bhandari, Managing Director, Electrotherm (India) Limited

lectrotherm (India) Limited, an ISO 9001:2008 certified, public limited company, was founded in 1983 to cater to the needs of all segments of steel industry, foundries and heat treatment industry. Today, Electrotherm is a well diversified conglomerate having businesses in the field of Engineering & Projects catering to steel and foundry industry; transformer manufacturing; steel making; ductile iron pipe making; manufacturing of battery operated vehicles; renewable energy; transmission line tower and education. The Engineering & Projects (E&P) division of Electrotherm is a leading designer and manufacturer of Induction Melting Furnaces, Electric Arc Furnaces, Metal Refining Konverters (AOD), Electrotherm Refining Furnaces (ERF) (patented for design & process), High Speed Continuous Casting Machine, Power Distribution and Furnace Transformers and other equipment

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for Steel Plants, Foundries, Induction Heating and Hardening equipment for Heat Treatment. The E&P division is a customer centric organization delivering total solutions. It is particularly renowned for providing endto-end solutions for steel melt shops from iron ore to long product, supplying sturdy and highly efficient plant and machinery and rendering outstanding pre and post sales services to its customers around the world. Due to high level expertise and vast experience, Electrotherm (E&P) is the most preferred mini steel plant maker up to 1 million ton per year capacity through various alternative routes. Moreover, Electrotherm (E&P) is the only Indian company having CE marking for its Induction Furnaces, LRF and MRK, certified by UL Laboratories, USA. The E&P division of Electrotherm has supplied over 3550 equipments for various applications, 1800 furnaces for steel, alloy steel and stainless steel making, 1400 furnaces for ferrous and non-ferrous foundries and around 350 equipment for heat-treatment applications. It has exported over 550 furnaces to 42 countries around the world. Besides, it has made several mini steel plants overseas on turnkey basis in countries like Turkey, Iran, Iraq, Saudi Arabia, Pakistan, Bangladesh and some African countries for capacities ranging from 50,000 TPA to 1,000,000 TPA. The Electric Arc Furnaces of Electrotherm are designed and manufactured under technical collaboration with Vitkovice Heavy Machinery, Czech Republic. Rest of the major machineries, including Coal

based DRI plants and power plant utilizing waste heat generated by rotary Kilns, are designed and manufactured by in-house expertise and facilities at Electrotherm. Being a customer centric organization with focus on meeting changing needs of its customers, Electrotherm has full-fledged Research & Development Centre at its Corporate Office & Works in Ahmedabad with state of the art manufacturing set up and modern office complex. Products and Services:

• Induction Melting Furnaces for steel plants for steel, alloy steel and stainless steel making • Induction Melting / Holding Furnaces for ferrous and non-ferrous foundries • Electric Arc Furnaces • Electrotherm Refining Furnaces (LRF) • Metal Refining Konverters (AOD) • High Speed Continuous Casting Machines • Coal based Rotary Kiln (Sponge Iron) Plant • Coal based Tunnel Kiln (Sponge Iron) Plant • Turnkey Projects for steel making • Turnkey Projects for Integrated Plant through DRI – SMS route • Air Pollution Control System • Material handling equipment like Hydraulic Grabs, Vibratory feeder, Lining Vibrator etc.. • Plant Design and Engineering • Plant Automation • Productivity Improvement Equipment (PIE) for improving plant productivity, end product’s quality and plant efficiency.

COMPANY SPOTLIGHT

Partnering the manufacturing & automation industry - HEIDENHAIN INDIA

Heidenhain plant in Germany 64

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the closed loop feedback systems and CNC controls that address the high end requirements like 5 axes machining, die mould manufacturing and high speed milling and turning applications. Some of the top end Indian manufacturers who make quality efforts for import substitution, produce world quality machines in India for both Import substitution and export markets, using HEIDENHAIN’s legendary products and getting back up support from India. Availability of a support hub for techno commercial back up equipped with state-of-the-art programming systems, simulators, and test and diagnostic equipment and manned by highly experienced managers, engineers and technicians with several years of exposure to precision Metrology and Control Electronics, is a value addition for HEIDENHAIN’s Indian buyers. HEIDENHAIN INDIA has also created a high level IT infrastructure which will ultimately mean faster communication and data transfer between customers, local support and factory, resulting in excellent logistics efficiency. Indian customers now have many more reasons to prefer HEIDENHAIN products known for a century of trust relating

Mr. A.P. Jayanthram, MD, Heidenhain India with his team in Chennai

“

Indian customers now have many more reasons to prefer HEIDENHAIN products known for a century of trust relating to unequalled precision, reliability and longevity.

“

ith an immaculate corporate pedigree taking off from 1889, Dr. JOHANNES HEIDENHAIN GmbH have been developing solutions for the machine building, and automation industries with products like optical and magnetic linear, rotary and angle encoders, gauges, touch probes and Numerical Controls, sold and serviced all over the world by over 50 subsidiaries. Heidenhain Optics & Electronics India Pvt. Ltd. is one of the youngest fully owned subsidiaries operating in India since 2008 under the leadership of A.P.Jayanthram, a machine tools /metrology professional with about four decades of experience in the industry. All industry segments like machine tool building, automotive, metrology, packaging, printing, elevator and escalator, electronic manufacturing, steel mills, solar and wind energy, robotics, etc. prefer HEIDENHAIN as a high quality supplier synonymous with accuracy, longevity and reliability. Over 70 percent of India’s machine tool requirements are met by imports and Indian customers of world renowned manufacturers get techno commercial support from HEIDENHAIN’s Indian subsidiary for all elements including

to unequalled precision, reliability and longevity. Whether it is for getting trained on the efficient application of high end CNC control features, or servicing of scales/scanners/encoders/CNC Controls/Inverters, or for ideas on proper mounting and maintenance of elements, HEIDENHAIN India could help Indian Industry. “If we have to ‘make in India’ for the world, we need to incorporate the best and quality enhancing elements that the world can offer and exporting countries use in their products”, says Jayanthram. Indeed, a world leader like HEIDENHAIN has an outstanding R&D strength that ensures unquestionable technological edge that creates incomparable product ideas that are augmented by local support. – P.K. Balasubbramaniian

COMPANY SPOTLIGHT

WIL’s Leadership in High-Tech Manufacturing

Mr. G.K. Pillai, Managing Director & CEO, Walchandnagar Industries Ltd.

strong mechanical base, sprawling state-of-the-art manufacturing facilities in three locations, and a tradition of engineering excellence spanning over a century are the core strengths of Walchandnagar Industries Ltd.(WIL), the home-grown engineering enterprise founded by the patriot-technocrat-visionary Late Seth Walchand Hirachand. With quality and excellence embedded in its DNA, WIL is making a significant contribution to the space program of the country today by developing and supplying critical components required for the satellites. Carrying the sobriquet ‘Metal Men’, WIL is known for its heavy engineering set-up fully geared to undertake critical manufacturing.

High-tech Manufacturing

WIL has actually been involved in the area of high-tech manufacturing for over three decades now. There are five distinct areas where WIL has been doing work in this niche domain with various government agencies: a. Nuclear Power Plant Equipment:

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Manufacture of critical and core components like Calandria, End Shields and Heat Exchangers. WIL has been one of the pioneers in the private sector to partner with Nuclear Power Corporation of India (NPCIL) and Bhabha Atomic Research Centre (BARC) to manufacture and supply such components to various nuclear power plants in India including 220 MWe Reactor, 500 MWe PHWR Reactor, 500 MWe PFBR and 700 MWe Reactor. As an added capability, WIL is in its last stages of executing a project primarily related to Sodium Piping and Chimney (Supply and Erection) for the 500 Mwe PFBR at BHAVINI, Kalpakkam. b. Missiles Components : WIL is one of the very few companies in India today who specialize in the manufacture and assembly of Motor Casings for Missile programs both strategic and tactical i.e. AGNI, AKASH, ASTRA, B05. Bharat Dynamics Ltd (BDL) is its major customer in this arena. c. Defence Equipment: WIL has been closely involved with the ATV (Ad-

vanced Tactical Vessel) program to manufacture equipment like Weapon Containers and Launchers for Nuclear Submarines. On board integration work at Ship Building Centre, Vizag on the indigenously built Nuclear Submarine is also one of its ongoing activities. It has also manufactured and supplied equipment like Mobile Bridges and Launcher Assemblies (both wagon mounted & truck mounted) in the past. d. Components for Launch Vehicles: WIL has been a strategic partner for the Indian Space Research Organization (ISRO) and it has proven the model of public-private partnership in this domain. Various core components of launch vehicles – for both PSLV and GSLV programs - like motor casings, strap-on motors and various segments have been manufactured by WIL and have successfully performed during launches. While all the launches done by ISRO have had WIL made components, it is notable to mention WIL’s role in the launch of Chandrayaan, Mangalyaan and the recently launched GSLV-C6 carrying the GSAT-6 satellite. e. Gearboxes : WIL’s offerings in this area are quite diverse ranging from high speed, low speed, planetary and marine gearboxes. These are designed for various applications/ industries including Sugar, Cement, Steel, Paper, Hydel Power, Fertilizer, and Petrochemical plants. Its marquee offerings are the heavy duty gearboxes designed specifically for the Indian Navy (Frigates, Corvettes and Submarines).

COMPANY SPOTLIGHT www.mtwmag.com WIL’s efforts to scale up and consolidate its already proven capabilities in hightech manufacture revolve around the following three key-themes:

a) Scale : Most of its offerings today especially in the defence business group (defence, aerospace and missiles) have been developed after a long iterative process wherein specific skills related to materials (and their metallurgy) and manufacturing processes have been developed and honed. It is now concentrating on scaling up its volumes in these areas so as to derive the benefits of economies of scale. This is being done through focused capital investments (e.g. purchase of specialized automated equipment like machining centres), inhouse expansion of sheds and integration areas, etc. and also strengthening its supply chain of supporting bought-out items. Adequate availability of land at its factory location in Walchandnagar places it in a favourable position as far as such an expansion (and consequent scaling up) is concerned. As a strategic asset, it also has a 56 acre plot of land available along the water front in Dahej, Gujarat which gives it the leverage to fabricate heavy equipment (e.g. Nuclear and Defence) which could be transported via sea to various locations.

b) Skills: Continuous skilling and reskilling of its workmen and supervisory cadres in areas like welding, machining, fitting and integration is being done by the company. E.g. it has a special ‘Welding Development Section’ wherein welders chosen to work on specific joints are trained and qualified to the satisfaction of its discerning customers.” Meeting the stringent quality requirements of all our customers mentioned earlier is our primary focus and hence ‘Skill-Development’ is very important”, says Mr. G.K. Pillai, Managing Director & CEO, Wil. It is primarily through such on-going efforts that it has developed welding procedure specifications for a wide variety of ferrous and non-ferrous materials. A project management approach is also implemented for all its long cycle manufacturing jobs so that program managers are able to deliver the right product within constraints of timelines and budgets. Specific training towards acquisition of project management capabilities is regularly provided to the concerned personnel through training programs both internal and external. c) Technology and Engineering : Any organization catering to this niche domain

has to be at the cutting edge of technology and engineering and that is exactly what WIL’s attempt is. It has an in-house division called “Walchand Technology Group” which supports various hi-tech manufacturing divisions in product and process development as well as troubleshooting, in addition to dedicated divisional engineering teams. The company is in the process of upgrading skills in this area – especially skills complementary to its core areas like hydraulics and electronics and control systems as well as composite materials. It already has existing tie-ups in some of these areas for specific project purposes. “While our core strength is Mechanical Engineering, we are well aware of the need to have a diversified portfolio of engineering expertise and that is what we are in the process of building,” states the company. EPC business

Over the years the EPC business (Sugar Plant Machinery, Co-generation and Cement Plant Machinery) has been the mainstay of WIL’s top-line growth. In case of Sugar & Co-generation, It offers end-to-end turnkey solutions (design, manufacture, supply, erection and commissioning) of complete Sugar Plants

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MACHINE TOOLS WORLD

COMPANY SPOTLIGHT Gear cutting & boring machines section

(500 TCD to 26,000 TCD). The company caters to supply of independent units like Sugar Milling Plants and Centrifugal Machines (batch and continuous type). The company also designs and manufactures and supplies Boilers both for Co-generation at Sugar Mills and also for independent Power Projects. These are biomass based Boilers and their combustion technology enables usage of a very wide variety of such fuels. As far as the recent set of projects are concerned, it is in the process of setting up Milling Plants and/or Boilers for three Private Sugar Plants in Maharashtra and also one Sugar Plant in Kenya. Bigger projects like the 12 Sugar Mill Modernization and Co-generation sites in Tamil Nadu (Tamil Nadu Electricity Board) as well as for Tendaho Sugar Factory in Ethiopia are also on in full swing. As far as Cement Plant Equipment is concerned, it has a diverse set of offerings – complete cement plants (upto 2 MTPA capacity), grinding units, vertical roller mills and ball mills, pyro section, separators and blending silos. It has successfully commissioned 48 complete cement plants including 11 export projects (primarily in Africa and Middle East). Currently it is in the process of executing a Pet-coke crushing facility at ACC’s cement plant in Gagal, Himachal Pradesh.

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A VTL at WIL - The biggest in Asia Exports:

WIL sees Exports as a strategic opportunity, more so for its Project Businesses like Sugar, Cogeneration and Cement. As far as Sugar & Co-generation business is concerned, it is executing a project in Ethiopia (Tendaho Sugar Factory) which , after phased completion , would be one of the largest facilities in the world based on tons of sugarcane crushed per day. In addition it has successfully executed Boiler Supply & Installation projects in Africa, Latin America as well as in New Zealand. South East Asia is also a strategically important region where it is in the process of building its presence. In the case of Cement Plant Equipment, some of its key clients are based out of Africa and the Middle East. “Given the thrust on infrastructure in the SAARC region, we are also actively

pursuing opportunities in countries like Nepal, Bangladesh and Sri Lanka and even Myanmar,” adds Mr. Pillai. The Government’s policies in the realm of defence equipment – offset policy, defence exports policy, etc. are seen as enablers for companies like WIL to be a part of the global supply chain for such equipment. Looking Ahead

“As an organization, we are hopeful that the Indian economy will eventually come out of its below par performance seen in the recent years – especially in the capital goods sector. We think that over the period of the next two years there would be a significant improvement in the Indian economy,” says Mr. Pillai in quiet optimism. – P.K. Balasubbramaniian

CASE STUDY

Kennametal

helps job shop triple tool life A job shop in the Midwestern US State of Indiana has cut insert costs in half and tripled its tool life with Beyond Evolution grooving and cutoff tools from Kennametal

ince the day some ingenious machine tool engineer first mounted a metal tube on an engine lathe, machinists have been looking for a better way to cut off parts. From handground bits to high speed steel blades to indexable carbide inserts, cut-off tool technology has continued to improve over the years, increasing metal-cutting efficiency and lowering operational expenses along the way. One large step in that evolution came with the development over recent years of multi-purpose cut-off tools able to switch hit as grooving, turning, and profiling tools, giving manufacturing companies the ability to simplify setups and shorten production cycles, and in some cases keep fewer tools in the crib.

Searching for reduction in tooling costs

One such company is EMC Precision, a family owned and operated precision machining job shop headquartered in Elyria, Ohio. Since 1925, EMC has provided prototype to production machining and value-added services to a range of industries including fluid management, hydraulic fluid & power, automotive, recreational, and other OEMs. Ian Dotson, manufacturing engineer at EMC’s Sheridan, Indiana facility says he was happy with the tool life and performance of his existing cut-off solution, and was only looking for a reduction in his tooling costs when he called his

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local Kennametal distributor, CCA Inc. The salesperson there introduced him to Kennametal’s Beyond Evolution, a single-sided grooving and cut-off system with multidirectional turning capability, through the tool coolant, proprietary chip control, and “Triple V” secure seating geometry. Dotson admits he wasn’t too concerned about the bells and whistles, as long as the tool performed as well as what he was already using, and saved the company some money. He was pleased with the results. “We were using a 0.118 in. wide (3 mm) PVD-coated insert to cut off 0.75 in. diameter (19 mm) 4140 steel hydraulic actuators,” he says. “We swapped out the old tool for a Kennametal Beyond Evolution cut-off and kept the feeds and speeds the same. After several runs, we determined tool life was essentially identical, so from a performance perspective there was no difference, at least not on this job. But the Beyond Evolution inserts are dramatically less expensive, roughly 40 percent of what we were paying for our legacy tools. It was a clear win for us.” Triple time

The next win came on a job Dotson was running on one of EMC’s Daewoo Lynx 220 CNC lathes, a transmission gear shaft made of 1-1/4 in. (32 mm) 8620 steel, and

using a 0.236 in. wide tool (6 mm) to back turn a journal on the left side of the part prior to cut-off. In this application, insert cost was still a concern, but Dotson’s primary goal was tool life improvement. “The Daewoo isn’t equipped with high pressure cutting fluid, and the standard pump was unable to generate enough pressure for us to utilize coolant through the tool on our old cut-off system,” he explains. “Because of this, we’ve been stuck with flood coolant, and have always had some chip control issues as a result— the chip would roll back on itself and starve the cutting edge of coolant.” Despite the less than perfect cutting conditions, the Beyond Evolution performed beyond expectations. “We achieved very good results,” says Dotson. “This time we increased the cutting speed a bit, from 350 to 400 sfm, and bumped up the feed rates by about 30 percent. Even so, tool life increased threefold, to just over 2600 pieces per insert. I’m confident we could have cranked up the feeds and speeds even more, especially if we had plumbed the tool for coolant through, but there was no need. This operation supplies another machine, and that one was already running as fast as it could go. The big thing for us was getting more parts between tool changes, and that’s exactly what the Beyond Evolution did. It’s an excellent product at a very competitive price point.”

Renishaw Solutions Centres... lowering the barriers to Additive Manufacturing UK

Stuttgart Shanghai

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Renishaw Solutions Centres - your pathway to innovative AM products Renishaw Solutions Centres provide a secure development environment in which you can build your knowledge and confidence using AM technology. Equipped with the latest AM, machining and metrology systems staffed with knowledgeable engineers, a Solutions Centre offers you a fast and accessible way to rapidly deploy this exciting technology in your business. Renishaw will support you throughout your investigation and business case development process, helping you to optimise your design, build your confidence in the process, and gain the evidence you need to make investment decisions.

For more information visit www.renishaw.co.in/solutionscentres

Renishaw India [Bangalore] G.K.Arcade, 3rd Floor, #125/1-18,T. Mariappa Road, Jayanagar 1st Block, Bangalore 560 011 T +91 80 6623 6000 F +91 80 6623 6060 E india@renishaw.com

www.renishaw.co.in

CASE STUDY

Haas Automation Improves Competiveness for

Lange CNC

The ease of operating a Haas machine coupled with support and accuracy of the machine, has helped the machining firm carve out its own unique identity

espite what the text books and the business magazines might say, there’s no ‘right’ way to start a company. Some of those that eventually turn out to be successful have very humble beginnings, and no particular business plans to speak of. Take Haas Automation customer Lange CNC, for example. Founded and owned by Jens Lange, and his wife, Steffi, the Stuttgartbased company wasn’t exactly an accident, but it started off as little more than a pastime, albeit a very time consuming one. Start of an entrepreneurial journey

Lange CNC makes low volume parts for special machines - machine control pedals or turning handles; as well as a lot of bearing flanges. Describing the initial journey, Jens Lange, Founder, Lange CNC, says, “I was working for a local manufacturing company. At that time, some friends and I were racing RC cars – in our spare time, as a hobby. One of my friends – a very serious RC car racer, asked me to make him some aluminium axels

“

for his car, which I did. He was so pleased with the axels – and others were likewise, very interested in the product, that I decided to buy an old, knee-type milling machine to see what else I could make. Pretty soon, local companies began to find out I was machining in my spare time, and a few orders came my way.” Discovering Haas

After 3-4 months, Jens Lange would finish his job at the end of each day and spend another eight hours a day working in his own machine shop! It was crazy, but he loved it. After a year or so – around 2008, he decided it was time to buy a milling machine with a tool changer, which is when he went to AMB, the manufacturing show in Stuttgart, and discovered Haas. Immediately, he could see they were the right CNC machines for him. “They were relatively low cost, very well equipped and, overall, great value for money. My first Haas was a VF-1 vertical machining centre, which is still running as hard today as it was the day it arrived,”

We are a young, growing company which values the support of our local Haas Factory Outlet” - Jens Lange, Founder, Lange CNC

MACHINE TOOLS WORLD JUNE 2016

Benefits of Haas machines • Haas machines are easy to run • Haas machines can run without heating or insulation • Extensive support &great accuracy remembers Jens Lange. Addition of Haas machines

Jens Lange continued in his day job while running the Haas in the evenings. This went on for 7 years, until he had a daughter and his wife, Steffi, said, ”You need to decide whether you are going to carry on like this or take the risk to run your own business full time.” A semiretired gentleman called Straub, with a background in machining, said he’d come and work for him, so immediately he had employee number one. When Steffi and Jens Lange decided to commit to running Lange CNC, they bought a Haas ST-10Y turning centre with live tooling, another VF-1 and a VF-2SS super speed machine. The team already had some new business,

CASE STUDY www.mtwmag.com Jens comments, “We are a young, growing company which values the support of our local Haas Factory Outlet. They provide us with invaluable peace of mind. I have no doubt we’ll buy more Haas machine tools.”

Lange run two VF-1 vertical machining centres; a ST-10Y turning centre with live tooling; and a VF-2SS super speed machine

The company makes low volume parts for special machines - machine control pedals or turning handles; as well as a lot of bearing flanges

Jens Lange founded Stuttgart based Lange CNC with his wife, Steffi

once customers knew we were full time, so the fact that the Haas machines were ordered and arrived within three weeks was perfect. “We make quite a few parts for local manufacturer, SMS Maschinenbau – parts for special machines. Our volumes are low – typically 1-10 pieces, such as machine control pedals or turning handles. We make a lot of bearing flanges – programmes run to 100,000 lines and tolerance are 0.02mm, but that’s no problem for the Haas ST-10Y. We often use it to make parts with tolerances of 0.008mm,” states Jens Lange. Florian is the machine operator running the ST-10Y. He’s currently making 250 little spindles for a miniature vice, used

in dental applications and metrology. At the most, the team makes batches of, say, 500 small prismatic parts for customers like VW. But small batches are the firm’s specialty, which is why the firm is about to merge with another local machining business that is set-up for larger batches: 2000+ off. Easy to operate

The Haas machines are so easy to run. One of the company’s operators – Hans Maier, spent 20-years out of machining before he joined the company. “We put him on a Haas VF-1 and he was running it within a couple of days, no problem. We also have a trainee, BahadirDeniz, a student from a local college, running our other VF-1. He’s

doing a great job and I know he’s very comfortable operating the Haas,” states Jens Lange. All Haas machines run from 6:30am to 10pm, every day. Before the team moved to the current premises, the workshop was a garage, without heating or insulation, and the Haas VF-1 would be running in temperatures of zero degrees. But, despite the demands that the team placed on them, the team had no serious issues and the Haas machines never lost accuracy. If ever we the team needed support, the local Haas Factory Outlet could send a replacement part or a service engineer within twenty-four hours. For a young, growing company like Lange CNC, that sort of peace of mind was very valuable.

JUNE 2016

MACHINE TOOLS WORLD

CASE STUDY

Kishan Auto Parts cuts costs by The company recently purchased a Renishaw Equator flexible gauging comparator, and has seen an immediate reduction in cost and gauging cycle times of more than 80%

80%

ishan Auto Parts, Rajkot (Gujarat, India) is a world leader in the manufacture of connecting rods for major names in the car, compressor, heavy commercial vehicle, tractor, marine engine and earth mover manufacturing industries. The company recently purchased a Renishaw Equator flexible gauging comparator, and have seen an immediate reduction in cost and gauging cycle times of more than 80%. Additionally, despite shop floor temperature variations of more than 21 oC (43 °F), measuring performance has been unaffected due to Equator’s unique comparator method which uses master parts calibrated on Kishan’s co-ordinate measuring machine (CMM). Versatile gauging on the shop floor

Kishan Auto is now using Equator to gauge multiple variants of connecting rods, and is adding more every day. Typical gauging times of 55 seconds per connecting rod are a significant reduction over previous methods. The operators can use one Equator machine for many different parts, gauging all the features in a single operation with an immediate pass/fail decision, along with a report of the component dimensions. Despite its location in Rajkot, Gujarat, where temperatures soar to 40 °C (104 °F) and drop to 19 °C (66 °F), Kishan is seeing repeatable results from its Equator system.

MACHINE TOOLS WORLD JUNE 2016

“

Equator and the CMM complement each other perfectly, one providing the traceable certified accuracy, the other providing the thermal capability and extra capacity” Shantibhai Changela, Managing Director at Kishan Auto

This is achieved by re-mastering at least every 3 hours, or when they know the temperature has changed significantly ‘re-zeroing’ the system removes the effect of thermal growth from the measurements, and therefore guarantees component quality. The master part must be kept close to the machine and subject to the same thermal conditions as the production parts. If at any time the ambient temperature changes rapidly and a part goes out of tolerance, an operator can measure

the master part to re-set the system and check the reported ‘fail’ is not due to the environment. Traceability and extra capacity

The master parts are ‘calibrated’ on Kishan’s CMM, which gives them the traceable accuracy they rely on to guarantee quality. However, the high thermal variation means that the CMM has to be used within the company’s temperature-controlled room. Equator gives Kishan the op-

CASE STUDY more important is the cost of gauging. They have identified 77 variants of connecting rods which the Equator system can accommodate, and operators use the system to measure 500 units per day in a 10 hour shift. If Kishan Auto were to invest in hard gauging for all 77 variants, it would mean an investment of Rs 23 millions (approx US $450,000), just for the hardware alone. There are also other costs to consider, such as skilled labour to set up and maintain these gauges, storage, and running costs. Kishan goes from strength to strength

cost Rs 6,000 (approx US $120), while the display costs Rs 30,000 (approx US$ 600). However with the 4th gauge, measuring ‘bend and twist’, the cost goes up to around Rs 300,000 (approx US $6,000) – this includes a golden part which can be easily damaged and often has to be replaced. In addition the whole process can take 120 seconds for each air gauge, so for each part tested the whole process can take more than 8 minutes. With increased demand for their products Kishan needed a faster method of gauging. portunity to extend the certified accuracy to the shop floor whatever the conditions. For this particular requirement, Equator has removed the need to purchase an additional CMM with scanning capability, as Shantibhai Changela, Managing Director at Kishan Auto, comments: “Essentially Equator and the CMM complement each other perfectly, one providing the traceable certified accuracy, the other providing the thermal capability and extra capacity.” Before Equator

For many years Kishan Auto has been using air gauges for checking diameter, circularity and ‘bend and twist’. For each of 360 variants of connecting rod they have used 3 or 4 different gauges. On larger connecting rods for heavy use applications, this can be at a 100% sample rate. In Kishan’s experience these hard gauges usually last up to 10,000 uses, and then have to be reworked. For each different connecting rod, 3 of the 4 gauges

MACHINE TOOLS WORLD JUNE 2016

The search for a fast inspection system

During September 2011 managers from Kishan Auto were in Germany for business meetings and to visit the EMO Hannover exhibition. Having searched without success for more than 2 years for an inspection system that could achieve the speed of operation they required, they did not have high hopes of finding a solution. It was only as they were on the point of leaving the show that they spotted one of the Equator system demonstrations on the Renishaw stand which was gauging a connecting rod - it was a chance encounter that ultimately solved their problems. They requested a demonstration within a few days of returning to India, & having seen an Equator gauging their own parts, immediately decided to purchase a system. Cutting the cost of gauging

Time and ability to cope with temperature are not the only issues for Kishan Auto;

The company was started by Changela in 1988. Kishan started by manufacturing 2,000 connecting rods per month and today they manufacture up to 50,000 per month with 360 variants. The customer list reads like a who’s who in the world of cars, compressors, heavy commercial vehicles, tractors, marine engines and earth movers. Kishan exports 90% of its production to leading industrial and developed nations including the USA, UK, Germany, Singapore, Italy, China, Poland, Brazil, and the Netherlands. The company has a reputation for high quality within required tolerances, but also at a competitive price. It specialises in manufacturing connecting rods from raw material to finished product within their own forging plants, with a lead time of 60 - 90 days. Quality is Kishan Auto’s mantra

For Kishan, quality is the result of the right work ethic and processes for both management and operators, plus having the right equipment to achieve the required aims. The introduction of the Renishaw Equator gauging system has significantly enhanced quality, such that the company is now in a position to operate 100% inspection of components, quickly and easily, and are happy to guarantee 100% quality assurance on all parts. As Changela comments “Quality is critical to us, we constantly strive to achieve 100% quality, at the same time as improving efficiency and passing those savings on to the customer. Equator has taken us to another level.”

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

INDIAN ENTERPRISE

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

TECH TRENDS

Vollmer

shows tool grinding in a new dimension

“

With the Vgrind 160, we are seeking to lay the foundations for growth in a new field of business, and to establish ourselves in the tool grinding market., says Dr. Stefan Brand, Managing Director of the Vollmer Group.

With the new Vgrind 160 grinding machine for solid carbide tools, Vollmer entered the worldwide market in the area of tool grinding in March 2014. From a technological point of view, the Swabian grinding and erosion machine specialist is literally expanding into a new dimension: Thanks to the two vertical spindles, multi-level machining can be carried out for the first time using the Vgrind 160. This enables tool manufacturers to produce large numbers of solid carbide milling cutters and drills quickly and precisely.

ith the Vgrind 160, we are establishing ourselves in the international tool grinding market for the first time,” says Dr Stefan Brand, Managing Director of the Vollmer Group. “For us, this is a logical and consistent step in order to develop our core competency in sharpening, and to further strengthen Vollmer’s international position as a comprehensive solutions provider for tool production. Machining solid carbide milling cutters and drills With the Vgrind 160 grinding machine,

MACHINE TOOLS WORLD JUNE 2016

five CNC-controlled axes ensure precise machining of workpieces. Using the Vgrind 160, tool manufacturers can produce solid carbide drills and milling cutters with a diameter up to 50 millimetres. The core of the Vgrind 160 is the new kinematics system, which is controlled by two vertical spindles. This is because, unlike with a single spindle or horizontal double spindle, multi-level machining can be carried out thanks to the vertical arrangement. In addition, the spindle arrangement solves the common problems related to fixed and floating bearings, which leads to more precise

TECH TRENDS www.mtwmag.com

results when machining workpieces. Speeding up production around the clock Thanks to short linear axis travel distances and swivel ranges, the Vgrind 160 enables you to reduce machining times for machining workpieces. Nonproductive times are shortened because tool manufacturers can load the two grinding spindles with different tools. An optional tool magazine with eight grinding wheel packages enables tools on the vertical spindles to be changed over automatically. The pallet magazine HP 160 enables up to 272 workpieces to be supplied. The HPR 250 free-arm robot is also a new addition which increases autonomy and efficiency during tool manufacturing – the HPR 250 makes it possible for the previous capacity to be tripled. The automation solutions ensure optimal utilisation of the machine, around the clock. Achieve precision across several levels The Vgrind 160 achieves more precise results thanks to multi-level machining, as a workpiece is only ever machined on the fixed bearing side of a grinding wheel set. In addition, the grinding

Using the two vertical spindles of the Vgrind 160 grinding machine, tool manufacturers can machine their solid carbide tools on two levels. wheel set is always located at the C-axis pivot point, which allows an accurate sharpening process. A further guarantee for precision and accuracy is the polymer concrete design of the machine, as this solid foundation provides improved damping and vibration behaviour. The design and the new wall concept of the Vgrind 160 lead to a compact and stiff construction with

With the Vgrind 160 grinding machine for solid carbide tools, Vollmer is entering the tool grinding business field.

low space requirements. Intuitive operation with established software Operation of the Vgrind 160 can be easily and individually adjusted thanks to a height-adjustable, pivoting control panel. The display can be positioned so that not only does the operator have an optimal view of the graphic interface, but the work area also remains visible. To control the Vgrind 160, Vollmer uses the software NUMROTOplus, which offers comprehensive applications for the production and resharpening of various tools. The software of the Swiss market leader, NUM, is used for around 40 different types of machine from 15 wellknown manufacturers in 50 countries. “We developed the Vgrind 160 as an innovative platform, with which tool manufacturers can produce their products for their market precisely and efficiently,” adds Dr Stefan Brand. “As a result, the Vgrind 160 can be, employed with extreme flexibility both in terms of quality and quantities.”

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

JUNE 2016

MACHINE TOOLS WORLD

TECH TRENDS

Sparkonix - from the first to make EDMs in India to being the first choice for its customers! Some of the key aspects for which Indian customers continue to choose Sparkonix’s EDMs, over others, include: EDMs with highest value for money Value for money is the most revered aspect for us Indians. Sparkonix understands and values this need very well. In less than a year, Sparkonix has added close to 40 new features to it’s range of Electric Discharge Machines (EDMs). As a result, Sparkonix EDMs are highly feature-rich, and yet remain the most competitively priced spark erosion technology option available in the Indian market. Customized EDMs for specialized applications Sparkonix is probably the only EDM manufacturer in India to offer highly

“

Indians have a unique approach to defining the value of technology and we realized that very early on, Shailesh Patwardhan, Director, Sparkonix (India) Pvt. Ltd.

“

parkonix is the first Indian company to develop and launch the Spark erosion or Electric Discharge technology. Today, Sparkonix Group manufactures a diverse range of machines and has an installed base of over 5,000+ machines across 32 countries. “From our experience of selling machine tools across the globe, we realized that there are several aspects where Indian customers tend to think differently”, says Shailesh Patwardhan, Director - Marketing at Sparkonix. From the beginning, Sparkonix has developed its Electric Discharge Machines (EDMs) technology keeping unique needs of Indian customers in focus. The evolution of Sparkonix’s EDM technology and machines is nothing but a reflection of the evolving needs of engineering companies in India.

customized EDMs to cater to specialized needs of the customer’s applications. “From building a customized EDM for extrusion application that does horizontal sparking over a distance of four meters, to fulfilling specialized defense applications, over one-fourth of our projects involve customization” adds Shailesh. Service to improve your performance Sparkonix’s EDMs are used across, from single man machine shops to some of the most advanced machine shops and tool rooms in the world. The know-how harnessed from serving a diverse range of applications is leveraged by the service team to help customers further improve their quality and productivity. Speaking of service, Shailesh says, “Customers have found Sparkonix’s EDMs, purchased by them in the early 90s, to deliver the desired performance and finish, even today. Our EDMs need very little or no service at all and that means our service team is entirely focused on improving the performance and life of the machines for you” With continual investments in R&D, Sparkonix has been leading the way to set new benchmarks for EDMs in India and several other key markets.

MACHINE TOOLS WORLD JUNE 2016

Accuracy in Continuing Development For years, absolute linear and angle encoders from HEIDENHAIN have been setting standards for accuracy in machine tools.This will also apply to the latest generation of our encoders.Today these products are diagnosable, feature more interface variants, and are provided with functional safety including mechanical fault exclusion. This is how we continuously develop our proven products to be optimally prepared for the demands of modern machine manufacture.

HEIDENHAIN OPTICS & ELECTRONICS INDIA PRIVATE LIMITED

Angle Encoders

Linear Encoders

Chennai 600031, India

Contouring Controls

phone +91 44 3023 4000

Position Displays

Length Gauges

www.heidenhain.in

Rotary Encoders

TECH TRENDS

Software version 4 provides new, user-friendly features TNC 640 with New Highlights By Abhilash Tripathi, Associate Director (Sales & Service), Heidenhain India

“

Since its market launch, the TNC 640 has increasingly been becoming the first choice for high-end controls with efficient and highly precise milling operations. Why? Because it makes milling so simple, because HEIDENHAIN has expanded its functions in a practical, user-friendly way with a keen sense of workshop needs, and because in addition to milling it also enables turning on the same machine.

he new features of software version 4 currently being dispatched for the TNC 640 range from the programming and simulation of operations directly on the machine to setup and configuration, as well as many machining functions. This makes milling even more simple, safe and precise. Operators also program for turning operations just as simply as for milling. The TNC 640 masters both forms of machining without complex switching over.

3-D simulation graphic with a host of benefits The most extensive new feature is certainly unique, true-to-detail 3-D simulation graphic functionality. This helps the HEIDENHAIN TNC 640

MACHINE TOOLS WORLD JUNE 2016

operator to identify missing information or inconsistencies in the program prior to machining, and without any risks to workpieces, tools or machines. It displays the workpiece at random viewing angles and simulates both milling and turning operations in a single view. Not only cuboids are displayed but also cylindrical forms such as cylinders, tubes and rotationally symmetric blanks. During simulation, several new view options expose a precise and freely selectable view of details. The graphic simulation is so detailed that the machine operator is able to identify undesired machining effects from NC programs, such as substandard surfaces, at an early stage. With maximum 3-D simulation resolution, the control can also display the block end points with corresponding block numbers in the display of tool motion as a 3-D line graphic. With externally created NC programs generated with CAM systems this facilitates the analysis of point distribution and pre-evaluation of the expected surface. The operator can choose to view only the workpiece, only the tool paths or both simultaneously. Views also enable display of the original workpiece blank dimensions as a frame with highlighted

main axes, or with the workpiece edges as lines for improved spatial perception. The “transparent workpiece” view option also enables a view of inside machining, even with rotationally symmetric workpieces. Color highlighting of the workpiece with a new color used for each new tool helps the operator to identify individual work steps and makes it easier to assign the tools used. The operator can also display the tools either completely or transparently and of course hide these at any time. Several advantages are provided for the operator by 3-D simulation on the TNC control. For example, he can rapidly and simply run through machining programs

The new 3-D simulation graphic: displays that are rich in detail focus on undesired effects

Turning and milling in a single setup: the TNC 640 alternates between machining modes as desired according to the program

TECH TRENDS www.mtwmag.com

created on the machine. But simulations on the control are also highly useful from programs he adopts from CAD/CAM systems, because the 3-D simulation graphic of the TNC 640 takes into account the kinematics model saved on the control, optimally modified according to the actual machine tool geometry, to realistically simulate machine movements. Milling and turning in one setup Does your workpiece, after complex milling operations, also have to be set up on a lathe for further machining? Here the TNC 640 helps you to save a great deal of time! A milling/turning machine equipped with the TNC 640 machines the workpiece in one run, combining milling and turning in any sequence. For this purpose, the control simply alternates between turning and milling mode according to the program and completely independent of the machine and axis configuration. During switchover, the TNC 640 assumes all necessary internal changes (such as switching to diameter display, or setting the datum in the center of the rotary table), as well as machine-dependent functions (such as clamping the tool spindles). In this way the TNC 640 not only saves space as well as money for an additional machine, but thanks to doing all operations on a single machine, it also avoids inaccuracies possibly caused by workpiece rechucking. The operator can create turning contours as usual in the HEIDENHAIN plainlanguage dialog, and he also has contour elements such as recessing or thread undercutting as well as cycles for turning shoulders, recessing, contour machining and thread machining. He can also use FK free contour programming to easily create contour elements or simply import contours in DXF format with the help of the DXF converter. In more sophisticated contour turning cycles, the TNC 640 uses the same techniques as used for milling. Here, too, there is no need for the TNC programmer to learn new ways of programmingâ&#x20AC;&#x201D;he build on what he already knows and quickly find his way into the world of turning on a milling machine. Another highlight of the TNC 640 is the

and reverse paths as well as through particularly smooth feed rate curves on parallel milling paths.

Always supplying the right values: the context-sensitive cutting data calculator of the TNC 640

Achieving maximum contour accuracy and surface quality - machining without (above) & with Advanced Dynamic Prediction (below) blank form update feature. Based on the defined blank, the control calculates the newly created intermediate product with each step to adapt the following machining cycles accordingly. This avoids air cuts and optimizes approach paths. Optimized motion control for clean surfaces and perfect contours An insufficient quality of data in NC programs frequently causes an inferior surface quality of the milled workpieces. The Advanced Dynamic Prediction feature (ADP) expands the previous look-ahead of the permissible maximum feed rate profile, thereby enabling optimized motion control of the feed rate axes with 3-axis and 5-axis milling. In this way, clean surfaces can also be milled with short machining times on contours characterized by strong point distribution deviations in adjacent tool paths. The control dynamically calculates the contour in advance and can therefore use acceleration-limited motion control with smoothed jerk to adapt the axis velocity at contour transitions in good time. ADP shows its strengths for example during bidirectional finish milling through symmetrical feed behavior on the forward

Fine tuning with attention to detail The TNC 640â&#x20AC;&#x2122;s quickly understandable user interface ensures an even better overview during programming and setup. The individual screen areas are clearly distinguished and the operating modes are indicated by unambiguous symbols. Value inputs, comments and syntax elements are color-highlighted, and error messages are categorized with colors according to importance. The latest software version 4 simplifies program creation and input of technology data on the TNC 640. With the context-sensitive cutting data calculator, the operator can calculate spindle speed and feed rate for the specific machining process and transfer these values directly into the open feed-rate or shaft-speed dialog. The calculator recognizes the open dialog window and automatically asks only for the required input data. Face milling cycles, of course, have long been a part of the performance range of HEIDENHAIN TNC controls, although this does not mean that familiar features cannot be improved. For example, a new face milling cycle enables the definition of up to three sides for limiting face machining on side walls or shoulders. For corners between by adjacent sides, even the corner radii can be specified as desired. Faces can be milled with various machining strategies: meandering, line-byline (with or without overrun) or helically. Operators can also specifically define the machining direction, for example for directing the operating pressure against the fixed vice jaw. In addition to such expansions & optimizations, many other detailed improvements have also been integrated that are too extensive to describe here. The new software version 4 for the TNC 640 converts a wide range of customer requirements into workshop-oriented solutions.

JUNE 2016

MACHINE TOOLS WORLD

TECH TRENDS

Totem - Solid carbide end mills

otem is a market leader in India for solid carbide end mills. Die & Mould segment has been our strengths. Our extensive and versatile range offers end mills and ball nose cutters in stub, regular, long, extra long and long reach lengths, catering to the soft machining as well as hard machining upto 70 HRc. In April 2016, Totem has launched a full range of End Mills for graphite milling. The target market being those customers who are using EDM to machine the graphite electrodes and dies. In many die and mould shops, the choice between EDM and CNC milling is far less clear than it was fifteen years ago. Evolving technology is changing the rules for machining these complex profiles. Milling had a lot of limitations, a few years ago. Now though, it can be applied more broadly than ever before. Machining centres, capable of following precise, complex tool paths at high feed rates have made it cost-effective for shops to use fast, light milling as an alternative to EDM. This is applicable more for applications involving hard metal, intricate details and smooth finishes. Today, the comparison is to be made,

MACHINE TOOLS WORLD JUNE 2016

not between Milling and EDM but milling and High Performance Milling which uses a combination of machine tool, control system designed to move at high feed rates and machine complex profiles.

2. 3. 4.

When to use EDM? 1. Sharp inside corners. ( The concern here is the sharp internal corners where EDM will always remain superior) Components where the reach becomes an issue High L/D Ratios above 15 times The strength of EDM is that the process can run round the clock without human intervention For high-expertise parts.

When to use Totem high performance milling cutters for graphite? 1. For textured surfaces , where the finish requirements are not very critical 2. Components where the L/D ratios is small less than 15 times 3. Cavity Milling. 4. For parts where high accuracy is required, milling tight tolerances can be achieved very easily. 5. In a machine shop, expertise is always

available but for EDM machining, you would need an EDM expert. What is the Totem Advantage? 1. High Accuracy 2. Smooth Surface Finish 3. Low Process Times 4. Excellent tool life 5. High production efficiency How does Totem do it? 1. Technology to minimize droplets during the coating process 2. Superior accuracy and tolerances 3. Improved performance and tool life What is the range Totem Offers? Diamond coated end mills for applications on graphite: 1. Center cutting high performance rougher for graphite 2. Center cutting high performance 3 flute end mill for slotting graphite 3. Center cutting high performance torus end mill with corner radius for graphite 4. Center cutting high performance ball nose for graphite 5. Center cutting high performance micro end mill with corner radius for graphite 6. Center cutting high performance micro ball nose for graphite

TECH TRENDS

Innovations in centerless grinding machine & its operations by Harsh Badani, Technical Director, Solitaire Machine Tools Ltd., Vadodara

enterless Grinding operation is a mass production process in which cylindrical components are ground without reference to center. This operation is used as the final process in majority of the components where the tolerances and the quality parameter are stringent. The grinding process is basically designed for mass production. As the cost of manufacturing is increasing, the users are trying to extract more & more production from a grinder in order to lower the cost per piece. The user feedback and experiences highlighted the problems faced during day to day work, and solutions need to be implemented for future expansion projects and existing machinery. Below are some suggestions, to improve the quality level and productivity, while bringing down costs in Centerless grinding: • Land costs are at an all-time high, which necessitates the reduction of machine foot print and floor space dedicated to a single machine. • In any centerless grinding operation, the major non-productive time is the dressing time. Hence, a method needs to be devised so that the dressing time also can be used productively. • As the working cost is increasing, more automation is required so that an operator can run more than one machine. • With cost of power increasing all around the world, more energy

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efficient motors should be explored. • The fuel prices are increasing at a phenomenal rate and it is essential to produce fuel efficient vehicles. This calls for components with higher quality standards and a need to explore different materials to reduce vehicle weight. Consequently, machines with capability to grind these components efficiently need to be devised. To resolve the above issues, our engineers did brain storming and devised various options: 1. To reduce the floor space there should not be any compromise in terms of the rigidity and stock removal capabilities of the grinder. We designed a grinder similar in size to our smallest model. At the same time, we increased its rigidity by adding weight to make it equivalent to our bigger sized model. The center of gravity was kept constant at the

working area so that the vibrations would always be at that point. The vibration analysis was conducted to ensure that it was maintained at a very low level. 2. Total Usage Time = Productive Time + Non-Productive Time (Dressing Time) The challenge for us was to convert the non-productive time into productive time. To achieve the same, we designed a diamond roll dresser for the machine. The CNC controls were programmed in a manner that when the dressing is done on the wheel, grinding of the component is also in process. Therefore, the total usage time is now equal to the productive time. This enables the customer to grind more components. The savings was substantial in terms of productivity. 3. Working Cost = Running Cost (Power + Employees + Overheads) + Consumables (Hydraulic Oil + Coolant + Grinding wheel + Regulating

Diamond Roll Dresser

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Linear Guideway

Servo Regulating Wheel Drive Wheel + Diamond Dresser) To reduce the working cost of a machine, it is important to reduce all the above costs to an optimum level. a. Power Cost: The maximum power consuming motor is the grinding wheel motor. We procure the motor such that during idling time of grinder in each cycle it would draw very low current, while providing full torque during the grinding process. Such motors have rating

of Eff 1 or better. The other options include soft start for grinding wheel motor or Variable Frequency Drive for regulating and grinding wheel motor. These options avoid peak current required for start-up of the motor. b. Employees Cost: Machine automation is designed in such a way that the operator can run more than one machine at a time. In mass production plants, the focus is to have one skilled person to look after the setting and inspection of finished components for all grinders. Loading, unloading and other routine operations are done by unskilled employees. CNC options also reduce the operator intervention to a large extent and thereby reduce the cost. At the time when customer sends the plant layout, we give suggestions and inputs to reduce material handling and make it ergonomically convenient in order to reduce operator fatigue. Variable Frequency Drive is installed to achieve Constant Surface Speed for Grinding Wheel. This helps in reducing the dressing frequency even when the wheel diameter is reduced.

Hence, the grinding wheel is used to its optimum level. c. The other consumables like oil, coolant, diamonds and wheels are selected with the help of various manufacturersâ&#x20AC;&#x2122; input and expertise, to suit each application. 4. The increase in fuel prices and depreciation of Indian currency has put a lot of burden on manufacturers to improve the fuel efficiency of vehicles. This calls for more close tolerance in manufacturing parts. Quality Parameters are a combination of Size Tolerance, Roundness, Cylindricity and Surface Finish. We use Precision Linear Guideways to achieve practically friction free movement. This enables the slide to move with high accuracy, as close as 0.25 microns and helps in maintaining size in close tolerance. To achieve roundness in 1 to less than 1 micron, it is necessary to have rigid spindles and vibration free grinding. We mount Automatic Wheel balancers, which balance wheel with vibration level less than 1 micron. This also helps improve Cylindricity. Coolant supply while dressing the wheel has to be forced at the point of contact of diamond and wheel. Proper forced coolant supply helps to dress well, which in turn helps in improving surface finish on component. Coolant supply during grinding is conventionally done by free flow of coolant on the part. Due to air turbulence because of wheel rotation, most of the coolant does not reach the actual grinding area. With redesigned nozzles and flapper to stop air turbulence, the coolant now reaches grinding hot spot to almost 90% level. The overheating of parts and burning marks are reduced and surface finish improved. The above are some of the innovations & adaptations incorporated in the machine to meet the demand of the industry for better & greener tomorrow.

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TECH TRENDS

Automation in sheet metal

cutting and welding The paper examines welding and cutting process trends in the sheet metal and plates used in various industries like automobiles, infrastructure, ship building, aerospace industries, wind tower manufacturing etc. Productivity gains in arc welding are reviewed, and the increasing use of laser cutting and welding, as well as laser-arc hybrid welding, particularly in Europe, is discussed and explained. Some friction technologies are already widely adopted, but they could make more impact with further development. Electron beam welding could also be used with economic benefit in some situations, but as with all non-arc processes, it will only be adopted if significant gains in productivity and cost reduction can be created to justify the more specialist welding equipment required. Many productivity improvements can come fromw non-welding activities in the fabrication process. 1. INTRODUCTION Leadership in manufacturing (welding and Cutting) can come from addressing the factors of QUALITY, COST, PRODUCTIVITY, SAFETY and CONTINUAL UPGRADATION OF TECHNOLOGY. Inflection in Metal Fabrication Technology has taken place in the Manual / Semi-Automatic Welding Power Sources - (Digital control inverters), Welding Automation - (Developments in HNG SAW, HNG MIG, Tandem MIG / SAW, Friction Stir, Electron Beam, Saddle Welding Automation, Robotics, Laser spot welding, Hot wire TIG, Orbital systems, automation with hybrid welding systems like Plasma â&#x20AC;&#x201C; MIG, Laser - MIG) and major advances in the cutting processes (Precision Plasma, Laser Cutting, Waterjet cutting etc.). This paper reviews current trends in arc welding and cutting processes used for Sheet metal processing and will discuss some of the newer processes which are beginning to replace arc welding for such steels, or have potential to do so in the next 10 years. 2. ADVANTAGES OF AUTOMATION a. Consistency in weld result - Error Proofing: A welding supervisor can limit the amount of changes an

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operator can make during a program, preventing him from accessing the override screen through the use of a key switch or password. Multiple parameters for multiple weld-run: In addition to the ability to adjust parameters between weld passes, operators of microprocessorbased welding machines can also program changes to weld parameters during each pass, which offers distinct advantages for certain applications. Store parameter for sharing on other machines with same applications: A microprocessor-based power source can store programmed welding procedures on data cards. This allows the operator to easily transfer programs developed on one machine to other machines being used either in the same facility doing the same type of work. Quality control: Microprocessorbased machines can immediately alert the operator if weld parameters fall outside pre-selected limits. Parameters can be directly to a quality-control computer program for storage or statistical analysis. This eliminates time-consuming radiography in many applications. Date storage and records: It is now

very easy to display a set of welding parameters and operator or supervisor can observe the welding procedure. Moreover, the data can be printed in the form of reports, which can be presented to the customer as quality assurance procedure. f. Quicker Weld-Fault diagnostics lower repair time: The system can be stopped if the measured values cross a certain preset variation limit. It is possible to stop the machine in out-oftolerance conditions. This enables the operator to perform timely functions and take necessary steps to prevent the deposit of faulty welds. 3. TANDEM MIG AND ROBOTIC WELDING Significant improvements in productivity are nowadays hard to gain in this mature process. In gas-shielded MIG/MAG processes, the growth of tubular wire over solid wire is still slow despite the deposition and bead shape benefits of the former although tubular wire usage is higher in the USA and Japan compared to other parts of the world. The lower price of solid filler wire, particularly in Europe, is still a dominant factor that continues to favour their use. Self-shielded cored wires are still widely used in the USA but

TECH TRENDS less so in Europe because of the fall-off in fabrication of large offshore installations. Care is always needed in selecting selfshielded wires if weld metal toughness is a critical design factor. Schematic of Equipment for TANDEM MIG

installations per annum, but generally robot take-up for welding is still majorly for the automobile sectors. Robots are being employed in situations where product repetition and/or tonnage throughput are high, combined with relatively standardised designs. Robot profile cutting is increasing in usage and in Japan, some building frames are now being welded on robot lines and agile robots are also used for site welding building column joints at height. The applications most suited to robot use involve butt and fillet welds in the fabrication of beams, welding of stiffeners to beams, welding of end plates and the assembly of panels or decking. A likely trend is to ‘take robots to the work’ and use them for large part and sub-assembly manufacture in cells which house autonomous vehicular robots. These robots, mounted on moving platforms are manoeuvred around the parts to be welded and are capable of all-positional welding using the MAG process with tubular wires, (Fig.2).

Fig. 1: TANDEM MIG Advantages of TANDEM MIG: • Exceptional welding speeds • High weld metal deposition rate • Superior weld quality: ◊ Reduced heat input ◊ Resists burn-through on thin materials ◊ Maintains low spatter levels ◊ Produces good penetration on thick materials ◊ Improves bead wetting at weld toes ◊ Resists undercut • Bead profile control • Lowers production costs • Increases productivity The greatest potential for productivity improvements comes from using robots. Japan still leads the work in new robot

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Fig.2. Schematic diagram showing autonomous robot vehicle navigated by vision system, being used for all positional MIG / MAG welding 4.NARROW GAP SAW In submerged arc welding, multi-wire, iron powder additions and narrow gaps are common ways to increase productivity. However, the use of tubular wires is increasing in popularity and can offer better weld quality compared to solid wires in some situations, e.g. when submerged arc welding of primed plate. In building and bridge construction MIG/MAG welding is more suited to automation and is now beginning to replace submerged arc welding, reducing costs and distortion significantly.

5 . LASER – IN CUTTING AND WELDING Low power CO 2 lasers were originally developed in the late 60s for cutting and welding operations, while Nd: YAG lasers entered the market only in the early 1980s. In the shipbuilding and off-road vehicle sectors, higher power lasers (3-10kW CO 2 and 2-4kW Nd:YAG) have become popular in the last decade because their use brings more precision in dimensional control, and greater accuracy in assembly, as well as the additional advantages of high cutting and welding speeds, and cleaner working. Laser cutting is now an essential route to accurate assembly in steel fabrication. Parts can be cut to a precision of ±0.3mm in 10 metres compared to ±1-2mm for conventional plasma cutting. Sub assemblies can then be arc welded to tolerances of a few millimetres in 15 metres, with the same lasers being used for marking and hole drilling on the cutting table. Even though arc welding is still regularly used for assembly of laser cut parts, cost reductions can be dramatic because of the improved accuracy of assembly and the potential for eliminating distortion correction and other processing operations downstream from welding. Direct costs have been cut by up to 50% using lasers for cutting in many shipyards, and this shows the extent of benefit which could follow from more widespread use of laser cutting in building, bridge and public infrastructure construction.

Fig.3. A typical laser welded sandwich panel and advantages over conventionally stiffened panels 6. LASER-ARC HYBRID WELDING There is tremendous interest in the use of CO 2 laser-arc or Nd: YAG laser-arc for steel construction at the present time. The concept has been around since 1978 and was actively developed in Aachen in the late 90s using high power CO 2

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Fig. 5. Schematic diagram of the FSW process: (A) Two discrete metal work-pieces butted together, along with the tool (with a probe). (B) The progress of the tool through the joint, also showing the weld zone and the region affected by the tool shoulder.

Fig.4a. Nd:YAG laser - MAG hybrid process being developed for land pipeline girth welding. Picture of the welding head

Fig.4b. macro section showing MAG root and cap beads & central hybrid weld bead lasers in combination with one or two MAG torches directed into the same weld pool in series with the laser. Already one shipyard in Germany has such a system in production on a panel line, the process replacing submerged arc welding. The advantages of moving from simple arc processes to a hybrid laser-arc system include higher joint completion rates and associated control of distortion. As noted above, laser systems alone are usually not sufficient to cope with variations in joint gap in large structures. However, where plates are thin, it is possible to produce stiffened panels successfully by laser welding. 7. FRICTION TECHNOLOGIES There have been many exciting

developments in friction welding and probably more process innovation in the last decade than in the previous 40 years when friction welding first came on the scene. In the context of metal joining and construction, friction stud, radial friction and friction stir welding are good examples of more recent approaches, with friction stud already being used in the production of sandwich structures comprising steel skins and a concrete core and for welding attachments in high volume such as shear connectors and reinforcing bars to end plates. Attachment of anodes under water to offshore installations using steel studs and electrical connections to railway lines are other applications of friction stud welding. APPLICATIONS Shipbuilding and Offshore, Aerospace, Automotive, Railway Rolling Stock, Fabrication

bridges. The two main areas of improvement are in gun development and reduced pressure technology. Reduced pressure electron beam welding system Reduced pressure EB welding using chamber pressures of around 1mbar has been another major step forward in simplifying EB welding operations. The beam shape and beam penetration at, say 5mbar, is identical to that at the more conventional pressure for EB welding of 5 x 10 -3 mbar. This reduced

8. ELECTRON BEAM TECHNOLOGY There have been several key improvements in this process in the last decade which have made EB welding increasingly attractive for large-scale fabrication of steel structures such as buildings and

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TECH TRENDS

pressure option does away with the need for large vacuum chambers and worries about leaks and seals. Simple mechanical pumps and local seals are sufficient to achieve ~1 mbar. These systems are also more tolerant to fluctuations in working vacuum pressure, gun to work distance and work-piece cleanliness. 9. WIND TOWER MANUFACTURING – SPECIALIZED CUTTING AND WELDING PROCESS APPLICATIONS Wind Tower fabrication employs extremely precision applications of metal cutting and welding processes like gas cutting triple torch, with Single pass three torch cutting Automatic setup which provides High accuracy, Capacitive height adjustment, Infinite rotation of cutting head, Automatic angle adjustment 20 - 50° (Option for 30 - 60°). In addition, plasma cutting system is used with Automatic Setup, Highest Accuracy, and Bevel angle adjustment: +/- 52°, Initial height setting with tactile sensor, Cutting height adjustment via automatic arc voltage sensing process. Precision High end CNC Plasma cutting process is utilized with high degree of automation needed to guarantee consistent quality. Programming software, Numerical control and Automatic rotating bevel tools are used to dispense with manual tasks. Automated SAW systems with Twin Wire, Tandem, Tandem – Twin and Multi – wire systems are used along with customized welding heads, wire feed systems, joint tracking systems, Column and Booms, TELBO systems,

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Rotators and Positioners. In addition, Tractors and Fit – up units are all used for this application and also for many other welding applications. 10. CONCLUDING REMARKS Where will engineering construction be in five years time? Productivity improvements can come from many different areas in the total fabrication process, e.g. general design, detailed design, contract drawings, CNC instructions, cutting and profiling, welding, inspection, finishing etc. It needs to be realised that optimising the welding process and procedure in isolation may have only a small effect on overall productivity. As an example, fabricators in the bridge and building sector continue to make big improvements in reducing the cost per tonne of steel fabricated by focussing on efficiency improvements in non-welding operations. These non-welding areas will continue to receive much attention in the next few years. For example, 3D solid model-

ling is expected to be at the heart of the improvement process enabling virtual assembly, direct instruction of cutting and welding machines, computer modelling of metal processing and welding operations and optimising of welding sequences. In addition automated inspection and data gathering will increase in usage to give more comprehensive Quality Assurance. Productivity improvements could also come from greater standardisation in steel specifications and in joint details and from modularisation of large structures to reduce the time spent on site fabrication and erection. Use of new welding processes and an increased use of automation and robots will take place slowly and gradually, only being justified where the introduction creates significant gains in productivity or cost reduction. As such, these changes can be expected particularly in situations where skilled labour is short, where welding cells can be kept fully occupied or where customised, made to order components are needed. (Contributed by Ador Welding Ltd.)

For more information Web: www.adorwelding.com

TECH TRENDS

Retro Track & Air Builds Masterpieces Using Haas

UK-based Retro Track and Air has invested in a Haas CNC VF-5/40XT

“

The Haas VF-5XT is perfect for machining the Merlin cylinder heads, designed more than 80 years ago by Rolls Royce - Gavin Faulks

he Haas CNC VF-5/40XT – a 40-taper vertical machining centre with an extra-long, 60 inch (1524 mm) table – will machine cylinder heads for the famous V12 Merlin aero engine. Installed in Retro’s newly built facility, beside the company founder’s family home, the VF-5/40XT is a snug fit, towering over an adjacent Haas CNC Toolroom Lathe, and working long hours under the supervision of Gavin Faulks, head of design. Building masterpieces As the company’s name suggests, Retro Track and Air specializes in rebuilding

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and maintaining winged and wheeled masterpieces from a bygone era. Housed in various outbuildings – as well as a hangar at a nearby airfield – are various single-seat racing cars undergoing rebuild and maintenance before the new season. There are also partly restored aircraft and aero engines, some of which are the property of the Royal Air Force Battle of Britain Memorial Flight. Gavin Faulks says, “The Haas VF-5XT is perfect for machining the Merlin cylinder heads, designed more than 80 years ago by Rolls Royce. With all the parts we make for old engines, we work from drawings that are at least as old, which means we often have to reverse

engineer components or best-guess dimensions, etc.” The castings are made to a material specification called RR50 – created by Rolls Royce. It’s exactly the same material and part design as it was when the Merlin engine was first run, in the early 1930s. It would be relatively straightforward to modernize aspects of the engine design – to remedy small design faults – but the demand is for authentic parts, without any changes from the original. This particular batch of cylinder heads – seven off – will take the company two years to finish and deliver to the Royal Air Force. Tolerances – between

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the arrays of bolt holes, for example – are 0.025 mm. Each face takes around a week to machine; the inlet/exhaust faces take another half a week. All the programming is done offline on OneCNC. Cutting down reliance on subcontractors The new Haas has enabled the company to keep more of this type of work in-house, and not rely so heavily on subcontractors. As a company, that’s the general direction that it is heading in. “To do so means making an investment, of course, but the difference between the parts we used to get – or make in-house

on old machines – is night-and-day. The repeatability of the Haas is excellent, and it’s very reliable and easy to use. Although we can’t change the design of the parts, we are machining them to a higher standard, which, in itself, is a big improvement,” says Gavin Faulks.

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TECH TRENDS

The vision of Industry

4.0

flesh out improvements in different areas. All this brings a number of truly significant benefits: manual actions are simplified, the margin for error is reduced, and automating the running of processes and decision making becomes more intuitive. Once managers have managed to get an advanced control of the plant, they will be able to simulate what might happen if they make changes. They will be able to make decisions taking into account the possible effect that manufacturing models, generated from the current factory set-up, predict for them.

ndustry 4.0 facilitates the vision and execution of a “Smart Factory” where cyber-physical systems monitor physical processes, create a virtual copy of the physical world, and make decentralized decisions. Over the Internet of Things, cyber-physical systems communicate and cooperate with each other and with humans in real time. Via the Internet of Services, both internal and cross-organizational services are offered and utilized by participants of the value chain. The objective The aim of Industry 4.0 is to improve the competitiveness of a company with the aid of technology. Companies need to be efficient and able to make decisions in the shortest time possible. Every second of a machine not in use is money wasted. With that said, nor should it be using all available machine capacity if managers aren´t sure that it is profitable. In the end, all actions must be measured so one can understand the effect they will have on the Income Statement. The strategy to move towards Industry 4.0 So how do companies move towards Industry 4.0? The answer is simple: Digitally model the factory. To do so companies need to explicitly define the manufacturing processes, choose key operational

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indicators and define how they are to be achieved. Managers then have to house these processes and indicators within a management system that allows them to view their status and to take operational decisions and steps to improve. Once processes have been specified one must then incorporate intelligence to digitally model them for continuous improvement. It needs the support of a production management system that is well established in a single software application or through an integration of several pieces of software that cooperate with each other. Managers also need to establish at what stage of the process they need to get information and of what type. Knowing accurate information will allow them to make the right decisions. Industry 4.0 integrators will then design the tools to get the right information, at the right time to make the right decisions. Once digitally modeled, a company will be able to collect relevant information, achieve real-time data capture, and measure what is actually going on in its plant. It can then extract behavior patterns and efficiency analyses for its factory. From thereon, knowing what the key business factors are, a company will be able to assess how it is being affected by processes and results collected during the analysis. With these analyses, based on real data taken directly from the operation, it can

Some examples of Industry 4.0 in action Lantek today is one of the drivers of Industry 4.0. Lantek interprets Industry 4.0 and applies it to companies that produce sheet metal parts, metal tubes and profiles, developing multiple functionality. Its technology is today in place in customers all over the world. For example: • Pricing according to the activity of the production plant. Examples: ◊ Stock in specific materials that are planned and that have available free space ◊ Supply in specific time periods and on specific production routes that have unassigned time • Automatic inventory control through digital cameras and artificial intelligence • Visual identification of parts to understand associated order, previous process undertaken or next to follow, operators and workplaces involved, delay, etc. • Automatic quotes according to customer ABC patterns • Catalog of service offerings in a web Marketplace aligned with production needs • OEE data analysis to establish the real machinery situation • Specializing the business based on performance by processes, technology, material or customer type, focusing on the most profitable

TECH TRENDS

TaeguTec launches two new products to improve performance Company launches TC3020 & TC3030 New Ceramic Grades for High Temperature Alloy Machining

excellent thermal shock resistance and thermal conductivity.

he demand for cutting tools to increase productivity and cut the cost of machining high temperature alloys is always increasing, that is why TaeguTec has launched two new SiAlON ceramic grades - the TC3020 and TC3030 - that offer superior performance. Suitable for high temperature alloy machining Both the TC3020 and TC3030 ceramic grades are suitable for high temperature alloy machining where difficult-to-cut materials such as Inconel, rene and titanium are used. These ceramic grades are characterized by their excellent toughness and anti-chipping capabilities making them the best choice for both interrupted and continuous machining. With the introduction of both these grades, the Asian metalworking giant has gone a step further by supplying even more optimal solutions for machining high temperature alloys than its current whisker ceramic grade. Available for turning, milling and grooving applications The new grades are available for insert lines in turning, milling and grooving applications. The TC3020 is ideal for high temperature alloy machining and runs in the same conditions as the whisker ceramic grade. Its superior wear resistance is due to its high stability

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while it offers better flank and notch wear resistance compared to the competitor’s similar grade. Furthermore, the TC3020 has excellent high temperature strength and fracture toughness. The other new offering, the TC3030, is also created to handle high temperature alloys with the difference being that the grade’s extreme toughness enables it more for higher feed and heavier depth of cut machining and is suitable for scaling and roughing applications while offering

Incredible chemical stability By combining silicon nitride and aluminum oxide, TaeguTec’s SiAlON grade offers incredible chemical stability in order to reduce notch wear in demanding operations and has the capability to run at 4-6 times the speed of conventional carbide inserts. Product testing in real-world machining conditions demonstrated increases in productivity and tool life. While performing a continuous grooving operation on an engine casing made from Inconel 718, the TC3020 grade’s productivity increased by 40 percent over the competitor’s similar ceramic grade. For an engine casing made from the same Inconel 718 with external interrupted turning and interrupted grooving operations, TaeguTec’s TC3030 increased tool life by 23 percent and 56 percent respectively. The biggest improvement over the competition was on a rene 108 material, the TC3030 performed incredibly well on a face milling operation of a shroud workpiece when it increased tool life by 100 percent. As one of Asia’s leading metalworking companies, TaeguTec is a highly regarded and respected supplier of cutting tools, tooling systems and industrial products for the metalworking and steel industries and is present in over 50 countries.

TECH TRENDS

The power of Power Tools By Ashok Kumar

W Safety is of paramount importance in the use of power tools. A smooth and controlled performance in power tools is obtained through the kickback stop feature. An integrated sensor detects sudden jamming, which can be caused by tilting in metal or a change in substance and cause the tool to kick. The integrated sensor stops the motor immediately to prevent potential accidents caused by the user being thrown off balance.

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hen we say power tool, an idea comes in our minds about a tool which uses some power to perform some activity. The power is of some form but necessarily not muscle power. It may be electric, pneumatic, natural power such as wind, hydro, etc. Power tools find use in industries, in the garden, in home tasks such as cleaning, around the house for the purpose of drilling, cutting, etc. There is a wide range of 350+ tools including cordless screw drivers, drill machines, impact wrenches, rotary hammers, surveying equipment, and range finders. Power tools are either stationary or movable. Movable tools are generally hand held. Hence, movable/portable tools possess low power and weight but they are convenient to operate but safety aspects should be taken into consideration with utmost care while using them. The safety aspects include using tools with proper guard, earthing, etc. Stationary power tools however, often have advantages in speed and accuracy, and some stationary power tools can produce objects that cannot be made in any other way.

Safety First Accidents with power tools are quite common leading from minor injuries to major injuries such as bone fracture, etc. It is also on record that many times, accidents have resulted in fatalities. This happens as a result of overpowering by powerful drill, grinding wheel, hacksaw, etc. We cannot overlook such dangers while using power tools. Accidents take place as safety aspects are overlooked while using them. It is not only the responsibility of users but manufacturers should also give proper attention to safety aspects while designing/manufacturing power tools. This is why impact drivers are so popular and are favoured in many high torque scenarios. There is competition among manufacturers of power tools having higher and higher torques. At the same time, it is essential to provide enough safety features to reduce accident risks in power tools. To think, the torque in drills is higher than the torque of impact drivers of only a few years ago. Major brands have been competing over who gets to say that they have the most powerful drill or any other power

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tool. Several brands are now boasting about how their most powerful drills deliver well over 1,000 in-lbs of torque, previously impact driver- only territory in tools of this size. The torque levels are already so high that at full power even the additional side handle is not enough to control a drill that binds without really bracing your body. So at what point are we going to say that we have had enough, that we have reached the limit of what is safe or necessary, that we are happy with what we have, and that we don’t need any more torque? Wouldn’t it be a better option for users to offload their high torque needs to their impact driver? At this point, manufacturers should be developing auger bits and hole saws that are designed to work with impact drivers. And if the 1/4” quick-connect chuck is not strong enough for such bits, maybe it is time for manufacturers to move away from them, or to adopt a dual chuck system like what is found in the Bosch Socket-Ready impacts. Latest Developments The latest development is availability of cordless drills. The power to operate such drills is provided by batteries. The torque requirement is most important considerations in cordless drills as it decides the battery capacity. As we

have come to expect from cordless tool manufacturers, with each new flagship drill model that comes out, we want a tool with more torque than what the previous model had. My question is, do we really need more torque or are we just after bragging rights for the highest number. Universal motor, which can operate on AC as well as DC, with brushes has been commonly used uptil now. Speed of these motors is about 10-20% more when operated on DC. These motors produce more torque also on DC. Now we have tools which use brushless motors. These motors allow the tool to be smaller in size, without compromising on power. This motor delivers up to 27% more torque, 25% more power, 30% faster screw driving and works more energyefficiently with a longer lifetime than conventional motors. A smooth and controlled performance in these power tools is obtained through the kickback stop feature. An integrated sensor detects sudden jamming, which

can be caused by tilting in metal or a change in substance and cause the tool to kick. The integrated sensor stops the motor immediately to prevent potential accidents caused by the user being thrown off balance. New Launches With Dewalt having launched nextgeneration compact brushless drills, it’s probably a matter of time before they upgrade their premium 3-speed drills as well. And if so, will they take the belt? In regard to runtime, higher capacity 4.0Ah, 5.0Ah, and even 6.0Ah packs have become the norm. For more compact drills, 2.5Ah is the sweet spot right now. Brushless motors, with their higher efficiency, squeeze runtime to its very limits.What we’ve noticed is that brands have hit a ceiling. How much more torque can a drill/driver possibly deliver before it starts being ridiculous? Individual battery cells seem to be topping out at 3.0Ah right now, although there’s room for manufacturers to improve upon the maximum continuous current rating. We wouldn’t expect to see same size battery packs with 7.0Ah or greater capacities anytime soon. As run time on single charge increases, the battery capacity also increases. It has been observed that Lithium-ion batteries provide optimum power with maximum endurance. It is achieved by managing the interaction between the Lithium-ion battery, motor and gears, creating the perfect conditions for the tool to continuously perform with outstanding efficiency. Up to 800 screws are possible with a single battery charge, preventing you from ever having to leave a task unfinished. M/s Bosch have started manufacturing power tools near Chennai using latest technology. The price of these power tools is less than the imported tools. Their aim is to increase market share from 10% to 25% in the near future.

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TECH TRENDS

Industrialising Additive Manufacturing of

Metal Components Additive Manufacturing (AM), also known as 3D Printing, has come so far in recent years that it is now possible to print high-quality parts and components from a variety of metals

he latest developments in 3D printing and the scope for, and limitations on, their use in industry will be discussed in the new “3D Metal Printing” trade forum at Rapid. Tech, the international trade show and conference for Additive Manufacturing, which takes place from 14 to 16 June 2016 in Erfurt. Various applications in fields such as aviation and medical engineeringillustrate that Additive Manufacturing processes offer completely new levels regarding product design, efficiency, speed and flexibility in the production of series parts. It is therefore hardly surprising

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that growing numbers of companies are investigating the industrial use of AM technologies. However, standards in series production are significantly more rigorous than in prototyping. “IT integration in product life cycle management (PLM), continuous processes from concept to finished component and reproducibility are fundamental prerequisites for industrialisation,” explains Helmut Zeyn, Business Development Additive Manufacturing at Siemens Industry Software GmbH. The AM expert will discuss these challenges in his keynote lecture on the first day of this year’s Rapid.

Tech (14–16 June) in Erfurt. Helmut Zeyn will also present innovative developments that enable manufacturers seeking to integrate AM processes into existing production lines to meet the requirements of modern series production for process reliability, process monitoring, traceability and data exchange. The potential for producing metal components The different trade forums will start after the keynote presentation. In the inaugural “3D Metal Printing” trade forum, the introductory talk by Jannis Kranz of Materialise will examine the

TECH TRENDS potential for producing metal components, including parts with hollow, lattice or protruding structures. Based on successful applications he will demonstrate that it is no longer the limitations of manufacturing technology but rather component functionality that drives the design of metal components – provided that developers recognise the design freedoms and opportunities offered by AM technologies, and make intelligent use of them. Water atomisation Simon Höges of GKN Sinter Metals Engineering GmbH will present water atomisation as a cost-effective alternative to the more conventional gas atomisation of metal powders. He will compare the microstructure and mechanical properties of components produced by laser melting of water-atomised 316L stainless steel powder with those produced from gas-atomised powder. His session will show that, when combined with the higher production speeds enabled by recent innovations, water atomisation significantly increases the range of possible applications for the series production of 3D-printed metal components. Expanding range of metal powders The expanding range of metal powders on the market is also a key factor, as Dr.-Ing Matthias Gieseke of Laserzentrum Hannover e.V. will highlight when he discusses the use of selective laser melting (SLM) of the first magnesium powder, Elektron MAP 43, in lightweight

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designs. He will outline the results of his study calculating the particle sizes, processing parameters and structures required to produce specimen components with a density of over 99 percent. Additive Manufacturing – Challenges and solutions Challenges and solution approaches of Additive Manufacturing with metals in series production will be discussed by Oliver Kaczmarzik of Concept Laser GmbH. He will examine issues ranging from how to increase productivity with a modular approach that combines several AM units and automated processes, to the physical separation of the construction, pretreatment and post-processing phases, all the way to the integration of AM machines in manufacturing to Industry 4.0 standards. Both the medical technology and aviation sectors use electron beam melting (EBM) in the production of series parts. One of the firms meeting the resulting increase in demand for process and quality control solutions is the Swedish company Arcam AB, and Patrick Ohldin will be on hand to present some of its innovative developments. These include a highresolution camera and an X-ray sensor that are integrated in the company’s quality systems. The camera takes images of

the entire powder bed after melting so that quality controls can be performed for each layer of the process. The X-ray sensor is able to determine beam parameters such as position, focus and beam profile with exceptional accuracy. Clemens Lieberwirth from the Department of Fluid Technology and Microfluidics at the University of Rostock will present a further exciting development: an extrusionbased additive process for producing high-density metal components known as Composite Extrusion Modelling (CEM). It consists of two phases – additive manufacturing of green parts from injection-moulded metal grains followed by industrial sintering – and has demonstrated distinct advantages over powderbased processes in terms of material handling and costeffectiveness. As with all sessions at the Rapid.Tech conference, simultaneous interpretation (German<>English) will be provided for presentations at the trade forum “3D Metal Printing”. The new trade forum is organised by Dr. Yves Küsters, Corporate Technology, Research in Energy and Electronics, Siemens AG. Küsters has been working on SLM for almost ten years and was awarded his PhD for his thesis on “Methodological Parameters

for a Robust Blasting Process”. His work at Siemens includes developing SLM processes and materials, with a particular focus on high-temperature alloys. The 13th Rapid.Tech, international trade show and conference for Additive Manufacturing, will include the trade forums “Additive Contract Manufacturing”, “Electronic Engineering” and “Automotive Industry” for the first time. Both the new conference sections and the well-established trade forums “Medical Technology”, “Dental Technology”, “Design”, “Aviation”, “Tools” and “Science” and the User’s Conference will provide opportunities for industry professionals to discuss specific AM issues in depth. For twelve years, the User’s Conference has been the platform used by experts and newcomers to discuss the current state of Additive Manufacturing as well as developing trends. “With the expanded conference programme and the extended, three-day duration of Rapid. Tech, we are keeping abreast of the latest developments in Additive Manufacturing and 3D Printing,” explains Wieland Kniffka, CEO of Messe Erfurt. Thanks to its unique combination of trade show and specialist conference, Rapid.Tech in Erfurt is among the world’s foremost events in the field of Additive Manufacturing and 3D Printing. For the fourth time FabCon 3.D, Germany’s 3D Printing fair for semiprofessional users and prosumers, will be held in parallel with the event.

TECH TRENDS

Decay & the single regulator We’re never surprised at how many engineers and technicians don’t know what droop and decaying inlet are, since so little is published about these effects. Nevertheless, understanding them and using the flow curves to properly evaluate a regulator’s performance for an application is the secret to a trouble-free installation. Mr. Rushil Shah, Managing Director, Shavo Technologies Pvt. Ltd.

ome people work with pressure regulators all of their lives and never know what is really going on inside. Tescom spends a great deal of time teaching our distributors and customers about the key operating characteristics of pressure regulators. We’re never surprised at how many engineers and technicians don’t know what droop and decaying inlet are, since so little is published about these effects. Nevertheless, understanding them and using the flow curves to properly evaluate a regulator’s performance for an application is the secret to a trouble-free installation. For the benefit of everyone in the Tescom family, we will review Decaying Inlet in this column, and Droop in a future column. Definition The decaying inlet characteristic is the amount of change seen on the set point of a pressure reducing regulator as the inlet pressure varies. The decaying inlet characteristic has an inverse relationship between the inlet and outlet pressure of a single stage regulator; as the inlet pressure goes down, the outlet pressure goes up (see chart below). Considerations We must consider decaying inlet when our pressure source is a compressed

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source, such as a cylinder, tube trailer, or hydril. When our source gas comes from a compressor, or liquid source such as a dewar, the inlet pressure is fairly stable, and the effect of the decaying inlet characteristic on set point is negligible. How It Works To see how decaying inlet works, let’s consider a few Tescom regulators for the same application.

Parameters: Our application is a compressed gas that is packaged at 3500 PSIG. Our process requires a 200 PSIG set point. Scenario A: We’ll look at the BB - 1, which is rated for 3500 PSIG max inlet pressure, and has a PSIG/ 100 PSIG decaying inlet characteristic. Assuming that we start with full inlet pressure of 3500 PSIG, and that the source pressure will decay to 500 PSIG before it is either changed out or recharged, the net change on the inlet of the regulator is 3000 PSIG. If the regulator is initially set for an outlet pressure of 200 PSIG with 3500 PSIG on the inlet, then the outlet pressure will rise by 210 PSIG to 410 PSIG. 3000 PSIG change in inlet pressure ÷ 100 PSIG = Factor of 30; Factor of 30 x 7 PSIG decaying inlet characteristic = 210 PSIG increase. Scenario B: The 44 - 2200 and 44 – 5200 have much lower decaying inlet characteristics (1.5 PSIG/100 PSIG). Using the same operating conditions in the previous example, we find that these regulators will see a pressure rise of 45 PSIG on the outlet, from 200 PSIG to 245 PSIG. Clearly, we get better outlet pressure stability with these regulators.

TECH TRENDS www.mtwmag.com

Scenario C: To further reduce the decaying inlet effect, we should consider taking the pressure reduction in two steps, or stages. We typically use a two-stage regulator like the 44 – 3400 to do this. The 44 -3400 is composed of two 44 – 2200 regulators built into the same body and internally connected in series with one another. The decaying inlet characteristic of the 44 – 2200 is 1.5PSIG/100 PSIG. The first stage is preset at a nominal pressure of, say 500 PSIG. The second stage is adjusted to our original 200 PSIG set point. When the source pressure decays from 3500 to 500PSIG, the first stage sees a net decrease of 3000 PSIG on its inlet. The outlet pressure of the first stage will increase by 30PSIG, to 530PSIG. The second stage now sees a net increase of 30 PSIG on its inlet. The outlet of the second stage will go down by. 45PSIG (.3x1.5 decaying inlet characteristic =.45PSIG). To anyone reading a typical pressure gauge on the downstream side of the two-stage regulator, the decaying inlet characteristic is transparent. Controlling decaying inlet characteristic Two-stage pressure regulators are frequently employed as cylinder regulators for packaged specialty gases. The flows are typically lo, and the two-stage reduction allows the operator to provide stable delivery pressures to the process. There are times when a single - stage regulator is used on the cylinder, which feeds a header in a lab or process facility. Points of use regulators are installed along the header, permitting individual users to adjust their pressures accordingly. The use of a single stage source regulator, along with point-of-use regulators, provides the two-stage reduction necessary for controlling decaying inlet characteristic. For higher flow applications, Tescom offers regulators with balanced main valves, like the 44 - 1300. The 44-1300 is so highly balanced that its decaying inlet

characteristic is a very low. 1PSIG/100PSIG with a 0 – 300 PSIG control pressure. For a 3000 PSIG reduction on its inlet, the 44 – 1300 would yield a 3PSIG increase on its outlet, nearly transparent to anyone working with this regulator. The 44-1300 is often used as a tubetrailer regulator because of its high flow, and extremely low decaying inlet characteristic. These qualities allow users to employ only one regulator to provide the required working pressure for their process. Mistaken Identity Many times, unknowing regulator users observe the decaying inlet characteristic and mistake it for a leaky regulator. In the non-flowing condition, the user observes that the set point has climbed above the original set point, and believes the regulator is creeping. One quick method to confirm that the regulator is not creeping is to observe the gauge reading for a short period of time. If the pressure has stabilized at a few pounds above the original set point, then this is probably decaying inlet. If the pressure is slowly climbing, and not stabilizing, then the regulator seat is contaminated, and the regulator must be removed for servicing. By confirming that the source pressure is a compressed source such as a cylinder, you can quickly correlate the drop in inlet pressure to the increase in set point. Sizing a regulator There are several reasons to consider the decaying inlet characteristic when

evaluating regulator first and foremost, can the system handle the increase in outlet pressure? What if the outlet pressure decays to a point where a relief valve triggers, or rupture disk ruptures, for example? Second, can the process itself tolerate the pressure swing involved? In our BB-1 example mentioned earlier, could the process tolerate a 210PSIG increase on the set point? Are gauges another instrumentation downstream of the regulator sized to handle this increase in pressure? Our responsibility as applications specialists is to consider all possibilities when selecting a regulator for our customer’s application. When we

take a few minutes to teach our customer about the nuances of pressure regulators, the customer is grateful, and looks to us as regulator experts, ensuring that we’ll be the first company contacted for future applications. Furthermore, by taking into account the decaying inlet characteristic when you size a regulator, you can avoid any surprises and unhappy customers that would otherwise result when the regulator is placed into service. If you need help with the decaying inlet characteristic of a particular regulator, please call us and we’ll provide you with this information.

For more information Web: www.shavogroup.com

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TECH TRENDS

The all-rounder for

Highly Flexible Shaft Machining

The gripper in the turret takes the raw part from the raw parts storage facility and transports it into and out of the clamping position

EMAG has unveiled the VTC 100 GT, a customized production solution to meet these requirements on a single machine capable of grinding with aluminum oxide or CBN and the complete final machining of the shaft.

“

This compact system is highly flexible and economical to use while also guaranteeing top component quality at all times - Dr Guido Hegener, CEO of EMAG Maschinenfabrik

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he “FAST 2025” study by the German Association of the Automotive Industry (VDA) describes a trend towards suppliers within the automotive value-added chain. At the same time, shorter product cycles and an increasing range of models will change the car market. But what these changes mean for the production processes of suppliers and subcontractors can be seen through the example of shaft machining. The production of various component versions must take place on a single system with ever greater flexibility and falling batch sizes. The term “shaft machining” covers a wide range of different work. The

machining process for gearbox shafts, rotor shafts, pump shafts, engine shafts, propeller shafts and balancing shafts can differ massively in certain circumstances. The strength of the component plays an important role, for example, whereas strong workpieces with a defined blade can be finish-machined by hard turning or using scroll-free turning technology, a final grinding process is the method of choice for thinner and more fragile parts. The required component quality, machining time (and therefore machining costs), tool costs and energy consumption differ depending on the process used. All these factors must be weighed against each other.

TECH TRENDS www.mtwmag.com

even difficult machining processes at high speed. The substantial benefit of the components’ vertical positioning is most clear when large volumes of chips are generated while turning the shaft. The vertical design ensures that the chips can fall freely out of the way, a major bonus for production reliability.

And it is at precisely this point that the challenge starts for project engineers: grinding or hard turning? Depending on the component, it may be necessary to invest in a single-technology machine for a specific process, however at the cost of the general flexibility of the production process suffering. Explains Dr Guido Hegener, CEO of EMAG Maschinenfabrik. “In our experience, lots of users manufacture very different workpieces on a single machine. For this, it is important that the best technology is always used for the specific component and design detail.” Emergence of a new paradigm With this in mind, the turning and grinding specialists at EMAG are pursuing a clear aim with their new VTC 100 GT shaft hard machining center: achieving maximum flexibility of final machining by integrating all hard processes in a single machine where the methods can be changed flexibly to suit the component. The important point for this is that the outstanding accessibility of the system ensures short tooling and retooling times.

The VTC 100 GT is a vertical shaft production center for combination machining involving turning and grinding

The machining area in the VLC 100 GT: all precision finishing processes (CBN grinding, hard turning and scroll-free turning) are completed in a single clamping cycle EMAG design for high speed, stable processes The typical EMAG design including integrated automation is the main reason behind this highly variable concept – the VTC 100 GT has a disk-type turret which can hold up to eleven tools, with the twelfth tool place in the turret taken up by a loading gripper. Optionally, the machine can also be equipped with a live-tool turret with powered tools and a Y-axis. It also has a grinding wheel. First, the gripper takes the component from the raw parts storage facility and transports it into the clamping position where the turret tools can then complete turning operations. Any grinding process takes place immediately afterwards in a second step. The downtimes between the operations are minimal and after machining, the workpiece is unloaded out of the machining areas by the loading gripper. Efficient processes are also ensured by the VTC 100 GT’s motor with a workpiece spindle torque of 75 Nm and a 19,5 kW drive rating providing the machine plenty of power in reserve to carry out

Quality comes standard Quality is the main criterion for shaft machining as these components determine the efficiency, or lack thereof, of the engine and gearbox. High performance components in particular have cylindrical bearing seats, shoulders and grooves which require high precision machining. The strength of the EMAG approach is its component quality. “If different machines or separate clamping operations are used for a shaft, geometry errors can have a cumulative effect. Our approach drastically reduces this risk. All the processes take place in a single clamping operation,” explains Hegener. At the same time, the flexibility of EMAG technology also pays dividends because the tool costs can be weighed up against each other when selecting the right production process. The choice of process has a massive effect on part costs. A cost killer all the way down the line Finally, the machine stands out due to its much lower investment and production costs compared to other solutions. For example, users save on automation and peripheral costs because the raw and finished parts storage facility and the tool gripper are integrated components. In addition, the compact vertical design requires an extremely small footprint in the factory hall, the system is only around 1.8 meters wide and 3.6 meters deep. “At last, we have combined all the benefits in this machine,” says Hegener finally. “This compact system is highly flexible and economical to use while also guaranteeing top component quality at all times. This technology ensures that the user is perfectly prepared for the flexible final machining of shafts.”

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TECH TRENDS

Design-led Manufacturing:

A Practitioner’s Point of View DLM or Design led Manufacturing combines the right elements of design, commercial goals, and limited application of new manufacturing technology to accomplish material improvements

By Dr. Venki Padmanabhan, Senior Vice President, Design-led Manufacturing, Cyient

“

The new DLM is not technology in pursuit of commerce. It is commerce in pursuit of assured business success

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o be asked to write a short note on the key developments in Design-led Manufacturing (DLM) is akin to being sat down under bright strobe lights and subjected to interrogation. Why? Because of the missing comfort of a long PowerPoint presentation or an article of indeterminate length, which would provide the cover for explaining that whose details one may not fathom fully in a short discourse. Thankfully, the abbreviation in this article will spare you the complexity, and perhaps help you find a simple, emerging answer to what DLM really means. To answer quickly one only has to follow the alphabetic arc of CAD/CAM/CIM all through the DFM/DFA methodology to today’s 3D Printing/IoT. There has always been design. There has always been manufacturing. There has always been technology in pursuit of commerce. I have had a front-row

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TECH TRENDS

seat at General Motors in the 1980s watching Roger Smith’s all-out panacea of robots and lights-out CIM factories crash and burn taking with them large amounts of wealth and employment it had created over a 100 years. And today, I bear witness to discussions of DLM under the lights of 3D printing and IoT as the key technology solutions to all that ails us. DLM has to change the direction of this discussion. It has to fundamentally change how we look at design. And at manufacturing. And this is how: First, there is a dawning realization that the conventional model of different sets of people designing a product and manufacturing it has severe limitations. Even if design and manufacturing happened in the same company, the goals and sensibilities of people doing it differ vastly. More often than not, by the time commercially viable and scalable manufacturing occurred, programs often embarrassingly exceeded their cost budgets with solidly delayed projects. As we practice the new DLM, we start with this basic question—what if the same people did both design and manufacturing of a new product? The same people, within the same team. And what if the purpose of this effort was to relieve techno-commercial pressure points in the addressed market’s business model? And for once, we would evolve to a method, where commercial success far outweighed the need to showcase and sell a new technology. The new DLM is not technology in pursuit of commerce. It is commerce in pursuit of assured business success. Where the right elements of design, commercial goals, and yes, limited

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application of new manufacturing technology accomplish material improvements in a customer’s enjoyment of a product’s features and total cost of ownership. What the new DLM means? So, to understand what the new DLM means, at least in the way we see it at Cyient, one has to understand what techno-commercial stress points are faced by our customers across the seven industries we serve. Stress points? The following are some examples. You are a start-up in medical technology with a great product idea, know that others are pursuing it too, but need to meet a low price point as well as a sharp go-to-market product timeline. Or you are a long-term, mature player manufacturing high-end electromechanical subassemblies for civil aircraft facing sharp budget cuts in critical engineering resources— the engineers you have need to be deployed to accelerated revenue projects, leaving a gaping void in the business of maintaining the required improvements in legacy systems. Or you are hit with the twin-whammy of a request for a significant price increase from a key supplier, just when your market is seized by a fierce competitor who offers materially lower prices to your customers. Or, as a final example, you can only deliver earnings growth to your board if you enter a new emerging market with a version of your product that suits the feature/price sweet spot of that market quickly. Understanding the value target For all or most of the above stress

points, there is no escape from having to understand deeply the value sought by the customer. DLM starts with understanding the value target needed to relieve the commercial stress. It could be a new cost point. It could be a new market price. It could be a set of new features to add. It could be a set of features to subtract. With that in mind, a DLM team needs to assemble and test the right set of solutions in design, sourcing and yes, manufacturing (in that order) to provide the right integrated solution. Perhaps use a new ASIC chip in a legacy design, perhaps find an existing supplier in a different country at a new price point. Perhaps find existing capacity for 3D printing close to the customer to make repair parts on demand. Perhaps, all of the above. DLM involves a dare-I-say, cross-functional team of designers, manufacturing experts, production superintendents, and program managers working together to iteratively, but swiftly arrive at the right solution set to deliver the value sought by the customer. My caution to you, as you digest this newly fangled “DLM” acronym is to get your antenna up if you find people peddling new manufacturing technologies in its name. Remember, DLM is not technology in search of commerce. It is commerce in search of assured business success. In summary, my take on DLM, the way we see it at Cyient is the following—it is the method through which customers across a range of industries can “permanently relieve current or anticipated points of technocommercial stress in their business model.”

TECH TRENDS

KASTO Presents Interesting Alternative for Storage

The automatic version organises storage, restacking and removal tasks, thus making the entire work process extremely efficient

ational storage, order picking and processing of profiles, tubes and beams often plays an important role in steel trading companies and metal processing centres. Here, traditional floor storage has distinct disadvantages with regard to speed and storage density, while on the other hand fully automatic storage systems are expensive to buy and are simply too big for many users. With the UNIBLOC stacking cradle system, saw and storage specialists KASTO therefore have an interesting alternative in their range for all storage needs when low to medium access frequencies are required. The UNIBLOC system stores tubes, bars, steel beams and other bar stock on sturdy, precision-welded cradle pairs. These have a working load of up to six

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tonnes and can be stacked on top of one another, making better use of the available space. The material is handled by means of a spreader beam with patented gripper arms, which transports and restacks up to three layers at the same time, depending on the model. This considerably accelerates turnover in the warehouse and reduces access times. The spreader beam can be moved manually by means of a stacker, automatically by means of a gantry crane or overhead crane, or by means of a magnetic lift. No need of electrical power No electrical power is required for the mechanical operation of the gripper arms. This makes the UNIBLOC system extremely energy efficient. The stacking

cradle system is easy and safe to operate â&#x20AC;&#x201C; for example, indicator lamps show when the stacking cradles are reliably detected. This makes the job easier and ensures economic restacking. The fold-in grippers can even remove laterally stored materials from adjacent pairs of cradles without difficulty. The advantage of automatic version of the system The automatic version of the UNIBLOC storage system has a further advantage. With the KASTO Inventory Control Computer, the system incorporates software which automatically manages materials and storage locations. It also organises storage, restacking and removal tasks, thus making the entire work process

TECH TRENDS www.mtwmag.com

Thanks to its simple operation and handling, the system provides quick access to stored goods and can restack them efficiently

The compact UNIBLOC stacking cradle system is a cost-effective alternative for all storage needs when low to medium access frequencies are required more efficient. Thanks to continuous inventory management, the operator is able to monitor stocks at all times and, if necessary, the organisation of the store can be optimised without the need for personnel, for example at night. Bars are managed individually to avoid unnecessary waste, thus reducing material costs. Manual UNIBLOC systems can also be retrofitted for automatic operation.

â&#x20AC;˘ Suitable for transporting and storing bar stock, sheet metal and bulky goods â&#x20AC;˘ Provides quick access to stored goods and can restack them efficiently

The material is handled by means of a spreader beam with patented gripper arms, which transports and restacks up to three layers at the same time, depending on the model JUNE 2016

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TECH TRENDS

High Precision

is a world to be respected In the light of today’s production environment and increased demands made by their users, there is an issue with the accuracy of precision machines By BP Poddar, Vice President, Fatty Tuna India Pvt. Ltd.

here is growing demand for superior precision in production for obtaining high surface finish and close dimensional tolerances eliminating any further machining requirements. Examples include: • Hard Turning substituting Grinding • Die –Mould applications eliminating further finishing / polishing operations MICRON -The thousandth of a millimeter is becoming more and more a “ MUST “. This requires COMPLETE ADHERENCE to the basic rules of PHYSICS and METROLOGY. A long standing problem Journey towards the precision in machining started in 1775 with Wilkinson , machining a bore of diameter 1800 mm with an accuracy of 1 mm. The dimensional unit for precision has changed gradually from millimeter thru Microns to Sub-microns and Nanometer and Angstrom units. Shall we go back by HUNDRED years ,when JIG BORING Machines were first designed and developed ..?? PRECISION Engineering was pushed to it’s extreme boundaries. Machines were required to manufacture small components for watch-making industry to produce accurate CENTER DISTANCES for MINIATURE WATCH MOVEMENTS.

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Positioning errors were also found to be caused by heat which is why hand-wheels were moulded in clay to eliminate heat transfer between hand and the lead screw. The fact is that even most remarkable technical advances still run-up against the laws of nature, and these laws must be studied and mastered by appropriate means. Concept of precision machines Many advanced technological products necessitate manufacturing processes and machines operating in the regimes of: • Precision Engineering • Micro Engineering • Nano-technology

KAFO / Superior Structure Design

Worldwide trend in industry reveals that two major thrust areas of manufacturing technology are: • Automation in Manufacturing [CAD / CAM / FMS / CIM ]

KAFO / Precision Machining

TECH TRENDS • Manufacture with High Precision. [ Precision Engineering / Micro Engineering / Nano-Technology ] These areas are no more laboratory propositions but commercial reality. To meet requirements of High / Ultra Precision Machines , considerable efforts have been put in the design of machine tools and their elements , materials used in construction ,machining methods, environmental controls required in manufacturing, inspection and assembly. The Micron - Dreamland or Reality Not so very long ago, only the manufacturers of measuring instruments, jig borers and metrology equipment talked in term of thousandths of millimeter and could claim to have some degree of control over how they were used. Today nearly all manufacturers and users of machine tools claim to be familiar with this microscopic unit of measurement and even specify it’s use in such a way they exceed the capability of their own manufacturing & inspection facilities!!! The micron must be treated with good deal of consideration and respected. Do you know, for example: • Steel enlarges by 0.011 mm / 1000 mm /degree Celsius . Slightest change in temperature cause variations in few microns. • If 500 mm long aluminium component is only 2 degrees warmer than assumed temperature of 22 degrees of measurement machine , longitudinal measurement error will be nearly 0.030 to 0.040 mm. • Thermal effect on any object is significant not only in linear dimension but also in shape. • Slightest heat radiation onto machine causes bending or deformation of workpiece or the machine component. • Along with temperature ; dust , humidity, vibration ,air velocity / air turbulence and noise have effect on measurement and machining. Many machine tool makers state

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accuracies in their brochures are having different meanings as per different standards. Standards and their meanings must be properly understood before getting carried away by Numerical Values or Numbers. What High Precision Means? Association between the accuracy required on a drawing and indicated accuracy of machine tool provides confirmation that machine needs sufficient accuracy in reserve to allow for the inevitable geometrical variations that occur , without upsetting into range of tolerance. This involves not just geometrical errors in positioning or on machine itself , but an accrual of all the minor faults connected in one way or other way with machining and work-piece measurement. What are these influences? What are these influences and to what extend do they affect the machines basic

KAFO / Ball Screw Cooling

KAFO / Precision Hand Scraping

accuracy ? Let’s consider ,if mean accuracy of 0.020 mm must be obtained for work-piece on machining center on 1000 mm cube, the sum of errors that can be imagined is as under •

0.002 mm

Unpredictability of work-piece or machining process

•

0.002 mm

Repeatability of Tool change

•

0.002 mm

Deformation of clamping the work-piece.

•

0.002 mm

Loss of accuracy at second or subsequent clamping

•

0.002 mm

Defect in fixture and / or work-piece resting face

•

0.002 mm

Thermal / Environmental effect

•

0.001 mm

Uncertainty of measurement

•

0.013 mm

Total of Errors unconnected to Machine Accuracy!

•

0.007 mm

Left for errors originated by machine itself under dynamic conditions, geometry and positioning, echanical deformation under load and internal emperature deformations.

It is decisive to consider the range of tolerances, total errors unrelated to machine, machine accuracies to understand the domain of high precision. Many times choice falls on machines those are foremost economical but at the same time based on unrealistic specifications. Following examples will throw light to illustrate these remarks: • Spindle speeds of 20000 rpm and more are demanded • Spindle power 15 kW and more • Rapid feed rates 40 mtrs. / min. & more • Positioning accuracy of 0.005 mm with repeating accuracy 0.002 mm We ask questions: • How to dissipate all excess heat that is unnecessarily generated? • How do we control acceleration and deceleration? • How do we control inertia moments? • Do high speed spindles and their bearings compatible with high accuracy under heavy duty conditions? Machines cannot be used for every conceivable job without certain limitations. There will always be some constraints that can not be ignored.

PROJECTS

Automotive Components Bosch India The company plans to invest Rs 1,000 crore to expand its capacity in Karnataka during 2016-17.

Automotive Components

Power

Contact: Roohie Menon, Assistant Manager, Post Box No. 3000, Hosur Road, Adugodi, Bengaluru-560030, Karnataka. T: 080-22992440, 41768204, F: 22992181, E: roohie.menon@in.bosch.com

Transport

Amara Raja Group

Airport / Aviation

PROJECT

Manufacturing Material Handling

UPDATE

Railways

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

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

operations is likely to start by May 2016.

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

Airport / Aviation GMR Hyderabad International Airport Ltd. Plans to expand the passenger handling capacity at the Hyderabad airport. The company is in the process of finalising plans in this regard and awaits regulatory approvals.

Place: Andhra Pradesh Contact: “Prashant Kumar, Manager (Corp Comm), Shamshabad – Hyderabad 500409 Telangana, T: 040-67394099, E: prashant.kumar@ gmrgroup.in 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: “Kshitiz Singhal, Manager (Corp Comm),

PROJECTS www.mtwmag.com

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 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 â&#x20AC;&#x201D; Bell 407 â&#x20AC;&#x201D; in India. The company is undertaking feasibility study. The facility will be set up by 2018-19. Textron has a development centre in Bengaluru.

Place: Karnataka Contact: Arneeta Vasudeva, 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

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

Manufacturing Johnson Electric Holdings Ltd Plans expansion of its production facility located at Chennai. The plant produces motors for engine cooling fan modules and gear motors for window lift systems.

Place: Chennai Tamil Nadu Contact: Siva Kumar, Project Manager (Engg Dept), Survey No: 88 & 90, Meppur Thangal Road Madavilagam Village, Thirumazhisai, Chennai 602103, Tamil Nadu T: 044-43912800, E: v.sivakumar@ Johnsonelectric.com

Odisha Industrial Infrastructure Development Corporation (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, 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 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 Bokaro Power Supply Company Pvt Ltd Plans augmentation of Coal Handling Plant at BPSCL. The completion is targeted in 24

months. Even after a year the project is not yet finalised.

Place: Jharkhand Contact: V.Agarwal, DGM (Project), M-01, Old Administrative Bldg, Ispat Bhavan, Bokaro Steel City827001 Jharkhand. T: 06542-240380, M: 8986874118, E: vagarwal@bpscl.inl L&T Construction The Metallurgical & Material 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

Railways Public Works Department, Indore Plans to construct of Railway over bridge near Burhanpur Lalbag Railway station on Itarsi Bhusawal broad gauge

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track dist Burhanpur.

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

Hindustan Power Projects Ltd

The Cabinet Committee on Economic Affairs has recently approved doubling of the 190-km Hubbali-Chickajur railway line.

The company has recently commissioned the first phase of 1,200 MW capacity as part of its 2,520 MW Anuppur thermal power project in Madhya Pradesh. The Power Purchase Agreement (PPA) is signed with Madhya Pradesh and Uttar Pradesh.

Place: Karnataka

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: Balaji Krishnaswami, Head Corporate Communications, 239, Okhala, Phase III, New Delhi-110020, Delhi. T: 011-47624100, M: 9971757474, Email: balaji.krishnaswami@ hpppl.in

Ministry of Railways

Power Bharat Heavy Electricals Ltd Plans to assign the design, engineering, manufacturing, testing, supply and E&C support services for coal bunker level monitoring system for various projects. i.e. Gadarwara 2x800 MW, Nabinagar 3x660 MW, North Karan- pura 3x660 MW and Unchahar 1x500 MW.

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

Place: Bihar

Contact: T Madhavadas,

Contact: S.Savithri, DGM

Executive VP & Head Power Transmission and Distribution, Post Box No-

(Electronics Division), P

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B No. 2606, Mysore Road, Bengaluru - 560026, T: 080-25146100, W: www.bhel.com

MACHINE TOOLS WORLD JUNE 2016

979, Mount Poonamallee Road, Manapakkam, Chennai-600089, Tamil Nadu. T: 044-22705306, 22705000, E: madhavadas@lntecc.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 Odisha Power Transmission Corporation Ltd The construction is on for 220KV transmission line existing 220/132/33 KV Grid substation at Balimela to 220/33 KV Grid substation at Malkan- giri and 220KV transmission line from proposed 220/33 KV GSS Malkangiri (from Gantry

to Old A.P. No. 06). (Total length 21.596 KM). Around 60% of the compound wall construction is done.

Place: Malkangiri, Odisha Contact: Uttam Kumar Samal, Sr. GM, Construction Zone-II, 132/33 KV Grid Sub Station, Ganesh Nagar, Bohidar Nuapali, Sankarma, Remed, Sambalpur-768006, Odisha. T: 0663-2540974, 2542320 M: 9438907730 E: sgm.con2.sbp@optcl.co.in

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.

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 IL&FS Engineering and Construction Company Ltd The company in JV with Unitech Power Transmission Ltd has received LoA from Power Grid for the works of 765 kV transmission line in the state of Gujarat. The scope

PROJECTS

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.

Place: Chhattisgarh Contact: S Verma, Manager, First Floor, Urjanidhi, 1, Barakhamba Lane, Connaught Place, New Delhi-110001, Delhi. 126

MACHINE TOOLS WORLD JUNE 2016

T: 011-23456123, 23456102, 23456000, E: cspfccl@gmail.com

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

Transport Larsen & Toubro (L&T) The heavy civil infrastructure division of the company has bagged orders from Chennai Metro Rail Corporation for the construction of Chennai Metro line Package 3 Underground - Bal- ance works. The scope involves engineering, procurement and construction of 4 stations at AG-DMS, Teynampet, Nandanam, Saidapet and Saidapet ramp portion with associated tunnel works.

Place: Chennai, Tamil Nadu Contact: D.K Sen, Sr VP (Infrastructure), Mount Poonamallee Road, Manapa-

kkam, P.B.No.979, Chennai â&#x20AC;&#x201C; 600089 T: 044-22526666 E: info@lntecc.com

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.

Taming power quality is now child's play

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

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Witness a true international event with state-of-the-art infrastructure

Venue: The Exhibition Center, Helipad Ground, Gandhinagar, Gujarat, INDIA.

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PRODUCTS

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

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

The CNC Controller – Phantom:

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

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

PRODUCTS www.mtwmag.com

Centraline Automatic Wire Rope Lubrication System Centraline offers an unique Automatic Wire Rope Lubrication System that would benefit end-users and Wire Rope Manufacturers with considerable cost & time savings in Lubricating their Wire Ropes automatically. Manual lubrication of wire ropes via the drip, brush, spatula or rubber glove method has always been a difficult and time-consuming maintenance task. Typically messy asphaltic or ‘blackjack’ type products are employed which have coating abilities but very little lubrication or penetration properties. The Centraline Wire Rope Lubricator provides fast and effective one pass lubrication of wire ropes from 8mm to 67 mm in diameter at speeds up to 2,000 metres per hour. It eliminates the slow and labor-intensive task of manual lubricant application, at the same time achieving more thorough results by forcing quality lubricant under high pressure right through to the core of the wire rope. The Wire Rope Lubrication System Package comprises: High Strength Collar, Grease Lube Pump, Air regulator with PG & Air control valve, High pressure Lube delivery hose & QDC, High pressure lubricant control valve, Excess lubricant drain hose, Retaining ratchet straps & shackles, Carry strap for the collar, Robust aluminum storage case, etc. The optional extras to be ordered separately are Highly durable polyurethane seals, Aluminum scrapers and Wire rope cleaner. Following are some of the unique features and benefits: • No more manual greasing • Stops corrosion / protects ropes • Penetrates to the wire rope core • Less waste and mess • Fast and efficient • High Pressure – Operates up to 6,000 PSI For Product Enquiry Contact Centraline Lubro Tech Engineersd P. Ltd Mr. Shaikh S.Y., G.M.Application Engg. & Sales, Pune Tel. : 0-93700 55449 E-mail: shaikh @shavogroup.com

Centraline WRL can be used with advantage in a plethora of industrial applications. Wharf Cranes, Ship Cranes, ROV Cables, Mine Winders, Mobile Cranes, Oil Well Platforms, Anchor Ropes, Deck Winches, Overhead Cranes and Ship Loaders. Centraline has more than 30 years experience in providing Industrial Lubrication Equipment & Solutions both in India and abroad.

JV Kraft-Vertical Machining Centre

For Product Enquiry Contact Lakshmi Machine Works Limited Machine Tool Division, Arasur Coimbtore 641407 Tel : +91 422 3021300, E-mail: mtd_marketing@lmw.co.in

LMW Machine Tool Division has introduced an All New Vertical Machining Centre “JV Kraft” in the X 800mm range which caters to the needs of diverse industrial segments from Aerospace to Job shops. The machine is equipped with robust spindle, constructed to minimize axial and thermal expansions and is dynamically balanced to ensure extremely low run-outs. The high precision feed mechanism provides high accuracy, rigidity and repeatability. The highly reliable swift Automatic Tool Changer (ATC) adds a new dimension to vertical machining. This state-of-the-art machine has been designed to meet the ever-growing demand for speed and accuracy of the user industry for high quality and high volume production.The machine is designed with the motto of best price-to-performance ratio and true to the goal of providing value creation through innovation, says I.N. Bhattacharya, General Manager-Marketing & Sales, MTD, LMW.

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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.

AT3 Class Tool holders Birla Precision Technologies Limited, erstwhile Birla Kennametal Ltd is established in 1986 as a Joint Venture with Kennametal Inc USA, primarily to manufacture CNC Rotating Tool Holders and accessories. We have constantly endeavoured to acquire new skills and technical expertise to produce engineered products and become cost competitive for addressing the needs of our customers. With BPT brand we are committed to provide; • AT3 Class Tool holders that ensure high precision, ease of operation and increased tool life • Products with unbeatable run out accuracy and balance quality • Full lot traceability of all tool holders for maximum reliability and process control. • Reliable & efficient engineering support to cater to your special requirements • World class quality at competitive prices. For Product Enquiry Contact Birla Precision Technologies 206 Dalamal House, 1st Floor, Jamnalal Bajaj Marg, Nariman Point, Mumbai - 400 021 Web: www.birlaprecision.org Email: himanshu.bhatt@birlaprecision.com

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Our all Tool Holders are manufactured in AT3 Class accuracy, with Shank DV/BT/ CV/HSK & Front Ends - ER/DA & TG Collets Chucks, Drill Chucks, End Mill / Shell Mill / whistle notch / Morse Taper / Jacob Taper Adaptors & Shrink Fit Tool Holders. We also produce the angle heads & rotary coolant adapters.

PRODUCTS www.mtwmag.com

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

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

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

Grinding Application: Primary 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

Secondary

Creep feed

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

Heavy roughing made lighter

For Product Enquiry Contact Dormer Pramet Unit 4 Lindrick Way, Barlborough, Chesterfield, S43 4XE Tel: 0870 850 4466 Web : www.dormerpramet.com

Pramet has launched a new chip breaker and grade for heavy roughing applications. The HR2 geometry expands Pramet’s range of single-sided inserts for machining a wide range of materials including steels, cast irons and stainless steel. Designed for rough forgings and castings, such as cylinders, shafts and large pins, the HR2 features a positive, stable geometry for improved tool life and performance. Its cutting edge design and wide peripheral land promote increased productivity, while offering reliable chip formation and evacuation at high feeds (0.7 mm/rev). This promotes a continuous production process with less machine downtime, resulting in a more costeffective operation. The new chip breaker compliments the existing HR insert which covers semi-roughing to roughing applications. HR2 is available with a new turning grade – T9226 – also launched by Pramet this April. The versatile T9226 grade achieves impressive results in heavy roughing and peeling operations. For these applications it replaces Pramet’s existing 6630 grade. Providing high insert reliability and durability in adverse cutting conditions, the T9226 offers greater cutting edge strength. This is primarily due to a new functional gradient substrate which contains a higher amount of cobalt binding and finer grain structure.

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PG. NO.

A ACE MICROMATIC GROUP

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ACMEE - 2016

ADOR WELDING LIMITED

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AMTEX - 2016

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ANCA MACHINE TOOLS PRIVATE LTD

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ATUL MACHINE TOOLS

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B BIRLA PRECISION TECHNOLOGIES LIMITED

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GRIND MASTER MACHINES PVT. LTD.

GROB MACHINE TOOLS INDIA PVT. LTD.

CNC SERVICING & SOLUTIONS (I) PVT. LTD.

CNC SOFTWARE, INC.

DELTA ELECTRONICS INDIA PVT. LTD.

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ERWIN JUNKER MASCHINENFABRIK GMBH

EXXON MOBIL CORPORATION

144

SEE LUBE TECHNOLOGIES PVT. LTD.

SHANTHI GEARS LIMITED

119

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132

SHAVO TECHNOLOGIES PVT. LTD.

INDOTECH INDUSTRIES

129

SOLITAIRE MACHINE TOOLS LTD.

SPARKONIX (INDIA) PVT LTD

SPRAYMET SURFACE TECHNOLOGIES PVT. LTD.

JIG ENGINEERING

JYOTI CNC AUTOMATION LTD.

INSIDE BACK COVER

116-117

MMC HARDMETAL INDIA PVT. LTD.

INSIDE FRONT COVER

NICKUNJ EDM WIRES & CONSUMABLES P LTD

NORD DRIVESYSTEMS PVT. LTD.

121 49

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U UCAM PRIVATE LIMITED

UNITED GRINDING GMBH

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MARPOSS INDIA PVT. LTD.

FIBRO INDIA PRECISION PRODUCTS PVT. LTD.

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SANJAY TOOLS & ADHESIVES

HOUGHTON

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GEM EQUIPMENTS (P) LTD.

SECO TOOLS INDIA (P) LTD.

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RENISHAW INDIA (PUNE)

EMAG INDIA PVT. LTD.

130

HEIDENHAIN OPTICS & ELECTRONICS INDIA PRAIVATE LIMITED

LAPP INDIA PVT. LTD.

ELECTROTHERM (INDIA) LTD.

RAJKOT MACHINE TOOLS SHOW - 2016

135

E 89

SBS PRECISION SYSTEMS (INDIA) PVT. LTD.

EFFICA AUTOMATION LIMITED

111

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PUNE MACHINE TOOL EXPO - 2016

PG. NO.

HARTING (INDIA) PVT. LTD.

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PMT MACHINES LIMITED

VOLLMER TECHNOLOGIES INDIA PVT. LTD.

W WALCHANDNAGAR INDUSTRIES LTD.

WIN INDIA - 2016

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