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

www.mtwmag.com

Executive Publisher

Contents

Vol 2 Issue 02 | JULY 2016

Shirish D.

BUSINESS NEWS

CEO Shekhar D.

Editor Shilpa Dongre

Mastercam Participating in Haas Demo Day Globally

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

Designer & Layout

ACMEE 2016 makes its mark

Arun P. Shinde, Nandan S. Moghe, Dinesh S. Gawade

Online Division Ganesh M., Pradeep M. Pillalamarri

Blaser Swisslube Productivity Trophy Award Winners Announced

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

NORTH

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

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

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

WEST (Maharashtra & Gujarat) Pune Sandeep - 09822751645 Gujarat Dinesh Shah - 09327344559 Rajkot (Saurashtra) Swapnil Bhatia: 09227909005

COVER STORY

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 JULY 2016

Bharat Fritz Werner : The Legacy of Technology Leadership Mr. Ravi Raghavan, CEO & MD Bharat Fritz Werner Ltd.

INDUSTRY FOCUS

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.

Onshape Introduces Fullcloud CAD to India

Mastercam 2017: Discover the best features at IMTS

By Akhil Jha, Vice President Technical, Shell Lubricants India

Shell Lubricants India Appoints Mansi Madan Tripathy as New MD

COMPANY SPOTLIGHT

Taiwan brings together Taiwan Machine Tool Industry at ACMEE

We are for those, who are in Metal Cutting!

Closer to the Customers in the Middle East

INTERFACE

FARO Announces Release of PointSense & VirtuSurv 17.0

Innovations in Operations & Maintenance

Renishaw Opens New Additive Manufacturing Solutions Centre in India

MEHTA CAD CAM: The legacy of excellence

Haas Demo Day at Manesar witnessed 700 visitors

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 BEST OF YESTERYEAR

Vol 2 Issue 02 | JULY 2016

CASE STUDY How DIETZ maintains its competitiveness

Innovations in centerless grinding machine & its operations

Ceramic Coatings from Spraymet for Refurbishing Machine Tool Parts

Robotics in machine tending

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

Schneto AG ramps up manufacturing with EMAGâ&#x20AC;&#x2122;s VL 2

TECH TRENDS DMG MORI Systems promises complete system competence

The New Generation of Angle Encoders with Integral Bearing

Recent developments in metalworking fluids

Automation in sheet metal cutting & welding

PROJECTS

106

PRODUCTS 8

MACHINE TOOLS WORLD JULY 2016

ROLLON for industrial machines: Automatically opening machine enclosures

Editorial Board

Editorial Index K

A Accusharp Cutting Tools Ador Welding

70, 106

Autodesk

B Balaji Diamond Tools Bharat Fritz Werner

110 38, 112

Birla Precision

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

Mr. GK Pillai Managing Director & CEO

Walchandnagar Industries Ltd.

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

108

Blaser Swisslube

Bosch Power Tools

C Centraline

107

Concept Laser

Effica Automation Ltd.

Renishaw Metrology Systems Ltd.

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

Massivit Mastercam

22 12, 44

Mate

Mehta Cad Cam Systems

N NUM

O Onshape

P Precision Technologies

Dahanukar Machine Tools 109

De Dietrich Process Systems 28

Renishaw

DMG MORI

Rollon India

Dormer Pramet

Shavo Technologies

Effica Automation

ELESA+GANTER

109

EMAG INDIA Ms.Samina Khalid Marketing Manager

Mr. Arjun Prakash Managing Director

Kennametal

F FARO Technologies

G Grind Master

H Haas Automation

34, 82

Hangsterfer’s

110

Shell Lubricants

90 20, 46

Solitaire Machine Tools

Sparkonix

Spraymet

T TaeguTec

Taipei World Trade Center

U Unity Controls

Heidenhain

Hypertherm

Ziehl-Abegg

107 26

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

JULY 2016

MACHINE TOOLS WORLD

BUSINESS NEWS

Mastercam Participating in Haas Demo Day Globally CNC Software, Inc., producers of Mastercam CAD/CAM software, will be participating in the Haas “Made in the USA, Celebrating Flag Day” Demo Day event at the local Haas Factory Outlet – Trident, in Windsor, CT. Mastercam Resellers will also be participating in their local Haas Factory Outlets. The Mastercam global Reseller network consists of over 860 agencies representing Mastercam, and serves as the backbone for Mastercam’s secondto-none service and support network. Averaging in 20+ years of manufacturing expertise, one will have a chance to meet your local Reseller at these events on June 14.

CNC Software will be showcasing the latest Mastercam software, Mastercam 2017 at this event. Mastercam 2017 features a more efficient workflow, improved usability, Dynamic Motion

improvements, and so much more. Attendees at many of these events can see Mastercam in action, cutting parts live on-site. In Windsor, CT, CNC Software will be using Dynamic Motion toolpaths to cut an Aerospace Tube Fitting out of 6061-T6 Aluminum on the Haas UMC-750. The part was modeled in SOLIDWORKS®, and uses a Raptor Dovetail Fixture

and ISCAR tooling. In Chicago, IL, Mastercam will be machining a Haas housing part on the UMC-750 running the new Haas control and highlighting seven times diameter depth of cut using Dynamic Motion. Haas Demo Day will feature live demonstrations on Haas machines and educational seminars on the latest trends for boosting output and increasing profits. There will be Haas applications engineers, along with representatives from major tooling, workholding, and CAD/ CAM manufacturers to share their insights and assist you in adopting the newest machine technology and manufacturing strategies to your shop floor.

ACMEE 2016 makes its mark ACMEE-2016, the 12th edition of the International Machine Tools Exhibition organized by the Ambattur Industrial Estate Manufacturers Association (AIEMA) in Chennai during June1620 is reported to be a grand success. This 5-day industry event, held at the Chennai Trade Fair Centre, had 465 participants, making it the largest Show in the series. The exhibit profile included the latest in CNC machines, CNC & PLC controls, CAD / CAM Systems, Special purpose machines, Co-ordinate measuring machines, Cutting tools & accessories, Hydraulics & Pneumatics, Instrumentation, Low

Migatronic with its welding products

MACHINE TOOLS WORLD JULY 2016

cost automation, Materials handling systems, Power tools, Testing & Measuring equipment, Welding Equipment, Industrial Robotics, Energy saving solutions, IT and Consultancy services. The Exhibitors included 125 overseas participants from 25 countries. The countries are Australia, Brazil, Canada, China, Czech, Denmark, France, Germany, Italy, Japan, Malaysia, Norway, Poland, Russia, Singapore, Korea, Spain, Sweden, Switzerland, Taiwan, The Netherlands, Thailand, UAE, UK and USA. The machine tools leaders from Japan and Taiwan were prominent by occupying almost

ELGI displaying its innovative compressed air solutions

20% of the exhibition space. Some of the prominent exhibitors from India included Alstrut, Baker Gauges, Beckhoff, BFW, Cosmos Impex, ELGI Equipments, Grind Master, Heidenhain, HMT, ITL, Jyoti CNC, Lokesh Machines, LMW, Mihr Metrology, Mieban, Micromatic, Migatronic, Mitsubishi, Mitutoyo, Ringfeder, S & T Engineeers, Sahajanand, Schmalz, Schunk, SMW Autoblok, Tespa Tools, etc. The Show attracted a large number of business visitors from India and abroad. - P.K. Balasubbramaniian

Grind Master showcasing its surface finishing solutions

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

Blaser Swisslube Productivity Trophy Award Winners Announced Blaser Swisslube India, with an aim to honor the exceptional cooperation and mutual success by enhancing productivity, economic efficiency and machining quality of its customers in India with the help of its Liquid Tool, awarded the Productivity Trophy for year 2015 | 2016 to five manufacturing companies in India. At the Productivity Trophy award ceremony held at The Westin, Gurgaon on June 13, 2016, five companies were awarded in the categories of Tool optimization, Total costs of ownership, Environment Health and Safety, Productivity increase and

Process optimization respectively. MM Singh, Director- Maruti Center for Excellence, Maruti Suzuki India honored the awards ceremony as the chief guest and he delivered an inspirational speech on Productivity & Quality in Automotive Industry. As a keynote speaker, Rajesh Khosla, Managing Director-

MMTC-PAMP India spoke on ‘The Art of Precious Metal Transformation’. While, Marc Blaser-CEO of Blaser Swisslube AG, addressed the participants on Different dimensions of Productivity & Competitiveness in manufacturing. Suman Bose, Managing Director & CEO- Siemens Industry Software India opened his tomes to make people more familiar about Industry 4.0 and revealed the finer picture of Industry 4.0. Customers walked through the Liquid Tool gallery and were excited to look at the different dimensions of Productivity and possible high returns by investing

(ROI) in the Liquid Tool. For Egger Pumps, Liquid Tool was able to provide an optimization in tool costs to the tune of 35% to 50% respectively which resulted into an annual saving of INR 1.3 million with improved machinability. Similarly, for QH Talbros, turning and machining centers saw an improvement ranging from 4-15%. Ognibene achieved 4-fold improvement in sump life & reduced the disposal volume by 24,000 litres. Thanks to Leverage effect of Liquid Tool, teams of Ognibene saw productivity improvement through cycle time reduction. Saving of 5% to 11% was achieved. Similarly, TBK achieved cut time reduction in the range of 8% to 35%. Quality of machining also got improved significantly and rejections in machining went down by 60%. For RSB Transmissions, productivity of the machining process got improved in the range of 2-18% resulting into savings of INR 1.5 million per annum.

Onshape Introduces Full-cloud CAD to India Onshape, the only company in the world 100% focused on cloud and mobile CAD, is formally expanding into the Indian market this month following the recent openings of Asia-Pacific regional offices in Pune, India and Singapore. Onshape CEO John McEleney visited Bangalore on Thursday, May 19 and Pune on Friday May 20. The India events are part of a six-country Onshape product tour of the APAC region. “Even though Onshape is only a few months out of beta, engineers and designers in more than 150 countries are already experiencing the benefits of full-cloud CAD,” says McEleney. “The design and manufacturing world has dramatically changed. More often

MACHINE TOOLS WORLD JULY 2016

than not, design teams are spread across multiple countries and time zones – and Onshape is the first and only CAD system specifically built for distributed teams.”

Built from scratch using a cloud-based technical architecture, Onshape runs on any computer completely within a web browser. It can provide instant and controlled collaboration and sharing becoming the first CAD system enabling multiple people to simultaneously work on the same model. “Because there are no files to copy – your CAD data and CAD system lives in one central place in the cloud – your intellectual property is now far more secure,” says McEleney. “You can easily grant and withdraw permission to access your models in Onshape, in contrast to files shared by email or Dropbox which can never be retrieved after you click ‘send.’”

BUSINESS NEWS

Renishaw Opens New Additive Manufacturing Solutions Centre in India Renishaw opened a new Additive Manufacturing Solutions Centre in Pune. 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 mentioned, “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,” said Clive Martell, Head of Global Additive Manufacturing. Renishaw Solutions Centres will lower this entry barrier by providing cost-effective access to

machinery, facilities and AM expertise. Solution 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 commented, “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.”

Shell Lubricants India Appoints Mansi Madan Tripathy as New MD Shell Lubricants India announced the appointment of Mansi Madan Tripathy as the new Managing Director of the company. Mansi, former CMO of Shell Lubricants, would succeed Nitin Prasad, who moves on to take over as the Chairman of Shell Companies in India with effect from August 1st, 2016. Mansi brings in 20-years of marketing, sales, insights and strategy experience to the office. In her new role, she shall be responsible for leading all the business activities for the Lubricants business in India, Bangladesh, Sri Lanka and Nepal.

MACHINE TOOLS WORLD JULY 2016

Mansi has been the architect of digital marketing & social media footprints for Shell Lubricants in India. Leading the marketing team at Shell Lubricants , Mansi has been an advocate of a new direction; weaving ‘direct consumer connect’, ‘industry influencer

engagement’ and ‘greater awareness initiatives’ intractably into the company’s brand marketing strategies. With her in-depth global knowledge of the market structures, consumer psychology and trade dynamic, as MD, her focus shall be to strengthen the company’s presence in India. Building and maintaining relationships with key business stakeholders and streamlining the efforts of Shell Lubricants across the country shall also be an important aspect of her new role. Prior to Shell Lubricants, Mansi’s experience spans across 17 years at P&G in key positions

like Director for Global Male Grooming, P&G and Asia Pacific Head for Consumer and Market Knowledge. As part of her global leadership roles, she has worked across countries like Geneva, Singapore and Boston; working on diverse product categories, new initiatives and equity development of global brands like Pantene, Olay, Vicks, Gillette, Pampers, Whisper, Ariel and Tide. Mansi is a B.Tech degree holder in Electronics and communication from National Institute of Technology Kurukshetra and an MBA in Marketing from S.P. Jain Institute of Management & Research.

BUSINESS NEWS

Taiwan brings together Taiwan Machine Tool Industry at ACMEE Taipei World Trade Center (TWTC) in association with Ambattur Industrial Estate Manufacturers Association (AIEMA) and National Small Industries Corporation (NSIC) launched high-quality innovations and total manufacturing machine tools products for India’s Aerospace, Automobile, Automation Engineering, Ancillaries, Consultancy and Services, Machinery, Machine Tools, Electrical, Electronics, Energy, and Environment at ACMEE 2016 at Chennai Trade Center. The event was graced by Charles C. Li, Director General, Taipei Economic and Cultural Center; Dr.Guann-Jyh Lee, Executive Director, Economic Division, Taipei Economic and Cultural Centre, and Mr. George Lin, Director of Taipei World Trade Center (TWTC).The Guest of Honour was Mr.C.V.Sankar, Additional Chief Secretary,

Government of Tamil Nadu, Industries Department. The representatives of six world’s leading machine tools and accessories brands from Taiwan – YCM, FFG, EXCETEK, TONGTAI, HIWIN and CHAIN HEADWAY were present at the Chennai Trade Center. Speaking on the occasion, Charles C. Li, Director General, Taipei Economic and Cultural Center said, “The total exports

of Taiwan-made machine tools and components to India in 2015 reached US$125 million. Of the machine models exported to India, machining centers, machine presses, lathes and metal cutting tools were in high demand. We are extremely keen on supporting the Indian government’s programme on ‘Make in India’. We have been bringing advanced technology and unique business solutions to India and will continue to excel our

offerings. Through our 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.” Dr.Guann-Jyh Lee, Executive Director, Economic Division, Taipei Economic and Cultural Center added, “Taiwan Machine Tool Industry has a key role to play in the Indian manufacturing industry. It is the 5th largest machine tool exporter in the world along with being the 7th largest machine tool manufacturer in the world. Taiwanese companies can offer their machine tools in broad spectrum of industries like Automobile, Aerospace, Automation Engineering, Ancillaries, etc. Through TWTC we are enabling the best of India and Taiwan to correspond and engage through strategic alliances that will benefit both the nations.”

Arrow Digital Joins Hands with Massivit 3D Printing Technologies The Massivit 1800 system, the largest, fastest and most advanced large format 3D printing solution, based on Massivit proprietary GDP (Gel Dispensing Printing) technology – is a solution that will ignite the market explosion in the use of large 3D objects, through a variety of markets worldwide. Massivit 3D is the next revolution in advertising after digital printing. The Massivit 1800 system is the fastest large format 3D printer. The printer can print objects up to 1.8m / 6ft high and grow them at up to 35cm / 1ft per hour. The system is also equipped with dual process option which allows for easy printing of two different objects in parallel. Last,

MACHINE TOOLS WORLD JULY 2016

but not least, it offers economical 3D printing as its special software features and it’s ‘supportless’ printing results in fairly low material consumption. The Massivit 1800 printer enables the creation of large 3D objects in a variety of markets worldwide. It allows print service providers, scenic fabricators and 3D service bureaus to produce unique, customized, unmatched large format 3D figures for a variety of uses for advertising, events design, theming of environments and more. At the heart of Massivit 1800 is the proprietary GDP (Gel Dispensing Printing) technology

which is based on the unique Dimengel printing material Massivit 3D has developed.

BUSINESS NEWS

Bosch Power Tools Launches GLM 50 C

Bosch Power Tools India, a market leader in the power tools segment that offers a complete range of power tools for construction, woodworking and metalworking industry, announced the launch of its innovative measuring tools recently in Bangalore. Intended to be time-saving, the launch caters to the needs of professionals associated with the real-estate, architecture, interior design, construction and the engineering space and helps them with surveying and measuring any given space. Professionals get to choose from a range of exciting tools such as the GLM 40 and the newly launched GLM 50 C. The tools are available across the wide distribution network of Bosch. GLM 50 C is a robust tool which measures upto 50 Meters/ 165 Ft. It has additional features of a Built-in inclinofmeter that has advances features like angles, min/max, stake out and double indirect Bluetooth functionality (Easily organize, document and transfer information using free Bosch apps). It even has an upgraded color display with back

MACHINE TOOLS WORLD JULY 2016

lighting for increased visibility. All in All this is on tools fits all size, a powerful measuring device for handling all your measuring needs are rolled into one convenient tool. The new range of “laser rangefinders” has a potential to change the way real estate is surveyed and measured. This coupled with an increasing number of professionals who are willing to use the modern tools that efficiently aid in completion of jobs effortlessly opens a new gamut of untapped market in the fields of interior designing and architecture for Bosch Power Tools. Commenting on the launch, Panish P.K, Regional Sales Director - India & SAARC - Bosch Power Tools said, “Following our leadership position in the power tool segment, our focus is to create products that enhances the measuring and surveying requirements of our customers. Our continued focus on being innovative has set a higher benchmark for the power tool industry and we believe this will only grow in the coming years.”

NUM to demonstrate advanced CNC milling solution

At IMTS, NUM will be demonstrating an exciting new development in CNC hardware and software technology that brings simple conversational style programming to CNC milling machines. This will be the first public showing of the new NUMmill control solution and is likely to be of special interest to CNC milling machine manufacturers and control retrofitters. Available as a fully scalable control system, it is suitable for a wide range of precision milling applications in markets as diverse as metal cutting, woodworking, plastic, and high precision machining. NUMmill provides a complete ‘off-the-shelf’ solution and offers an extensive suite of canned cycles, ranging from simple centre drilling, boring and threading through to pocket cycles and complex profile milling cycles. All with 3D simulation for pre-process verification. NUM will also be showing a number of its latest generation CNC products at IMTS. These

include new additions to its renowned NUMgear portfolio of CNC gear production solutions, such as a highly flexible electronic gearbox function that produces superb accuracy at extreme cutting speeds, a new conversational style user interface for cylindrical and surface grinding – with 3D simulation – and the latest edition of the company’s MTConnect interface which simplifies the integration of CNC machine tools with third party manufacturing software.

Automation for a Changing World

Delta Motion Control Solution ASDA-A2 Series Offers intelligent motion control while eliminating the external controller & making it competitive for different industrial verticals of Printing, Packaging, Machine Tools and Special Purpose machines. Key features include : 64 Point Internal Position task table with 35 Homing Methods Full Closed Loop Control to reduce mechanical backlash E-CAM Function: Flying shear, rotary cut and other CAM applications Profile Cutting Application: Integrated Gantry Control High Speed Print Mark input CAPTURE and Position COMPARE Function Fieldbus connectivity: Modbus, DMCNET, CanOpen and EtherCAT Built in turret Sequence controller Meet us @ Amtex 2016 Venue: Pragati Maidan, New Delhi, Hall no. 11, Stall no. C-83 Date: 8th- 11th July 2016

www.deltaelectronicsindia.com

BUSINESS NEWS

AMTEX 2016 to Commence on July 8th in New Delhi AMTEX 2016, an exhibition of international standards, catering to the machine tool needs of production and consumption hotspots is scheduled to take place between 8th-11th of July 2016 at Pragati Maidan, New Delhi. This much awaited biennial event will primarily focus on end user industries like Automotive, Power & Electrical Equipment, Textile Machinery and Consumer goods. Industry experts estimate India’s manufacturing sector to touch US$ 1 trillion by 2025 accounting for 25-30 per cent of the country’s GDP and act-

ing as a job creator with millions of domestic jobs on offer. The 11th edition of this coveted platform will aim to provide deep insights into the Indian machine tool industry through it’s exclusive Conference Programme, with an emphasis on future trends, growth strategies, new technologies and innovations, , keys to sustainable growth and the challenges and expectations of the industry players. Registrations are on with multiple exhibhitors from India and 30% overseas players participation from countries like

ESPRIT Worldwide Conference 2016 Held in Florida ESPRIT its ESPRIT World Conference 2016 June 6th through June 10th in Naples Florida at the Hyatt Regency Coconut Point Resort. At this year’s five-day conference, attendees from around the world learnt about the current and future of ESPRIT CAD/CAM software, giving them the latest tools and technologies to continue making the most innovative machining parts for ESPRIT customers worldwide. The ESPRIT World Conference 2016 featured both customer and reseller tracks, more than 20 technical sessions, over 60 ESPRIT engineers, and hands-on classes to help attendees integrate new technologies into their machining processes. Tailored for the ESPRIT community, the General Sessions offer an insightful look into various trends and technologies that are shaping the future of manufacturing. Future attendees can register via the ESPRIT World Conference

MACHINE TOOLS WORLD JULY 2016

2016 registration website. “We have the most amazing ESPRIT community in the CAM industry and have a great week planned for them,” said Paul Ricard, DP Technology’s president. “The ESPRIT World Conference is the place to be updated on the latest advancements in cutting edge technology for manufacturing. We are also providing visionary speakers who are experts in the CAM, Machining and Manufacturing industries. “Attendees are able to customize class schedules for five days of comprehensive learning that will help to program more high-quality parts in less time. Anyone interested in learning more can visit the schedule page of ESPRIT World Conference 2016 website for more information (www.espritworldconference. com/schedule ) to gain access to various classroom sessions.”

China, Germany, Japan, Korea, Singapore, Taiwan and Turkey among others already joining in. The last date to book the exhibitor space is June 30th, 2016. Said Cyril Pereira, Managing Director, Reed Triune Exhibitions Pvt. Ltd, “AMTEX 2016 will act as the exquisite ground for exhibitors to interact with the entire machine tool fraternity. India is currently the 14th highest producer and 10th highest consumer of Machine Tools. The time is ripe with ‘Make in India’ bringing in lot more opportunities compared to

previous years and AMTEX will act as the seamless platform in ushering in positive interest from international organisations to produce/manufacture and invest in India”. Some of the major companies participating in the event this year are Ace Micromatic (MICROMATIC MACHINE TOOLS PVT. LTD.), Jyoti CNC Automation Ltd., Mitsubishi Electric India Pvt Ltd., Renishaw Metrology Systems Private Limited, Muratec (Murata Machinery Ltd.) and Meiban (Meiban Engineering Technology), to name a few.

Closer to the Customers in the Middle East David Miller is Managing Director at Ziehl-Abegg Middle East. The German company is the leader in technological research leading to the development and the production of innovative fans and drives. “Our business in Middle East is growing rapidly, and his appointment enables an improved service for our local and regional customers” explains Peter Fenkl, Chief Executive Officer of ZiehlAbegg. Miller has already worked for different companies in the Middle East, Europe and the US. “He has an excellent technical knowledge of the cooling, heating and ventilation business”, emphasizes Peter Fenkl.” he also has very good personal and professional behavior.” The 31 years old engineer is now responsible for the market in Middle East. His vast experience in the HVAC business and regional knowledge provides a good base for the new challenge: to help Original Equipment Manufacturers (OEMs)

by sharing expertise and supporting their product development. “My goal is offer the market innovative solutions that reduce both noise and energy consumption, whilst demonstrating the quality benefits and reliability of our German engineered products”, David Miller says. This is only possible if the OEM works closely together with the fan and drive producing company. “Ziehl-Abegg produces not only fans and drives but provides also the control technology. We can subsequently offer a tailored system solution from one source.”

BUSINESS NEWS

Dr Tony Bannan Appointed OBE of British Empire Dr Tony Bannan, 52, Chief Executive Officer of Rochdale-based Precision Technologies Group (PTG), has been appointed an Officer of the Order of the British Empire in the Queen’s Birthday Honours List 2016. The OBE has been given in recognition of Dr Bannan’s services to the UK economy, international trade and inward investment. Referring to his appointment, Dr Bannan said: “To receive the OBE is obviously a huge thrill, a tremendous honour and very surprising. In business you occasionally meet people who have been granted such recognition, but never imagine it might happen to you. It is also very humbling, because you are being rewarded as an individual for what is, in truth, the combined and sustained efforts and creativity of many people in business – many of whom

have gone before you and laid the foundations of success.” Today, in addition to his role as Group Chief Executive Officer of Precision Technologies Group, Dr Bannan is a Director and Officer of Chongqing Machine Tools International (CHMTI). Dr Bannan joined PTG company, Holroyd Precision, as Technical Director in 1999, becoming Managing Director of PTG’s machine tools divisions (Holroyd Precision, Binns & Berry and Crawford Swift) in 2007. He became Group Chief Operating Officer in September 2008, and then PTG’s Group Chief Executive Officer in June 2010. PTG is an export-driven manufacturer of special purpose CNC machine tools, such as the globally acclaimed Zenith 400 helical profile grinder and the Powerstir range of friction stir welders.

Mate Introduces Tool-Less Thick Turret Punching System

De Dietrich Process Systems to launch new external protection of glass-lined parts

Mate is starting a punching revolution with its newUltra® QCT™ a quick change, tool-less thick turret punching system. Ultra QCT is simple and intuitive to setup, and fully compatible with Mate’s Ultra® family of guides and standard canisters. Designed for easier, faster setups, Ultra QCT features a simple, intuitive tool-less punch retention mechanism. Flip the latch to remove and snap the new insert into place; it’s that easy! The punch is keyed at the perimeter of the tool – not the center – providing superior angularity control. The shoulder of the punch remains securely guided by the guide when punching. Most important, Ultra QCT is very durable. First the punch insert

MACHINE TOOLS WORLD JULY 2016

is made from MPM4™ tool steel, proven to be the most durable, longest lasting tool steel in the industry. Independent studies have shown M4PM to last as much as 56% longer than conventional high speed tool steels. Further, the punch driver is coated with SuperMax™, Mate’s next generation coating, to minimize wear and preserve fits. “Mate’s Ultra QCT tooling is a true tooling revolution and designed in response to fabricators needs,” reports John Galich, Mate marketing manager. “Fabricators want their machines up and running as quickly as possible, which is what Ultra QCT provides. Tool changes should be tool-less and intuitive. Just snap the insert in place and you’re ready to go. From a cost/value perspective, Ultra QCT enables fabricators to lower their manufacturing costs with premium M4PM steel inserts that last longer and cost less over time than conventional punches,” Mr. Galich stated

To address the problems of its customers, particularly in pharmaceutical and fine chemicals, sensitive to the risk of contamination of their products by paint chips, De Dietrich Process Systems has developed a new exterior nickel coating for glasslined parts. This coating is particularly suitable for glass-lined accessories such as manhole covers, protection rings and even some AE reactor covers, or process peripheral such as piping. The external protection of process equipment (reactors, piping, etc.) in glass-lined steel is traditionally provided by the paint. These paints have excellent corrosion resistance but may in places be subject to high mechanical stress, and flake. The GMP (Good Manufacturing Practices) standards of the pharmaceutical industry prohibit the fact that a paint flake can

contaminate the final product. To address this risk, De Dietrich Process Systems has developed a nickel coating solution that provides corrosion protection comparable to painting, while eliminating the risk of chipping.

Indeed, nickel coating has outstanding properties: • Bonds perfectly with the base material • Impact resistant • Easy to clean thanks to a specific surface preparation • Makes it possible to apply homogenous surface coating to components with complex geometries.

Industrial Matrix Drive U1000

Increase your green space with YASKAWA’s Industrial Matrix Drive (U1000), the product that that goes beyond conventional drives, providing outstanding harmonic performance and regeneration in a single stand-alone component. Enjoy extremely low harmonic distortion and regeneration in a space-saving design, completely without the need for additional components. Unlike conventional drives, YASKAWA’s matrix technology creates a variable output by switching directly from the input power (no DC bus). Additionally, the Matrix drive is a member of the YASKAWA industrial drive family, and provides the same user experience.

USING COMPLICATED SYSTEMS FOR LOW HARMONICS OR POWER REGENERATION?

TRY THE EFFICIENT WAY WITH THE U1000 INDUSTRIAL MATRIX DRIVE

12/18 PULSE SYSTEM 12/18 -Pulse Transformer

Input Fuses

Standard Drive U1000

ACTIVE COMPONENT SYSTEM Input Fuses

LC Filter

Active Rectifier

Standard Drive

PRIMARY FEATURES & BENEFITS • Full Regeneration • Low Input Distortion Across a Wide Load and Speed Range • IEEE-519 Compliant (<5% THD) • Eco-Mode to Achieve Near Across-the-Line THD • High Eﬃciency Design Provides Extra Energy Savings as Compared to Other Low Harmonic Solutions • Near Unity True Power Factor at Full Load • Integrated Input Fusing Provides 100kA SCCR • Compact Design • High Reliability with an MTBF of 28 Years

LESS SPACE, FASTER SETUP, HIGHER EFFICIENCY

• Embedded Modbus RTU Communications • Removable Terminal Block • Safe Torque Oﬀ rated for SIL CL3 and PLe • High Carrier Frequency (Low Motor Noise) Capability • 0-400 Hz Output Frequency • 120% Overload for 60 Seconds (ND) • 150% Overload for 60 Seconds (HD) • Multi-language LCD Display with Copy function • DriveWizard® Software • Start into Spinning Load (Speed Search) • Both Induction and Permanent Magnet Motor Control

415 V POWER RANGE • 2.2 – 220 kW (ND), 5 – 185 kW (HD) AMBIENT OPERATING TEMP • -10°C to 50°C (OPEN TYPE IP00) CERTIFICATION • UL, CSA, CE, RoHS STANDARD I/O • (8) Digital Inputs • (3) Analog Inputs • (1) Pulse Train Input • (2) Safe Torque Off Inputs • (4) Relay Outputs • Analog Outputs • (1) Pulse Train Output • (1) Safe Torque Off Output STANDARD COMMUNICATIONS • Modbus RTU CONTROL OPTIONS • EtherNet/IP • Modbus TCP/IP • DeviceNet • Profibus DP • Profinet

• Expandable I/O • Incremental Encoder • Absolute Encoder • Resolver

MECHANICAL OPTIONS • NEMA 1 Kit • External Heatsink

YASKAWA India Pvt. Ltd.

17/A, 2nd Main, Electronic city, Phase 1, Hosur Road, Bangalore 560 100 Tel: 080 4244 1900, Email: info@yaskawa.in / sales@yaskawa.in / service@yaskawa.in www.yaskawaindia.in

BUSINESS NEWS

FARO Announces Release of PointSense & VirtuSurv 17.0 FARO Technologies recently announced the release of PointSense and VirtuSurv 17.0, laser scanning plug-ins for the Autodesk® environment that ensure seamless integration with the recently released Autodesk® 2017 product line. 3D laser scanning is quickly becoming the accepted practice for fast, efficient and accurate capture of as-built data by engineers, architects and construction specialists. However, designers are often left with CAD programs that have manual and inconsistent methods for transforming scan data into final design needs. The PointSense and VirtuSurv 17.0 programs provide BIM-CIM CAD designers with comprehensive tool kits for solving the challenge of converting massive point cloud data sets into intelligent 3D models. Customers can choose software modules that match their specific

workflows and plug-ins are available for both AutoCAD and Revit. With each major release, FARO continues to push innovative design techniques and improve workflows within the Autodesk® environment. Product features are inspired by customer demand. For example, PointSense for Revit 17.0 now provides support for “work-sharing” projects, allowing all BIM-CIM stakeholders to simultaneously use

PointSense on a common Revit® project file. In addition, an enhanced wall-fitting tool allows users to accurately extract walls from point clouds without having to scan both sides of the wall. “FARO understands the significance that Autodesk software plays in completing our clients’ workflows within the BIM-CIM market.” stated Andreas Gerster, Vice President, BIM/CIM and Product Design. “Our engineering team worked closely with Autodesk to provide a seamless transition to Autodesk® 2017 products so that our customers have immediate, uninterrupted access to the latest design platform.” FARO also announced the launch of the FARO Design ScanArm, a portable 3D scanning solution tailored for 3D modeling, reverse engineering, and CAD-based design applications across the product lifecycle management (PLM) process.

“The FARO Design ScanArm was purposefully-engineered to meet the needs of the Product Design market,” stated Dr Simon Raab, President and CEO of FARO Technologies. “By combining FARO’s best-in-class 3D scanning technology with 3D System’s Geomagic software offerings, the Design ScanArm provides a turnkey solution that allows users to quickly digitize any part or object, easily design or modify reverse engineered models.”

Hypertherm Announces ProNest 2017 Hypertherm, a US based manufacturer of plasma, laser, and waterjet cutting systems, recently announced a major version upgrade to its ProNest® advanced CAD/CAM nesting software for automated cutting. ProNest® 2017 contains a number of improvements designed to make customers more efficient and profitable. New features include: (1) Manual nesting improvements, including drag array, anchor part to cursor, and automatic bumping functionality for greater control and faster nesting, (2) Color by part property that fills parts with different colors based on a designated attribute (name, priority, work order number,

MACHINE TOOLS WORLD JULY 2016

due date, etc.) and ProNest reports that show fill colors in part images making it easier to locate parts, (3) Redesigned drill machine interface for plasma or oxyfuel machines that incorporate drilling, tapping, and other spindle operations to seamlessly tackle jobs directly in ProNest, (4) Native 64-bit support allowing ProNest to take advantage of the extra accessible memory available on a 64-bit CPU/Operating System. “The outcomes our customers expect as a result of using Hypertherm CAD/CAM software drives us to deliver exceptional solutions so they may achieve more…and do it more profitably. ProNest 2017 will deliver increased

material savings, boost productivity, lower operating cost and improve part quality,” said Derek Weston, Product Marketing Manager for Hypertherm CAD/CAM software products. “In addition, ProNest 2017 contains more embedded cut process expertise in the NC code than any other software, allowing our customers to leverage patented technologies like True Hole, True Bevel, and Rapid Part.” More changes to Hypertherm’s nesting software family of products are also taking place as part of this major version release. Hypertherm nesting software for cutting in production environments, formerly named TurboNest, is now called

ProNest LT. Also, Hypertherm nesting software for cutting in job shop environments, formerly NestMaster, is now ProNest LTS. ProNest LT and LTS contain many of the features found in ProNest 2017. Users with an active Software Subscription can upgrade to the new version of their respective product at no additional charge and continue to receive unlimited technical support, and other benefits.

BUSINESS NEWS www.mtwmag.com

Pramet launches New Milling Grade Pramet has launched a new milling grade and also expanded its face milling range for stainless steels. The M6330 grade has been developed specifically to achieve longer cutting edge durability and reliability in a range of difficultto-machine materials with and without coolant. Particularly suited to adverse cutting conditions, including interrupted cutting, the grade is now available with many of Prametâ&#x20AC;&#x2122;s most popular inserts, including the ADMX, HNGX, LNGX, LNMU, OEHT and numerous other ranges. It promotes greater operational reliability and tool life, with a high resistance to heat-related cracks. This is due to improved abrasion resistance from a new substrate and PVD coating. The new grade is the latest of many new products recently launched by Pramet for machining stainless steels. Meanwhile, Pramet has also added to its face milling range for stainless steel with new, larger diameter cutters and inserts for greater depths

of cut and more powerful machines. These latest tools include the octagonal OEHT 09 inserts, suitable for unstable conditions and machining fragile components in stainless steels and soft steels up to depths of 5mm. The versatile tool can be used for both roughing and finishing operations, providing increased tooling economy and significant savings on machine time. In a recent product test, machining a piece of steel (3900mm x 3200mm) with coolant, the OEHT performed the roughing and finishing operation in 52 minutes. A competitor tool performed the same task in the same conditions in 252 minutes with roughing and finishing operations done separately. A new range of round inserts, REHT 24, for face and copy milling and the XEHT 09 wiper inserts add to the options available. All can be clamped into the same milling cutter, further increasing versatility and cost efficiency. A wide assortment of new milling cutters, ranging from 80 - 315mm diameter, is also available. Internal coolant delivery is supported by each cutter, including for large diameters.

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MACHINE TOOLS WORLD

BUSINESS NEWS

TaeguTec to offer diverse solutions for machining With the increasing application of composite materials in the market, TaeguTec is launching new PCD milling inserts, diamond coated solid carbide end mills and drills for effective machining of composite materials. In recent years, the demand for strong, lightweight materials from industries ranging from aerospace, motorsport to power generation, has led to the development and implementation of composite materials. Composites, such as CFRP (carbon fiber reinforced plastic) are 70 percent lighter than steel and 40 percent less than aluminum alloy. In various industrial fields such as automotive, wind power energy and recreation industries, the advantages of using composite materials are more effective due to the material’s lighter weight and superior stability over conventional counterparts. These new tooling solutions satisfy the unique cutting conditions of difficult materials as they have been designed to combine the specific

grade, required geometry and high technology diamond coating for processing composite materials. Polycrystalline diamond (PCD) inserts allow for faster speeds and feeds compared to other conventional cutting tool materials. TaeguTec specifically designed its PCD inserts to prevent surface delamination of composite materials. To offer a wider range of option while machining CFRP, TaeguTec’s diamond coated solid carbide end mills come in four different types: (1)

RRFE-080-TT610 (Ideal for splitter routers, the RRFE type eliminates delamination, offers low cutting force and less vibration), (2) RCFE-040TTD610 (Another diamond coated solid carbide end mill offered by TaeguTec used to machine CFRP is the RCFE type, which like the RRFE eliminates delamination, offers low cutting force, less vibration and is a high productivity tool for roughing applications – the difference being that it is used on multi flute routers), (3) RCOM-4060TTD610 (For finishing applications, TaeguTec recommends the diamond coated solid carbide end mill RCOM which eliminates delamination and comes in a left and right handed helix type), (4) RDCF-4100 (The fourth offering by TaeguTec to machine CFRP, which is also for finishing applications and eliminates delamination and splintering, is the low helix RDCF type) As for diamond coated solid carbide drills, TaeguTec’s CFRP drills are a perfect choice when looking for a tool that eliminates delamination during through hole machining.

Kegelmann Technik Teams with Concept Laser in 3D Metal Printing

The Kegelmann Manufacturing GmbH & Co.KG was founded on May 1st 2016 to focus on mass production in 3D metal printing (metal laser melting) as a part of the Kegelmann Technik Companies. The Group has just concluded a comprehensive framework

MACHINE TOOLS WORLD JULY 2016

agreement with Concept Laser, a pioneer and major driver of the 3D metal printing industry. The agreement provides for the installation of several lasermeltingmachines and a strategic partnership in mutual knowledge exchange, particularly on the reproduction and optimization of seriesproduction quality in 3D printing. “Our customers expect us to deliver process quality, flexibility and speed. Excellent quality control and verifiable results in real time during the actual laser melting convinced us to partner with Concept Laser,” explains Stephan Kegelmann, CEO of Kegelmann Technik GmbH. Kegelmann Technik offers an extensive range of innovative manufacturing processes under one

roof and decades of knowledge in establishing and maintaining reproducible quality in additive manufacturing. “We will most certainly learn from Kegelmann Technik’s wealth of experience in the future”, says Oliver Edelmann, Vice President Global Sales & Marketing at Concept Laser. Kai Kegelmann, CTO of Kegelmann Manufacturing GmbH & Co.KG, expressed his excitement over the technology found in the M2 cusing Multilaser that boasts two 400 watt fiber lasers by adding, “I am fascinated by lightweight and bionics’ ability to improve component performance. By investing in high-power lasers and additional QM accessories we underscore our values of speed, flexibility and process quality.”

BUSINESS NEWS

Haas Demo Day at Manesar witnessed 700 visitors More than 700 customers visited the recent Haas Demo Days held at IMT Manesar - Haas Factory Outlet- A division of CNC Servicing and Solutions. A ribbon cutting ceremony, facility tours and live cutting demonstrations were among the highlights of a highly successful event at this Auto hub in north India. “To attract over 1100 people highlights the growing importance that this high tech, engineeringdriven city gives to adopting the latest CNC technology,” states Terrence Miranda, Managing Director, HFO Mumbai. “It also reinforces how Haas solutions offer an unmatched combination of technology and affordability, which are so crucial in today’s

competitive environment.” Manesar is a rapidly expanding Auto hub located around 30 kms Southwest of New Delhi. Less than 2 kms away is plant of Maruti Suzuki Udyog, where around 5000 people are employed. The automotive, steelmaking, automation and power generation sectors are also well represented in the area. All this made for a well-attended series of Manesar

Demo Days 2016. The event opened with a high profile ribbon cutting ceremony. Given the honour of performing the opening by Mr. Hideo Yoshioka - Managing Director of Munjal Kiriu. Following photos for the press, the crowd left the red carpet and headed inside to witness live cutting demonstrations on two of the company’s best-selling CNC machine tools: A Haas VF-2 CNC

vertical machining centre and a Haas ST-35 CNC turning centre. Like all Haas CNC machines, the VF-2 and the ST-35 are built at the company’s one and only factory in California, USA. Haas Factory Outlet – A division of CNCSISPL 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.

Bigger & Better: PhillipsCNC Open House 2016 – Manesar The Machines on display were:

The second PhillipsCNC Open House concluded on 24th June 2016 at Phillips CNC Technical Center in Manesar. The Multi-Brand Open House was inaugurated by Managing Director of Munjal Kiriu, Mr. Hideo Yoshioka.

MACHINE TOOLS WORLD JULY 2016

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 IMT Manesar from June 22-24, 2016. The event witnessed approximately 1100 visitors & 700 companies over 3 days of the Open House.

1. Kent KGS-510 AHD Precision Surface Grinder 2. Tsugami M08J CNC Lathe 3. Tsugami B0205 Sliding Head Turning Center 4. Maple Taiwan ME- 850 Vertical Machining Center 5. Zeiss SF&G machine 6. Zeiss Contourcord 7. Zeiss Rondcom 8. Pinacho Smart Conventional 200 x 750 9. Pinacho Smart Turning 225 x 1500 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.

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

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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

TECH UPDATE

The real

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

Unique Tooling Solutions: UTS is distributors for Mitsubishi tools & also makes speciality tools for various metal cutting needs, many of them designed for specific purpose. Challenge: UTS has a designing centre in Pune and a manufacturing unit for special tools at Kolhapur. Synchronising two different processes at working at distance has many technical & human interface challenges

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.”

MACHINE TOOLS WORLD JULY 2016

Fusion 360: a real time collaboration function helped a real time dialog between distant teams, which enabled them take on-the-spot decisions, it has made stunning difference to whole process .and all this within 4 days. Mr. V. S. Kulkarni says “given its enablement of multi-locational real time working. The savings on cost, manpower and time resources has been immense! To say the least…”

Rex Engineering and Metal Industries is a distinguished 40-year old, Thane -Maharashtra based service provider and component supplier to the steel plant sector. Its pedigreed client list including Godrej, Mukund ,Virat in India and Qatar steel & COSCO from across the shores. Challenge : Many of our jobs have multiple stake holders coming from multiple locations, Also, building expertise of our team with every different software & version is always a challenge. Solution : Fusion 360 delivered all in one capability of CAD-CAM & CAE. It allowed to import, open & edit variety of file formats with great ease. The ease of learning Fusin 360 helped them make it mainstream software in just few days. In Mr. Gulati’s words, “It has been extremely easy for us to adopt Fusion 360. The learning process has hardly taken us 3-4 days.”

TECH UPDATE www.mtwmag.com

Precision Tool Room and Moulding House is pioneer in thermoset plastic and sub-assemblies. Manufacturers and suppliers of moulded components, moulding dies and specialities in compression moulding, transfer moulding and injection moulding.

M PLUS CNC TECH PVT LTD is over a decade old, Chakan-Pune based designing & Manufacturing company, manufacturing machines & equipment, precision parts, Capital Tooling for various Engineering Verticals, acts as a complete solution Provider,

Challenge: CNC is Outsourced. Dependency on outsourced CNC vendors for estimates, leading to time pressures, no scope for negotiations & restriction of choice.

Challenge: Dependency on different softwares, different computers and different expertise to complete every single job.

Fusion 360: Cost & All in one ability of fusion 360 allowed in house estimation of material & CNC process, This offered us control on the process, ability to negotiate & choose the vendors, all in all shortened our time to respond our customers.

Solution: Fusion 360 is capable of carrying out all 3 processes, and also allowing to work with various file types sent by vendors & customers. The entire process has become like a computer game. We learned it while playing, and mastered it just by playing it few times.

Mr. Sanjay Mudholkar is happy to state “In house control gained over outsourced operations is a big boon, it has made us competitive yet manage our profitability.”

Mr. Nivas Mane says “It’s wonderful to have Fusion 360 in our facility, it has substantially increased our productivity & that too with a great ease”

Yash Die-casters are Thane-Maharashtra based manufacturers of Pressure Die, casting Die, Plastic moulds, trimming tools, jigs and fixtures & caters EDM Wire cutting jobs. Challenge: design and manufacture process depended on several separate distinct software, working independent of each other. Very often it is required to make On-the- Fly changes. Earlier the changes effected in one would be adapted in other through manual intervention, a time consuming process, also prone to mistakes Fusion 360: a tightly integrated CAD -CAM process practically reduced endto-end solutioning time by 50% and more. Its cloud based nature helped it swiftly develop its vast library & allows one to access it as if it’s on ones fingertips. Mr. Samir Dalvi quotes “Fusion 360 is extremely economical, complete solution for all of us. It is a gamechanger, I call it real support of Make in India”

Watch their videos on http://bit.ly/29b1lCD JULY 2016

MACHINE TOOLS WORLD

COVER STORY

Bharat Fritz Werner The Legacy of

Technology Leadership Mr. Ravi Raghavan, CEO & MD Bharat Fritz Werner Ltd.

Q1. BFW has gained substantial market share in Indian machine tool industry, please elucidate the success story of the company? We started our journey in 1961 as a collaboration of Kothari Group and Fritz Werner Germany. We have been at the heart of Manufacturing Industry since last 55+ years. Strong, rigid and reliable machines have been

MACHINE TOOLS WORLD JULY 2016

the foundation of our products. Over years we have been closely working with our clients – understanding their needs and meticulously embedding them in our products and services. Customer Centricity is the core of BFW organization – our world revolves around our customers. Our organization DNA is woven with structured product development, Innovation, process

driven manufacturing. We are a learning organization with passionate team focused on clients. Over recent years our thrust on innovation has significantly increased. We are bringing out new offering and are acquiring new technologies – organically and inorganically. Our capability to respond with customized solutions is one of the aspects, which have added

COVER STORY www.mtwmag.com

value to customer. Today the width of BFW product-range to meet metal-cutting products – Milling, Turning, Multitasking and customized solutions - is unmatched by any other Indian manufacturer. Our drive towards more innovation & more customer-value creation will ensure that it stay that way. We are grateful to our customers who have consistently supported us, presented us new challenges to work on and trusted us to be a part of their manufacturing success. Substantial gains in Market share is a result of all of above.

Q2. Please brief us about the exports and overseas operations & what are the global alliances that has been made in order to out-front the competition? BFW has been active in select markets & geographies. We have also been a ‘supply partner of choice’ for reputed Global Automotive OEMs like Renault, Honda and Toyota, wherein we have supplied machines to their multiple locations in India & overseas. In the recent past, we have been successful in scripting the acquisition of Matec, Germany – a brand associated with the sophisticated 5-axis Travelling column enabled machining technology, and also a strategic alliance with SPINNER – a reputed brand of VMCs and Turning Centers, to distribute their Turning Centre range in India. Both relationships have been formed with companies from Germany – the land of meticulous engineering. BFW has been the proud recipient of EEPC (Engineering Exports Promotion Council) awards for Outstanding Export performance for three consecutive years of 2013, 2014 and 2015.

TO STOCK’ and ‘MADE TO ORDER’ machines, and are being positioned depending on the market segments & industrial sectors that they are being allocated to. For example – Accutron TSP – 350V has been aptly positioned as the machine providing ‘Precision with Agility’ as it is meant for the mass-production automotive industry; which has a large of number of ‘repeatable’ parts to be manufactured within short-cycle times. We have top-of the end HMC productplatforms like ORION, which has set new bench marks in HMC specifications and performance and is the result of IndoGerman engineering excellence for clients seeking cutting edge performance. Orionseries will be instrumental in bringing true-blooded HMC impact on shop-floor productivity and performance. For Die & Mould segment, we have KRYPTON-series to deal with challenges related to hard-part machining – its bridge-type modular construction will ensure that the machine will be a racehorse for true Die & mould machining performance, and will be front-runner for ‘MADE IN INDIA’ quality machines in the near future. We have recently entered in Horizontal Turning product-line and based on the encouraging response – we will continue to expand our offerings in it. BFW’s Performance Turning Solutions- the PL-series; are apt solutions for meeting the demanding requirement for the heavy-duty turned components user

industries, and represent a differentiated product range. We are the largest Indian Producers of Vertical Turning Lathes and our product mix of pure turning- and turn Mill technology is well accepted.

Q4. Can you brief us about the marketing strategies that were applied in order to stand out in the competition of machine tool industry? I believe that ‘innovation’ and “Meticulous Product strategies “are the Key issues. – Whether it is in products, “Go to Market strategy “, positioning of products and communicating to customers about the products. ‘Innovation’ for me is ‘treading the less-trodden path, believing the unbelievable, and achieving what is perceived impossible’ – it is the culmination of human efforts, that may or may not result in immediate value creation; but definitely has the potential for value creation in future.

Q5. Please elucidate in brief about the BFW’s infrastructure & what are the measure that are being taken from the product manufacturing to distribution? BFW has always resorted to in-house manufacturing of critical to quality components to drive product quality and bring down costs. We have number of precision mother machines for structural parts. With our Foundry, we are fully backward integrated for all structural

Q3. What are the market prospects for the BFW products in India and how do you plan to position these products? Market prospects for BFW products get defined at product development stage, even before it comes out of the factory. BFW has the right balance of ‘MADE

JULY 2016

MACHINE TOOLS WORLD

COVER STORY parts – from casting to finishing. We also have our own spindle manufacturing, assembly and testing facility. For other components, subsystems and subassemblies we have closely knit network of our supply chain partners, with whom we work closely. For bought out components we have always sourced them from only the best global and domestic brands in business. With reference to distribution – domestically BFW has a wide distribution network through its 10 Regional offices and 21 channel partners; BFW are well covered in terms of market penetration for Indian geography. Overseas BFW is already present through its international partners in 18 countries and currently we are planning to increase our depth in select geographies.

Q6. Brief us about the R&D and Quality policy for your business? Being a leader, I believe- core R and D is key for us to continue to create a sustainable differentiation. R&D policy of the company is to develop products for the manufacturing industry for application that are developing /

MACHINE TOOLS WORLD JULY 2016

expected to develop at least 5-8 years into the future. With the establishment of Dr. Kalam Center of Innovation, BFW will conduct core research & development into energy efficient machines & alternative materials etc, which would change the dynamics of metal-related manufacturing industries in the years to come. Quality policy of BFW is to ensure quality at every step of the machine production and to ensure complete waste elimination through ‘first time right – every-time’.

Q7. Please comment on the current machine tool scenario in India? The Machine tool scenario in Indian consists of few organized companies and many small regional players. According to IMTMA, the Indian Machine tool Industry has around 1000 units in the production of machine tools, accessories/attachments, subsystems and parts. Of these, around 25 in the large scale sector account for 70 percent of the turnover and the rest are in the SME sector of the industry. While the demand for machine tools is chiefly driven from automotive industry, demand from other industrial sectors, will

definitely catch up in due course of time, and it is therefore more beneficial to keep a balanced customer chart, to ensure less over-dependence on any particular sector. I always believe that industry is still on its growth path, and several years away from maturing into a full-fledged industry – hence the opportunities for already established players like BFW is limitless.

Q8. Could you brief us on Indian & Global perspective of machine tool industry? What are the distinguishing factors? As per domestic perspective, Indian machine tool industry is not able to even meet 50% of the demand, that itself illustrates the huge window of opportunity that exists for all of us. Opportunities for growth are immense in the Defence & Aerospace sector and with 100% FDI permitted in these sector, we see growth of both markets, which would be beneficial to the industry – the key challenge would be to increase competitiveness vis-à-vis imported machines; and Indian industry should now gear up-to meets these challenges through an entirely innovation driven approach.

COVER STORY www.mtwmag.com

Globally- machine tools that are MADE IN INDIA have yet to make their mark in a meaningful manner, and hence exports of machine tools from India have remained a small percentage of the Global machine tool consumption. BFW is able to establish its global footprints in 18 countries. However there is lot of work that needs to happen in enhancing Brand BFW globally. we will continue to strengthen this activity through slew of initiatives and through our Germany subsidiary – matec.

Q10. What are the key technological trends that are driving machine tool industry? Key technology trends driving the machine tool industry today is the proliferation of Internet & Computing Technology in the workplace arena through Industrie 4.0 & the Industrial Internet Network that will ensure Machine-to-Machine communication and result in Smart Machines & Smart Workshops.Another key trend is the development of 3D printers (additive machining) and its potential to replace subtractive processes like milling and

turning in the future course. BFW has been one among the Indian Machine tool Manufacturers to take note of these developments, and will come up with a suitable product range in this area in due course.

Q11. How do yourperceive the future of the Indian machine tool industry? The success of the Indian machine tool industry in general depends upon the success of its user industries like automotive, aerospace, die and mould, general engineering etc. In future we see a more advancing user industry, will ensure radical changes in production range and operational methodology in the Indian machine tool industry, and we are well enabled & ready to embrace the change, in keeping with the developments.

Q12. How far the factors like government norms, excise duty, taxation, exim policies are affecting your business? Government norms like Excise duty, taxation & EXIM policies do have a major impact on operational performance & profit realization for each business. We expect GST tax regime expected to be realized, to ease our existing tax burdens and allow useful funds to be utilized for R&D and Innovation purpose – the Indian Industry today is one of the most heavily taxed globally, and any lightening of the tax burdens would definitely be a welcome move. Further EXIM policies should be more pro-active & not leave demand generation to the individual companies alone – on this context I believe MAKE IN INDIA is definitely a positive step, as it paints an optimistic picture of the Indian Industry to match up to global requirements – I see that better progress on this particular area will lead to the setting up of a more robust and proactive supply chain, which is weak presently, which will augur well for the industry. We would also like to see more fundallocation to the industry for ‘R&D’ activities; which will help to increase

competitiveness of the Indian players, by matching upto global brands on most parameters.

Q13. What are the best possible remedies you can advise in order to maintain the high profitability in the shrinking margins market of India? The best possible remedy is to strike the right balance between a mass markets (highly competitive) and niche ones (least competitive); by delivering products + feature innovation to enable better value creation & thus better price realization from customers. At the same time there should be a thrust on cost reduction by standardizing machine through modular constructions, and ensuring process innovation through relentless reduction of wastes & increased people effectiveness through training & development. Shrinking margins would also be eliminated through entering the ‘volumes’ game by ensuring that low margins get amplified several times to ensure better realization.

Q14. What is your vision for BFW? I would like my company – BFW to transform itself into one of the most loved & respected companies for all its stakeholders – vendors, customers, employees and shareholders.

Q15. Please address the issues that are affecting the machine tool industry? The key issues address the industry today is the challenge to rise against the odds – fluctuating demand cycles, dearth of skilled manpower in design & hi-tech engineering, weak logistical infrastructure and an overbearing reliance on imported bought-outs; that has ensured ‘design to market’ turnaround time is the highest in India vis-à-vis most other countries. The only solution to most problems faced by the industry is to follow an ‘innovation-driven’ approach, and BFW is determined to swim against the tide of a weak Index of Industrial Production (IIP) by adopting this approach.

JULY 2016

MACHINE TOOLS WORLD

COMPANY SPOTLIGHT

We are for those, who are in

Metal Cutting!

tarted in 1999 at Pune, Accusharp Cutting Tools Pvt. Ltd; stands today as a leading company, in design, manufacture & supply of special cutting tools in HSS and Tungsten carbide for Automobile, Engineering, Textile, Energy Sector, Machine Tools Industries, etc. Our business objective is to assist customers for their productivity improvement coupled with reduced tooling cost. Our business strength lies in 3-‘P’s - i.e. Products, Process, & People. Products: Having quality to meet customers’ expectations. Processes: With modern equipment of high efficiency.

MACHINE TOOLS WORLD JULY 2016

People: With competence and passion for the organisional objectives. Professional team of competent application engineers provide unmitigated solutions for metal cutting processes for customers. Manufacturing setup consists of modern equipment, like, 5-Axes CNC Tool & Cutter Grinders - ANCA, WIDMA, Rollomatic, Strausak-, and Zoller Geninus3, & Rapid-I, as Q.C. equipment. We strongly believe, that customer is our first concern. For a number of MNC’s & OEM, as well as other satisfied customers, we have established strong support teams across India, and logistic network, a step closer to customers.

Accusharp Cutting Tools Pvt. Ltd. is a company certified for ISO: 9001-2008 for QMS. Environment, Industrial Safety, Health of employees and Social Responsibility hold an integral part of all our business operations. We have been approved by a number of MNCs for their audits of Safety, Environment, Supplier Code of Conduct aspects. And this remains as our work culture.

For more information, Website: www.accusharp.co.in

Group GROB based y o n a rer f rm ufactu , offering The Ge g man es in d in a h is a le al mac epts univers g conc in in h 5-axis c a e and m v e ti v o ti innova Mold, Autom & for Die ustries. d allied in

G-Series

Precision at the highest level

A promising future with the G-series

Contact: GROB-WERKE GmbH & Co. KG Mindelheim, GERMANY Phone: +49 8261 996-0 E-Mail: info@de.grobgroup.com GROB Machine Tools India Pvt. Ltd. Hyderabad, INDIA Phone: +91 40 4202-3336 E-Mail: info@in.grobgroup.com

GROB_Indien_Anzeige_Magazin_die_and_mould_Maerz_2016_DINA4.indd 1

GROB 5-axis universal machining centers stand out due to their absolute precision and reliability in the automotive, medical and mechanical engineering industries, in tool and mold making as well as in the aviation industry. The proven 5-axis simultaneous technology with horizontal spindle position enables you to machine parts of various sizes and materials in a flexible and failure-free way while offering maximum stability of the machine. Fast chip-to-chip times and the innovative further development of our spindle technology guarantee a high economic efficiency and productivity. The GROB G-series â&#x20AC;&#x201C; for the most versatile machining possibilities.

www.grobgroup.com

17.03.2016 15:51:15

INDUSTRY FOCUS

Mastercam 2017: Discover the best features at IMTS This year’s IMTS will feature the latest in the line of powerful Mastercam machining software

f you stop by booth # E-3340 at McCormick Place, Chicago, IL, September 12-17 for a look at Mastercam 2017, the latest release, you will discover a more efficient workflow, improved usability, dynamic motion improvements, and much more. Meghan West, President of CNC Software, will be presenting Acquaint, Convince, and Excite: ACE the Next Generation of Manufacturing on Thursday, September 15th from 3:15 – 4:10 PM in Room W194-A. Learn about the increasing “skill gap” in manufacturing and ways to can get students excited about a career in manufacturing. Come talk with us about aerospace manufacturing at the TRAM Aerospace Conference in Room W375-B. And lastly, one must also visit the educational booth at the Smart Source Student Summit.

Designed for faster workflow Mastercam 2017 features a new ribbon interface and makes it easier to find the functions you need to complete your tasks. “Many of our more powerful tools

MACHINE TOOLS WORLD JULY 2016

were underused because customers did not know where to find them,” says CNC Software President, Meghan West. “We spent a lot of time with users determining the best way to simplify this, and the response has been overwhelmingly positive.” The ribbon tabs group similar functions and displays them in order from simple to more complex. Each tab relates to a type of activity, from creating wireframe geometry to generating toolpaths. Editing functions are on the same tab as creation functions so you have all the tools you need, when you need them.

Dynamic Motion Technology Mastercam’s Dynamic Motion technology can slash machine time by as much as 75%. And, Dynamic Motion will help you get the most out of any machine in your shop—new or old. Mastercam’s Dynamic Motion technology extends tool life, reduces cycle time, saves wear and tear on machines, and cuts hard materials more easily. New to 2017, micro lifts now use

a line-of-sight approach to move the tool where it needs to go through unobstructed areas. This results in reposition moves during micro lifting that are more efficient, less complex, and travel a shorter distance.

Complex Machining Made Easy Mastercam 2017 introduces Maximum Stock Engagement for select 3D HST Finishing toolpaths, allowing you to select a previously made stock model and set the maximum depth so that you can limit how deeply the cutter engages uncut material. HST Raster allows you to limit raster passes relative to a cutoff distance, and then fills in the limited area with perpendicular raster motion to create a clean result. Mastercam Mill-Turn now supports multiple sessions, multiple Machine Groups, and multi-station tool locators for turrets as well as half index positions. New features have been added to Multiaxis Drill, such as using a line length for the drill depth and recognition of the stock model for depth and top of stock purposes.

MEASUREMENT ERROR

MEASUREMENT PRECISION The non-contact Mida ML75P laser tool pre-setting and verification system is the key to maintaining the micrometric accuracy required by the most demanding machining applications, as in the aerospace field. You get consistent quality, less waste and more profit. Marposs means precision.

www.marposs.com

Y O U R G L O B A L M E T R O L O G Y PA R T N E R

MARPOSS INDIA Pvt. Ltd. 147, Sector 7, IMT MANESAR 122 050 - Tel. +91 124 4735700 |sales@in.marposs.com

INDUSTRY FOCUS

Innovations in Operations & Maintenance Choosing the right lubricant can result in significant benefits in terms of improved efficiency, equipment protection and profitability By Akhil Jha, Vice President Technical, Shell Lubricants India

perations and Maintenance as an industrial function, comprises of a broad spectrum of activities required to assure that the set-up, equipment and parts of a factory/unit perform the functions for which the facility was constructed. Typically, O&M comprises of a host of everyday activities necessary to operate and maintain a building and its systems. There are multiple benefits that timely maintenance practices bring to the table â&#x20AC;&#x201C; these ensure maximum utilization of capital investment; minimized factory down time; increased efficiency and profits, as well as the safety of employees handling heavy machinery.

Changing face of Indian Industries With the advent of newer technological

MACHINE TOOLS WORLD JULY 2016

innovations and changing industry requirements, there has been a paradigm shift in the way Indian industries are functioning â&#x20AC;&#x201C; digital technology has caught the industryâ&#x20AC;&#x2122;s attention; there is a greater focus on sustainable development; and equipment requirements are rapidly evolving. In particular, with the changing emission norms and a greater demand for reliable equipment and reduced operational costs, OEMs and customers are facing numerous challenges that are compelling them to change their standard operating procedures. In the near future, there will be many cases where the equipment and systems belonging to the previous technology generations will be unable to meet the new requirements. This is the main challenge that customers are facing in their day-to-day operations. For industrial decision-makers, this calls for changes in the equipment hardware designs as well as external requirements. The nature of these changes varies depending on industrystipulated emission levels, energy efficiency demands of customers, total cost of operation, reliability of equipment, and a shift towards renewable energy. Equipment manufacturers are constantly evolving their offerings to suit these factors. This brings in the additional challenge for makers of ancillary products to provide their patrons with the most advanced tailor-made offerings, as per the changing industry requirements.

Importance of Lubricants and the Shell offer Considering the time, effort and resources that go into running any industrial unit, it is relatively simple to understand that factors like machine availability, efficiency and capacity are becoming more and more important with each passing day. Customers need equipment to be more reliable, costeffective and there is a greater focus on making operations more sustainable and environment friendly. Lubricants have a critical and ongoing role to play in this process and can have a significant impact on the operation of equipment in any industrial unit. Choosing the right lubricant can result in significant benefits in terms of improved efficiency, equipment protection and profitability. At Shell Lubricants India, we offer a broad range of market leading products, ranging from the latest synthetic products to mainstream lubricants. All of these products have been designed with years of global R&D and are meant to optimise equipment performance and cost efficiency for industry. Additionally, we often work closely with original equipment manufacturers (OEMs) to develop products to fit their needs. Our collaboration and our experience in working with customers have enabled us to understand the challenges in operation and maintenance activities, in line with the actual needs of the equipment and its life cycle performance.

THE EMAG VL-MACHINES MAXIMUM PERFORMANCE GUARANTEED HIGH STRENGTH

FULL AUTOMATION

SIMPLE HANDLING

COMPACT

VERTICAL MACHINING: SAFE AND EFFICIENT

HIGHLIGHTS + + + +

Machining of chuck parts = Standardised machine platform Small footprint = Reduced floor space cost Integrated automation = No additional cost Simple workpiece conveyor & interlinking = Flexibility and lower automation costs

+ Short traverse distances = Minimal idle time, high performance

+ Operator friendly = Quick set-up, change-over + Standardised parts strategy = Low maintenance costs + High energy efficiency = Reduced energy cost

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

INDUSTRY FOCUS Major innovations in the industry In particular, if we talk about the power sector, the feed-in of electricity by distributed generators increasingly poses new challenges to distribution companies and generator manufacturers, particularly in light of the volatility of renewables-based power generation. Consequently, interventions to stabilize the grid are required much more frequently than they were in the past. There are numerous complex tasks entrusted to grid operators - they are required to manage loads, keep voltage stable across the system, guarantee security of supply, and avoid plant shutdowns. What is required in such a situation is an innovative, flexible, and scalable solution with smart control functions for distributed plants. Significant improvements in performance and cost-effectiveness can be achieved by applying new technical solutions to existing plant elements. For example, advanced engineering simulation systems, such as thermal modelling, have greatly improved the life of mechanical components in steam turbines and increased the power output.

MACHINE TOOLS WORLD JULY 2016

While the technology trends increase the turbine efficiency, the turbine OEMs are demanding good quality lubricants which can provide longer oil life, reduced varnish formation, improve surface properties, and provide inservice monitoring, etc. A recent study suggests that as many as one-third of all units show some signs of oil varnishing. To keep a check on this, the right course of action is to set up special oil condition monitoring program for analyzing the trending in the initial days. An oil condition monitoring program should be part of the maintenance schedule, and should comprise of a combination of inspection and oil analysis. Field experience indicates that turbines that are being operated at higher operating temperature are more susceptible to oil varnishing. This is due to thermal degradation of the oil. In addition to oil products, we at Shell Lubricants also offer services such as support with commissioning, flushing, filling and filtration, equipment inspection LubeExpert service and ongoing oil condition monitoring through LubeAnalyst, Oil Change unit for oil replacement in wind turbine.

Akhil Jha is the Vice President Technical for Shell Lubricants business in India. His current job portfolio includes representing Shell Lubricants as technology leader by Application & Partnership, building technology relationship & technical intimacy with customers & OEMs. At Shell Lubricants, Akhil leads a team of Lubricants Technical Advisors to deliver 1st class superior technical support to the customers across lines of businesses. Akhil has been with Shell Lubricants for more than twelve years now. Prior to Shell, Akhil has around ten years of experience working with Hindustan Petroleum Corporation Limited where he was responsible for technical support to commercial fuels & lubricants business for eastern and then western part of India. Akhil has studied at NIT Jamshedpur & IIM Calcutta. He has also been awarded Fellowship by The Institution of Engineers (India). Besides work, his other interests include books, music, travel & photography.

THE ALTERNATIVE TO TURNING

HIGH-SPEED PLUNGE-CUT GRINDING Machining complex contours using grinding instead of turning technology offers two decisive benefits: The grinding concept is up to three times faster, and the long service life of profile grinding wheels ensures optimum availability.

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

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

INTERFACE

MEHTA CAD CAM:

The legacy of excellence

e believe that Fiber laser technology is the best example of ‘Benefits to the common people because of the revolution and development in technology’. Fiber laser technology has made tremendous revolution in cutting, marking, engraving and welding requirement. The major advantages of Fiber laser technology is, it has very long life, trouble and maintenance free, better laser beam quality, super performance and lower cost. Because of this advantages Fiber laser technology is becoming very popular world wide in many applications along with cutting, marking and welding. Mehta Cad Cam Systems Pvt ltd is the oldest and largest company in laser and CNC technology feel pride to have its roll in spreading the advantages of Fiber laser technology to common users and made them beneficial. Mehta’s metal laser cutting machines,

MACHINE TOOLS WORLD JULY 2016

marking machines and welding machines are equipped with most latest fiber laser source which is not just lowest in price but also provide the best and maintenance free performance. Mehta Cad Cam has its H.O and two manufacturing facilities at Ahmedabad and 20 Branch offices across all India to provide quick sales and service support. Mehta Cad Cam is growing very fast in these industries. Their manufactured Fiber laser metal cutting machine – “Gloria” and marking machine –“ Evan” are not just becoming popular in Indian market but in some countries like Egypt, Kuwait, Dubai, etc. Fiber Laser metal cutting machine can cut SS,MS, Aluminium, copper, Brass etc. The different power of fiber sources can cut various thickness at a different speed. We have list down the table showing the power, cutting thickness and speed parameters as follows:

Mr. Shailesh Mehta, CEO, Mehta Cad Cam Systems Pvt. Ltd. The good news is the customer who wants to cut SS less than 1.5 mm and MS less than 2 mm thickness need not to go for more than 300w fiber laser source and Mehta’s Gloria series can be available less than Just Rs. 30 lakhs. We believe its really a good news for them. Gloria Fiber laser metal cutting machine are made in different size and capacity to fulfil various requirement of the customers. They have a complete solution to cut SS and carbon steel from less than 1 mm to 10 mm of thickness. Gloria laser cutting machine are equipped with 300 w, 500w, 750w, 1000w, 1200w and upto 2000 w and Evan laser marking are available from 10 w to 50w as per the requirement of the depth to be created. Its a great time for all users of metal sheets processing to have in house facility of Mehta’s Fiber laser cutting machine instead of giving a job work outside to save time, energy and money. They have several installations in Maharashtra side and north in Delhi side. Mehta Cad Cam provides 2 years warranty on there all range of products. The best quality, the best service support and lower the price keep Mehta Cad Cam on the top in Indian Engineering industries.

INTERFACE www.mtwmag.com

Mr.

Shailesh Mehta

CEO, Mehta Cad Cam Systems Pvt.Ltd.

My Life’s Goals

the leadership in these industries.

Aim & Ambition: Keep growing, I strongly believe growth brings happiness and happiness brings peace. It requires to be happy and energetic to keep ourselves engage in for the new innovation. Love your work and work you love. Life cannot be separated - family and business, business time and family time, it should go all together. A happy person only can spread happiness around.

Social Goal: Before I try to make other people enrich and happy, I would like to make my people happy who stood up continuously and consistently with me and our company who itself are my society. I wish our company contribute regularly to the people who are the victim of natural disasters.

Vision: Mehta Cad Cam to be one of the world class organization. I am passionate about my work/company. We want to grow more and more in the field of laser cutting, laser making, laser welding, CNC router and digital printing technology and striving for maintaining

Business Goal: Leadership in the field of CNC, laser and digital printing technology not only in Indian market but also in international market all over the world. Innovating, developing and distributing high end technology in laser cutting, laser marking, laser welding, CNC router and digital printing making it more stable and af-

fordable. We want to provide complete solution with regards to equipments, its consumables and accessories and also related technology which help our customer to grow time to time so we as well.

My Leisure Choices I would love to do jogging and exercise keeping myself fit, energetic and young and the best is spending time with family. Also love to play tennis and table tennis and listening music.

Ask My Taste Buds Favourite Food: Italian Pizza and Pastas and Kathiyawadi Gujarati Food.

In Awe of Mahatma Gandhi who stands for his word “Freedom of India” throughout his life.

JULY 2016

MACHINE TOOLS WORLD

BEST OF YESTERYEAR

Innovations in

centerless grinding machine

& its operations

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.

by Harsh Badani, Technical Director, Solitaire Machine Tools Ltd., Vadodara

• 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 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

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.

MACHINE TOOLS WORLD JULY 2016

Diamond Roll Dresser

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

BEST OF YESTERYEAR

Linear Guideway

Servo Regulating Wheel Drive (Power + Employees + Overheads) + Consumables (Hydraulic Oil + Coolant + Grinding wheel + Regulating 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

MACHINE TOOLS WORLD JULY 2016

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.

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

BEST OF YESTERYEAR

Ceramic Coatings

from Spraymet for Refurbishing Machine Tool Parts

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

achine Tool Industry has undergone major developments in providing enhanced service life to spindles, arbors, bearings, etc. Ceramic Coatings by Plasma Spray have been in use in many industries since 1960. Since last decade, this process and ceramic coatings are being used to provide surfaces to seal areas of spindles, contact faces of arbors and electrical and heat insulation to bearings. Apart from OEM level coatings, many user industries are using ceramic coating for refurbishing of spindles and other machine tool parts. Typical Spray Materials used with Plasma Spray

Metals and its alloys: Steels, Ni alloys, Co alloys, Moy, bronze, copper, Babbit, etc. Ceramics: Chromium Oxide, Aluminium Oxide, Al Oxide + TiO2, ZrO2, etc. Carbides: Tungsten carbide, Cromium carbide, TiC Hardness range of coatings: From SOFT 60Rb (Bronze) to HARD 70 Rc (ungsten carbide) Benefits of Plasma Sprayed Ceramic over Hard Chrome

Environmental: Less hazardous as there is no Hexavalent chrome involved dust disposal; easier than bath liquid. Performance: 3-4 Times more wear resistant than Hard-chrome; Micro porosity holds lubrication; Selective area coating is possible; Higher thickness up to 300 microns per side is possible.

MACHINE TOOLS WORLD JULY 2016

Limitations: Ceramics are brittle and are to be handled carefully. The process is not as widely available as hard-chrome. Spraymet Surface Technologies

Bangalore-based Spraymet Surface Technologies Pvt. Ltd., headed by Mr. P.T. Bindagi, Technical Director and a veteran metallurgist, is engaged in thermal spray, ENP plating and weld surfacing. While their main plant is in Bangalore, the second plant is located in Pune, to stay closer to its customers especially from the automobile sector which is demanding technical excellence, proximity and service all at the same time. Spraymet has the distinction of having pioneered the carbide

coatings in the steel mills and galvanizing line roll coating. Spraymet owns a few proprietary coatings like Moly bend (Spraymet MoB) for metal-to-metal wear, and Ductile matrix carbide (Spraymet DMC) for plastic process feed screws. Mr. Bindagi is working towards expanding applications in turbine industry, medical implants, and other frontiers. In his quest to spread knowledge, Mr. Bindagi also picks students from universities for project work related to tribology and wear metallurgy. Spraymet has helped the industry save a lot of money and helped conserve its scarce resources. â&#x20AC;&#x201C; P.K. Balasubbramaniian

BEST OF YESTERYEAR

Robotics in machine tending By Arjun Prakash, Director, Effica Automation Ltd., Coimbatore

he advent of continuously falling prices in electronics and power electronics combined with the ever increasing cost and scarcity of labour has certainly pushed us into the age of robotics. The fact that China, a country where all economic factors were identical to that of Indiaâ&#x20AC;&#x2122;s in the 1980s and a country that was known in the past decades as the worldâ&#x20AC;&#x2122;s manufacturing hub due to its low labour costs, is today also the worldâ&#x20AC;&#x2122;s largest consumer of industrial robots. This itself is a proof that we have already entered the age of robotics. They say people should think and machines must work. The youth of our country certainly have great aspirations and a job as menial as pick and place certainly does neither inspire them nor provide enough value addition to the end product to justify a fat paycheque. This is where robotics fits in with machine tending. Most CNC machines installed in India are typically used for mass production where a few variants of the same type of part are manufactured for long periods of time with no changes in design or dimensions. A CNC machine operator typically even with some knowledge of programming the machine is reduced

Part stacking magazines for various types of components

to the task of loading the machine and unloading the machine. This is certainly a waste of talent. Robotic machine tending

Robotic machine tending is the process of loading and unloading components for all types of industrial machines including CNC machining centers. The greatest advantage that is derived in the Indian context is the increased uptime from the CNC machine. Industrial Robots are generally not much faster than the human counterparts when they are timed on a single operation. But practically

Multiple CNCs machines can be handled based on cycle time. 58

MACHINE TOOLS WORLD JULY 2016

when you factor in human fatigue, refreshment breaks, inefficient night shifts and absenteeism in India, Robot users experience as much as 30 percent increase in machine uptime. In projects where one robot caters to 3 CNC machines, this is equivalent of getting one more CNC machine. With robotic machine tending solutions in India falling below CNC machine prices, this translates to instant breakeven from machine uptime alone. The manpower savings is completely a bonus. This is of course only true when factors like machining cycle time, CNC machine cost, payload and required reach permit it, but in most cases a major portion of the breakeven is achieved from the machine uptime alone. But of course this does not mean that implementing a robotic machine tending project is as simple as writing out a cheque. There are many technical considerations that need to be given careful thought and analysis. First, if a robot loads a CNC machine without human intervention, then we need to have a part stacking system so that the robot can operate at least a few hours without human presence before the entire stack is replenished again by a human. The same hold true

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

BEST OF YESTERYEAR at the unloading side, where machined components have to be emptied time and again. Since robots programmed to pick or place the component at fixed location within a few microns accuracy and with the correct orientation to grip, the part stacking magazines need to be designed in such a manner that they accommodate the part. This can often be a challenge with castings and other molded products where flash is a hindrance. The shape of the product is also a consideration where it is not possible to stack in the correct gripping orientation with good volumetric efficiency of stacking. This is important as robots have a predefined reach. The other big hindrance can be the presence of burr after the machining operation. Burr is normally cleaned using a hand operated air gun manually. This can of course be automated by fitting an air jet on the robot, but the cycle time lost due to that should be kept in mind. If there is a possibility to fit permanent air nozzles close to the chucks and fixtures inside the CNC, where burr is typically a hindrance to the process, then it should be preferred. But sometimes even this does not solve the problems. In some types of steel and aluminium burr formation is often long coils and this gets stuck in chucks and fixture where heavy force

is required to clear it. This should be solved either by tool geometry design (Chip breaking inserts) or by poke-yoke deflectors before the machine tending project is taken up. Gripping in CNC machine tending is a straight forward process most of the time. Various types of two jaw and 3 jaw grippers are available. 3 jaw grippers are suitable for ID and OD gripping and 2 jaw grippers are suitable to hold long shafts. But again casting burr will lead to improper centering in 3 jaw grippers. This is a problem when the chuck center does not align with the part center. Even if sufficient clearance is provided in the chuck opening , enormous forces are subjected upon the robot wrist as the robot tries to resist the pulling related to the offset. This can be overcome using an offset compensator device.

Burr can sometimes be a serious hindrance to automatic machine tending

A typical compliance unit to compensate for component offset with respect to chuck Other considerations

Other considerations to be factored in are to ensure the safety of human operators. Since robotic accidents can even be fatal, it is important to completely cordon off the area with safety fences. Despite this, human access will be required, in the form of refilling and emptying magazine stacks. CNC machines also require frequent tool offset resetting and other minor changes. Doors and other openings need to be interlocked with safety switches and sensors. Conclusion

A complete robotic cell tending to two CNC turning centers 60

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Finally having invested a great deal on the CNC machines and the machine tending project, it is always good to give some more thought to optimize the areas that tend to slow down the entire process. Non-machining activity like door open / close, chuck open close and where applicable tail stock and other accessories must be optimised for automatic operations and their speed can be considerably increased as sensors can be used to interlock their operation and prevent collision. The process of tool offset resetting should also be automated where it is very frequent, as no human should be present in an automated cell with 2 or 3 CNCs and one robot, or else the entire cell will come to a standstill while fixing one machine.

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New Milestones in

Microfinishing - Precision

engineered finish for automotive powertrain parts Preamble

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

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

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

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

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

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Meeting Advanced Specifications of State-

Bearing ratio is illustrated in the figure

of-the-Art Crankshafts

below :

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

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

Reducing Friction requires the following features on the crankshaft :

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

MACHINE TOOLS WORLD JULY 2016

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

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

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

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

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

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

MACHINE TOOLS WORLD JULY 2016

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

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

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

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

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

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The New Generation of

Angle Encoders with Integral Bearing By A.P. Jàyanthram, Managing Director, Heidenhain Optics & Electronics India Pvt. Ltd.

Figure 1: Aufmacherbild: The new family of angle encoders with integral bearing

EIDENHAIN’s angle encoders with integral bearing have long been the standard for applications where angular measurement in the range of a few angular seconds is necessary. The encoders are characterized by their simple mounting and very high accuracy. Particularly on rotational axes in machine tools, such as rotary tables and tilting axes, they are the best solution for position and speed control. HEIDENHAIN has now developed a new generation of absolute angle encoders with integral bearing based on the field-proven encoders. The goal was to retain the positive properties of the angle encoders while at the same time adding numerous new and useful features. So that the new encoders can be used in existing machine designs, it was ensured that their

dimensions are compatible to those of their predecessors. Comprehensive analyses and simulations were necessary in order to set another milestone in angular metrology. The knowledge thus gained resulted in a new generation of angle encoders that is completely different from the previous generation: not a single component remained the same. The new, absolute RCN 2000, RCN 5000 and RCN 8000 angle encoders have shafts ranging from 20 mm to 100 mm in diameter, and are characterized by numerous outstanding properties regarding scanning, design and signal interface. Scanning

The new angle encoders of the RCN series operate with two graduation tracks. The

absolute position data on the circular scale is encrypted on one track and never recurs within the same revolution. The additional incremental, higher resolution track is scanned according to the single-field scanning principle. The scanning signals of the incremental fine track are interpolated for the position value and are processed together with the information from the serial code track to obtain absolute position values of high resolution. This enables, for example, the RCN 8000 to measure to a resolution of more than 536 million positions per revolution. Thanks to the special optical filtering of the innovative scanning components, the encoder produces scanning signals of very high quality. Test results with the new RCN encoders show that the position accuracy relevant to feedback control, often described as position error within one signal period, is typically superior to the absolute angle encoders of the respective previous series by a factor of three. The optimized scanning now makes it possible to specify the subdivision accuracy values as better than ±0.5% (the value for the previous RCN encoders was ±1%). Particularly on direct drives, the high signal quality has positive effects on the control behavior and results in noticeable quality improvements of the finished workpiece surfaces. Although the angle encoders with integral bearing are sealed and feature the IP64 degree of protection, the contamination risk was to be reduced further to the point that this risk could practically be excluded. This goal was met with single-field scanning, which

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BEST OF YESTERYEAR is characterized by its improved signal quality and a significantly reduced sensitivity to contamination. This has been achieved through large scanning windows and the special arrangement of the scanning fields. Even relatively large contaminated areas result only in slightly weaker scanning signals and somewhat increased signal deviations. In many cases, depending on the contamination, this can even prevent encoder failure where four-field scanning, which up to now was used in the angle encoders with integral bearings, cannot. The results of testing with the angle encoders are also confirmed by positive experience with linear encoders, which have been using this scanning principle for some time now. To be able to meet the growing demands for better performance on machine tools, design engineers are increasingly using rotational axes that distinguish themselves through high accuracy and high rotational speed. They are intended, for example, to make it economical to run milling and turning operations on the same machine. The new, absolute angle encoders fulfill these demands as well. The single-field scanning and the new scanning and evaluation electronics made it possible to dramatically reduce the influence of the rotational speed on the generation of position values. This ensures that, even at high speeds, the scanning signals have a high signal quality and continue to interpolate well. For example, the RCN 2000 with its purely serial interface achieves speeds up to 3000 min-1.

Figure 2: Single-field scanning principle

MACHINE TOOLS WORLD JULY 2016

Design

The simple mounting of the new angle encoders is also impressive. Unlike the modular angle encoders, which usually consist only of a scanning unit and a graduation carrier, the hollow-shaft angle encoders with integral bearing feature an integrated stator coupling. In this way it is ensured that the components involved in scanning are ideally aligned to each other, even if there are deviations within the defined mating tolerances of the shaft coupling. Radial and axial error in the measured shaft is assimilated in the stator coupling so that the coupling remains free of torsional rotation. The new stator coupling, conceived and developed for the RCN encoders is characterized in its axial and radial deflection and torsional rigidity by excellent behavior and operates virtually without angular error. This permits relatively generous mounting tolerances without limiting the function or accuracy. For example, together with the encoder sealing technique, which is also new, it can tolerate deviations in axial direction of up to ±0.3 mm. The new angle encoders have an even more impressive set of design details. The encoders feature a plug-in cable assembly. Because the separate adapter cable has a quick disconnect (push-pull design), mounting the plug-in cable assembly to the encoder is very simple. No tools are needed. At the same time, the connecting element has a high leak tightness of IP67, preventing ingress of liquids through this connection. The advantages of the plug-in cable assembly are particularly evident when a cable has to be routed through a tight installation space during mounting. The machine tool manufacturer is also more likely to have the encoder on hand because it can be ordered separately and stocked without regard to a specific cable length or type of connecting element. The RCN 5000 series consists of angle encoders with compact overall dimensions but large hollow shafts. With a hollow shaft diameter of 35 mm, the crosssection of the RCN 5000 encoders is over three times larger than that of the RCN 2000 encoders, whose hollow shaft only

measures 20 mm. This means that there is more room for stiffer machine shafts and hydraulic leads, which are frequently led through hollow shafts. Interface

The bidirectional EnDat interface enables the encoder to configure itself during installation without additional transmission lines, since all encoder-specific information such as resolution, ID number, etc. is stored in the encoder and transmitted to the subsequent electronics via EnDat. In addition, it is possible to extensively monitor and diagnose the encoder. For example, the encoder generates warnings when it nears certain tolerance limits before it transmits any incorrect position values. Valuation numbers can be read from the encoder cyclically for diagnostic purposes. The valuation numbers provide the current state of the encoder and ascertain the encoder’s “functional reserves.” The monitoring and diagnostics can be used to signal the need for preventive maintenance, and can prevent unnecessary maintenance cycles. This increases machine availability. Cables with M12 connecting elements at the ends can also be used with the purely serial EnDat interface. This enables you to replace the previously common M23 connectors with smaller connecting elements. Safety Technology

The benefits of a purely serial interface can also be used for safety-related applications. Safety-related applications require axes with redundant position information. To obtain independent position values, HEIDENHAIN has decided upon a singleencoder design because two encoders per axis would be both more expensive and unnecessary. HEIDENHAIN is currently the only manufacturer who can offer purely serial single-encoder solutions for safety-related applications. For the single-encoder version, two independently generated, absolute position values are provided to the safe control (e.g. the iTNC 530 HSCI from HEIDENHAIN) via the EnDat protocol. This makes it possible to realize a purely digital machine with safe

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Figure 3: RCN 5000 series with plug-in electrical connection absolute positions. In addition to the data interface, the mechanical connection of the encoder to the motor is also relevant to safety, since it is not guaranteed that such faults can be detected by the control. Therefore HEIDENHAIN secures the encoders with special methods that fulfill the requirements for excluding the possibility of the mechanical connection coming loose. The new RCN encoders with functional safety will be available soon. They can be operated as single-encoder systems in combination with a safe control in applications with control category SIL-2 (according to EN 61 508) or performance level “d” (of EN ISO 13 849). They form a qualified subsystem within the larger “safe drive” system. It greatly simplifies the evaluation and realization of safety-related processes for the machine tool builder. This makes a simple, purely serial solution possible, especially for axes with direct drive. Summary

The new series of angle encoders with integral bearing distinguish themselves with numerous impressive characteristics. Thanks to the new scanning process, the signal quality is improved once more, the tolerance to contamination is optimized, and higher shaft speeds are permitted. The relatively large mounting tolerances and the plug-in cable assembly help make mounting much easier. The EnDat interface with its diagnostic capabilities enables preventive monitoring of the encoder without requiring an additional transmission line. Encoders with purely serial interface can also be installed as qualified subsystems in safety-related applications. There is also the new RCN 5000 series, whose hollow shaft with a diameter of 35 mm is impressive considering its compact outside dimensions. The RCN 5000 will prove to be the proper angle encoder for a multiplicity of applications, and will likely even replace many absolute angle encoders with a hollow-shaft diameter of 20 mm.

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Recent developments in

metalworking fluids By Ashok Kumar With the growing rate of industrialization, metal working fluids, commonly known as cutting fluids, continue to be extensively used in machining industries even after the development of advanced processing techniques such as MQL and dry machining.

etal working fluid (MWF) is the name given to a range of oils and other liquids that are used to cool and/or lubricate metal workpieces when they are being machined, ground, milled, etc. MWFs reduce the heat and friction between the cutting tool and the workpiece, and help prevent burning and smoking. Applying MWFs also helps in improving the quality of the workpiece by continuously removing the fines, chips, and swarfs from the tool being used and the surface of the workpiece. Swarfs are the small pieces of metal removed from a workpiece by a cutting tool. With the growing rate of industrialization, metal working fluids, commonly known as cutting fluids, continue to be extensively used in machining industries even after the development of advanced processing techniques such as MQL and dry machining.

The mechanics of metalworking

The mechanics of metalworking which governs the requirements for metalworking fluids includes (i) the bility of the fluid to provide a layer of lubricant to act as a cushion between the workpiece and the tool, in order to reduce friction, (ii) functions as a coolant to reduce the heat produced during machining or forming, (iii) prevent metal pick up on both the tool and workpiece by flushing away the chips as they are produced, (iv) produce the desired finish on an accurate

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piece-part. The impetus in the days of the industrial revolution, is to machine or form part at the highest rate of speed with maximum tool life, minimum downtime and the fewest possible part rejects (scrap), all while maintaining accuracy and finish requirements, which can only be achieved by metalworking fluids properties. In metalworking processes, the use of mineral, synthetic and semi-synthetic cutting fluids have gained widespread acceptance. However, the harmful effects and high risk of life threatening occupational hazards to the machinists as well as causing environmental degradation is discouraging to continue its use in the near future. As mentioned above, MWFs are primarily used for three reasons â&#x20AC;&#x201C;viz; to remove heat during machining operation, to provide lubricating effect and to facilitate faster chip removal from the machined zone. While MWFs enhance the tool life and reduce the cost of machining operation, it is posing a very serious threat to the health and safety of machinists as well as to the environment. As a result, there is tremendous pressure from global energy authorities and environmental protection agencies to develop bio based alternatives or any other alternative to the presently cutting fluids. It has also gained worldwide importance, making green manufacturingâ&#x20AC;&#x201C;a philosophical process.

The entry and dominance of new, modified, cost effective petroleum and synthetic chemical based cutting fluid has still worsened this condition. A study conducted by the Occupational Safety and Health Administration (OSHA) agency reveals that the detrimental effects of the conventional lubricants, till date, has given rise to sixty three identifiable health hazards such as skin infection, allergy, acute respiratory disorders etc. Another major problem associated with this, is the disposal of cutting fluids to the environment. The discharge of these nonbiodegradable cutting fluids can widely affect the environment due to hazardous metal carry-off, reduction of nutrients in the soil and oxygen depletion. Research & Development

Research and development efforts are going on throughout the world to find metal-working fluids that eliminate these problems. One proposed solution is to develop a cutting fluid from microalgae oil. Although there are a large number of vegetable oil based cutting fluids available in the market, the sustainability of its production is questionable due to factors such as farm land utilization where food

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crops are cultivated and soil fertility depletion. The susceptibility of MWFs to biological contamination and the potential for this to lead to health risks associated with bio-aerosols and infection from hazardous microbial species calls for new technology to detect microbial growth in real-time. The fast response is especially important since microbial outbreaks can occur faster than dip-slides can detect harmful microbial species. In the future, we believe that applications of flow cytometry will offer the opportunity to conduct real-time analysis of microbial species and total biomass load. These challenges have encouraged researchers for the development of a more sustainable bio based alternative. The use of algae based third generation bio-lubricants allows effective utilization of industrial waste water and sewage sludge material, which is otherwise hazardous to the aquatic fauna when discharged to the surrounding environment. Minimum quantity lubrication (MQL) techniques represent another growing class of EALs (environmentally adapted lubricatns). MQL typically involves sprays of compressed air and a small amount of oil to provide the function of a MWF without the large volumes of aqueous waste. However, air is an inefficient coolant and today’s oil-inair MQL systems are only suitable for mild machining operations that do not require significant heat removal. Therefore research is currently focused on developing new approaches that extend the reach of MQL to more intense machining processes. MQL technologies are relatively new and therefore face technical and economic barriers to implementation. They require new delivery systems dissimilar to those used for aqueous systems. Pilot-scale implementation has shown that MQL systems are less expensive to operate but require significant capital investments in both infrastructure and expertise. Unless environmental and health costs are considered, many companies have considered these costs too high to warrant

switching from current systems. Still some manufacturers are making significant investments in MQL due to cost savings and higher performance, as well as for environmental and worker health reasons. Several other large OEM and supplier companies are currently following suit. The environmental, health, performance, and economic benefits of switching from water-based systems to gas-based MQL systems have been observed in industry. The cost savings mostly arise by eliminating major infrastructure components in the plant, which represent a significant fraction of water-based MWF system costs. This is important since life cycle MWF costs can represent 10-17% of metals manufacturing costs. Delivery of minimum quantities of lubricants using a spray of air (also called near dry machining) reduces purchase and operational costs while dramatically reducing energy consumption at the MWF system level. MQL systems are even claimed to increase safety and operator morale, largely from the elimination of mist and other oily waste associated with flood delivery of water-based MWFs. To date however, MQL has only been adopted on a limited basis because most workers are not familiar with how to design and implement MQL systems. Technical questions also remain about how to achieve sufficient cooling using MQL in challenging machining operations involving advanced materials. Some form of contaminant control and chemical addition is almost always performed in recirculating MWF systems, driven by costs of MWF acquisition and disposal. In an ideal MWF system, such control systems would achieve a perfect separation of contaminants and return the MWF to its “as new” state. However, contaminant removal on its own cannot address issues such as accumulation of hardness ions, evaporation, pH reduction due to microbial growth, and loss of surfactants. Therefore, even under ideal separation, direct chemical maintenance and biological control is required to extend the life of the MWF. Microfiltration is a membrane-based

separation technology that can not only remove microorganisms, but can also remove contaminant particles and free oil from MWF to produce a high quality recyclate. A major difference between conventional filtration and membrane filtration is that conventional filters operate by capturing particles within a filter matrix, and the filters cannot be regenerated after use. Membrane filtration is typically performed with filtration tangential to the channels of bulk fluid flow. This crossflow mode of operation discourages the accumulation of particles within the filter matrix, and the separation takes place at the surface Membranes can be cleaned and re-used for long periods of time, and essentially indefinitely for ceramic membranes. Therefore, rather than filter clogging with contaminants, the principal limitation to high filtration rates in microfiltration and ultrafiltration is the physical-chemical interaction of MWF ingredients with the membrane surface. Membrane filtration processes, while challenging, have proven to be able to restore the MWF to “good as new” condition. For instance, research has demonstrated the technical feasibility of using ceramic microfiltration membranes to supplement or replace biocides and other treatment technologies as a means to control MWF contamination and create a recycled MWF indistinguishable from new MWFs. However the primary limitation to wider application of membrane filtration technology is its sensitivity to MWF formulation design, particularly to the selection of oils and surfactants and their application concentration. While we know how to design semi-synthetic MWFs to greatly increase their flowrates through microfiltration membranes, no commercially available MWFs have yet used this sustainable MWF design approach, even though it leads to more stable microemulsions regardless of whether they are recycled using membranes. This makes membrane filtration as an approach to improve the sustainability of MWF systems less profitable than it should be.

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Automation in sheet metal

cutting & 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

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Proofing: A welding supervisor can limit the amount of changes an operator can make during a program, preventing him from accessing the override screen through the use of a key switch or password. b. 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. c. 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. d. 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. e. 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

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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 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

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 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). 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

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. 6. LASER-ARC HYBRID WELDING

Fig.2. Schematic diagram showing autonomous robot vehicle navigated by vision system, being used for all positional MIG / MAG welding

Fig. 1: TANDEM MIG

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

There is tremendous interest in the use

Fig.3. A typical laser welded sandwich panel and advantages over conventionally stiffened panels

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MACHINE TOOLS WORLD

BEST OF YESTERYEAR 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.

8. ELECTRON BEAM TECHNOLOGY

There have been several key improvements in this process in the last decade which have made EB welding increas-

7. FRICTION TECHNOLOGIES

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 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 lasers in combination with one or two MAG torches directed into the same weld

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.

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.

MACHINE TOOLS WORLD JULY 2016

ingly attractive for large-scale fabrication of steel structures such as buildings and 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

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more conventional pressure for EB welding of 5 x 10 -3 mbar. This reduced 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, 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 modelling 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

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CASE STUDY

Kennametal

helps aerospace job shop meet

critical delivery date By opting for Kennametal’s series of 4 and 6-flute high performance full ceramic end mills, Stellar Precision Components could meet an extremely tough deadline at a fraction of the price

ost shops evaluate new cutting tools in an effort to reduce machining time, increase tool life, or improve part quality, and sometimes all three. Stellar Precision Components Ltd., a Tier II aerospace supplier in Jeanette, Pennsylvania, did it for an entirely different reason. “We’d just taken an order for some Inconel parts,” says production manager Edward Frieze. “None of us were really worried at that point about tool life or making a profit on the job—our only concern then was how the heck could we get them shipped in eight weeks.” Stellar prides itself on continual updates to its equipment list, and has an eclectic mix of CNC machine tools from Haas Automation and Okuma, although that balance is steadily tipping in Haas’ favor as the shop’s older machines go into retirement.

Not Too Tough

Stellar is used to meeting demanding requirements. Frieze explains that Stellar had just received a purchase order for a handful of Inconel 625 prototypes. The raw material blanks for the job measured 18 in. square x 3 in. thick (457 x 457 x 76 mm), and weighed nearly 300 lb. each (134 kg). The project team suffered little

MACHINE TOOLS WORLD JULY 2016

indigestion over the tough material’s poor machinability; Stellar routinely cuts Inconel and other nickel-based superalloys, as well as tungsten, maraging steels, 60 Rc 4340 (300M), and tool steel. Nor was tolerance an issue. Frieze points to one recent titanium part that called out a 0.005 in. (0.127 mm) profile tolerance over its 12 in. length (304 mm), the equivalent of holding “a

couple tenths” in parts that cost over $5000 apiece before machining. Meeting the relatively wide open tolerances on the Inconel part was not a concern. The problem was one of raw material removal: when finished, the Inconel plates weighed in at a svelte 30 lb. (13.6 kg), 90-percent lighter than their starting weight. Frieze knew there weren’t enough hours in the day to remove

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CASE STUDY

It was something we’d never seen before. But within the first hour, we knew it was going to work - Edward Frieze, Production Manager, Stellar Precision Components that much material using conventional carbide tooling, not if he were to meet the deadline. He needed a better solution. Seminar Payoff

Earlier that year, Frieze and several of his coworkers had attended a learning event sponsored by a local chapter of the National Tooling and Machining Association (NTMA), and hosted at the Kennametal technical center in the nearby town of Latrobe. There he met product manager Matthieu Guillon, who introduced him to a cutting tool that Frieze was initially skeptical of. That tool was Kennametal’s series of 4 and 6-flute high performance full ceramic end mills. Constructed of SiAlON KYS40 grade ceramic and designed specifically for roughing in nickel-based high-temperature alloys, these end mills often out-produce carbide by up to 20 times. Says Guillon, “We recommend a starting speed of 825 SFM up to 3300 SFM (250 to 1000 m/ min) and feedrates starting at around 0.001 IPT (0.03 mm) depending on the tool diameter and other conditions. Despite the far higher cutting speeds, we have some customers who have reported 2 to 3 times greater tool life than carbide.” Stellar didn’t have any immediate use for the ceramic tools, but after making

MACHINE TOOLS WORLD JULY 2016

some quick feed and speed calculations, Frieze knew they would be an effective solution given the right application. Several months later, that application arrived with the Inconel plates. He called Guillon to say he might have a good use for those ceramic cutters they were talking about, and wondered how soon he could get some. Skeptic to the Last

Frieze remained skeptical. He’d tried indexable ceramic cutting tools on both milling and turning jobs in the past and had mediocre results. In this case, however, he was willing to try anything if it meant meeting the customer’s deadline. “We weren’t certain what would happen so started out with a block of test material. It was something we’d never seen before. But within the first hour, we knew it was going to work.” “The tools aren’t inexpensive,” he says. “At one point, Lori had around $20,000 worth of end mills sitting in her office and we were starting to question the investment. But once you calculated in the machine costs and reduced cycle time, we figured it was three to four times more cost-effective to go this route. Each end mill gave us one half hour of cut time, at which time we replaced it whether it was worn or not. The process was so predictable we were

able to run lights out. It led to drastic savings.” Enjoying the Heat

Best of all, Stellar delivered the parts on time with zero scrap, and is now quoting a second, even larger order. Owner Lori Albright was quite pleased with the outcome. “This type of situation is the nature of our business. We have to react to our customers’ needs and employ the best technology available to do so. That’s one of the reasons why Kennametal is so welcome here. We work together as a team to solve challenges.” Looking forward, Albright anticipates continued growth. Having expanded Stellar’s existing facility six times, she figures it might be time to put up an entirely new building on nearby property. She also looks forward to bringing additional young people to the machining trade. “I find that it’s often our younger people that drive our innovation. It’s too easy to keep doing things the old way and not invest in tooling and equipment, or pursue new technology. The days of high volume, round-the-clock fender clip manufacturing are gone, and it’s only by continually improving their manufacturing processes that companies can succeed and grow. For us, Kennametal is part of that success.”

CASE STUDY

Schneto AG

ramps up manufacturing with EMAG’s VL 2 The recent addition of the VL 2 vertical turning center from EMAG has given a significant boost to the company’s productivity

chneto AG, located in idyllic Bennwil, near Basel, specializes in the production of turned parts up to 65 mm in diameter. The company has made a name for itself because of the outstanding quality of the parts it manufactures. Its output covers a broad range of parts, including parts for furniture making, for hydraulics and pneumatics, electrical equipment, automobiles and construction equipment. The company was founded in 1947 and has been run since by two generations of the Baumann family. This lasting success in the marketplace is based on a superbly trained team of employees, and use of innovative modern machinery. Alongside various multi spindle machines and horizontal production lathes, demanding follow-up work is also carried out, including hard turning, fine turning,

MACHINE TOOLS WORLD JULY 2016

honing, and grinding. In particular, the recent addition of the VL 2 vertical turning center from EMAG has given a significant boost to the company’s productivity. Sophisticated automation

The VL 2 is one of EMAG’s modular machines and has a very compact design. “The footprint was a decisive factor for us,” said Michael Baumann, managing director of Schneto AG. “The VL 2, with its compact design, fits into our production layout perfectly, even though we installed a complete automation system for pallet loading next to the VL 2.” Like all modular machines from EMAG, the VL 2 also features integrated pick-up automation. This means that the working spindle automatically loads and unloads itself from the integrated parts storage unit. This has two distinct advantages:

non-productive time is cut to an absolute minimum, as the loading position is directly alongside the machining area. The second is that it’s possible to integrate any kind of automated system to supply the machine with raw parts. Schneto opted for a ROBAX robotic system from HandlingTech, a long-term partner of EMAG. The ROBAX system permits the use of pallets, ensuring high utilization of the VL 2. “The VL 2 has very high availability, which we are able to utilize to the full because of its integrated automation. Using the VL 2 gave us a crucial productivity advantage, especially for parts in medium and large production runs. All the more impressive considering the outstanding quality of the parts manufactured on the machine, which is in part due to EMAG’s great after sales service,” explained Baumann.

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Excellent machining quality

The quality of the parts manufactured at Schneto is verified by the company’s own in-house measuring station. The VL 2 easily reaches the high standards set here. The machine base made from MINERALIT polymer concrete ensures high stability and outstanding vibration damping, which is reflected directly in the quality of the machining. The machining action itself is done with a 12-station tool turret, which allows for very short indexing times. Turning and milling work can also be performed using driven tools. “Here at Schneto we also opted for a VL 2 with a Y-axis, which added yet another major expansion in the machine’s versatility,” added Michael Baumann. “The ease of access to the machining area and turret allows our employees to change the machine setup in a relatively

short time, which at the end of the day results in lower costs, of course. All the service units are easy to access as well, which makes servicing work much easier. All in all, we are very satisfied with the quality of the machine and EMAG’s support services— all of our inquiries are handled very quickly and the service technicians really know what they’re doing,” said Baumann. Investment in the future

“For us, the VL 2 was an important investment in the future of the company,” Baumann went on. “The possible range of parts for machining, up to 100 mm in diameter and 150 mm in length, fits into our range of parts and allows us to react flexibly to the needs of our customers. With the automation and the pallet system, we’re able to manufacture even

“Using the VL 2 gave us a crucial productivity advantage, especially for parts in medium and large production runs” - Michael Baumann, Managing Director, Schneto AG high part volumes efficiently, quickly, and with top quality—so well that they can be inserted directly into our customer’s production processes. That gives both us and our customers considerable advantages in terms of productivity.” Low unit costs, stable processes, high component quality, and excellent value for the money as well: in view of all that it’s no surprise that the turning specialists at Schneto AG decided to acquire the VL 2 from EMAG.

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MACHINE TOOLS WORLD

CASE STUDY German based DIETZ-motoren is a privately owned business that has spent almost 100 years perfecting electric motors and radial fans used in niche industry sectors, such as food production, textiles, specialist machinery, etc.

How

DIETZ

maintains its competitiveness

ased in Dettingen, not far from Stuttgart, Germany, DIETZmotoren is a privately owned business that has spent almost 100 years perfecting electric motors and radial fans used in niche industry sectors,

MACHINE TOOLS WORLD JULY 2016

such as food production, textiles, specialist machinery, etc. None of the company’s products are made in great volume; some of the manufacturing processes, such as winding, are in fact still done by hand.

However, DIETZ manages to produce around 150,000 motors and fans of various sizes and power outputs every year, most of which are shipped to customers overseas. The company’s finishing and assembly buildings are busy, but light and relatively quiet, and are dotted with small tress and plants, which give a peaceful, natural feel. The adjacent machine shop, on the other hand, is noisy and, by comparison, frenetic. On most days, it’s open and running round the clock. This is just one of the company’s two factory sites. The other is in the Swabian Jura, the low, snowy mountain range of the state of BadenWürttemberg. The Haas advantage

The Dettingen site, with the bigger of the

CASE STUDY www.mtwmag.com The company finds the Haas CNC is another feature of the Haas machines that gives them greater flexibility, being very easy to use they are able to move operators between machines – whether vertical mill or lathe

high spindle speed. “We have a large and varied product range, so we also needed the optional 40-station tool changer. The table on the VM-3 – which has T-slots in X and Y, allows us very quickly and easily to create fixtures for our parts.” Assured Reliability

“They’re very reliable machines. It doesn’t matter how many hours they work, they always keep tolerance” - Chief Engineer, Irsiegler

DIETZ-motoren has eight Haas CNC machine tools, including two Haas VM-3s which do most of the higher-volume machining

two machine shops, is home to six of the company’s eight Haas CNC machine tools. As well as Haas SL-30 and ST-30 turning centres and a Haas Mini Mill, there’s a Haas VF-5 and two Haas VM-3s, which do most of the higher-volume machining. “The VM-3 was our first Haas machine,” says Chief Engineer, Dieter Irsiegler. “We needed a flexible vertical machining centre with good power and

Between them, the VF-5 and the VM-3 can be called upon to machine any part from a database of 400 different programmes, to tolerances of 0.02 mm. All the Haas machines work between 16 and 24 hours a day, depending upon demand, and each of them is equipped with a Haas HRT310 CNC rotary table. “They’re very reliable machines,” adds Chief Engineer Irsiegler. “It doesn’t matter how many hours they work, they always keep tolerance. The VF-5 is actually ten years old, so it has made a lot of parts in its life so far.” After the company had bought its two Haas vertical machining centres, it also invested in a Haas SL-30 turning centre, which, like the other Haas workhorses, runs 24-hour shifts. It’s used to machine high-tolerance surfaces on flanges. “The Haas CNC is another feature of all the Haas machines that gives us greater flexibility. The control is very easy to use, and it’s essentially the same on all Haas machines, so we’re able to move operators between machines – whether vertical mill or lathe – when we need to.” Again, according to Eng. Irsiegler, the Haas SL-30 has proven to be 100-percent reliable. “Reliability and service are very important,” he reiterates. “We have no back-up, so if a machine were to break down, we’d need it fixed and up-andrunning straight away. The local Haas Factory Outlet is very efficient, and they give us good and prompt support.” For engineers like Dieter Irsiegler, who run CNC machines round the clock, and who want to sleep soundly at night, reliability and dependable support are essential. Unlike finishing and assembly areas, machine shops are very noisy places. They need to stay that way.

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EVENT GLIMPSES

MTW Magazine - Participation @ ACMEE 2016, Chennai

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TECH TRENDS

Sparkonix’s Tyre

Mould EDMs

open new opportunities for Mould manufacturers in India

n another first, Sparkonix introduces a new range of specialized EDMs for Tyre Mould manufacturing. The demand for spark erosion technology in Tyre Mould manufacturing is expected to grow with greater use of advanced mould materials and shift towards two-piece moulds by tyre manufacturers. Sparkonix launched its Tyre Mould EDM range at the recently held Tyrexpo 2016 in Delhi. Large scale need for tyre mould manufacturing in India will be driven by multiple factors such as: • Steady and sustained growth of automotive industry • Huge investments by tyre manufacturers in India • Presence of world’s leading tyre manufacturers • Growing number of vehicle and tyre variants From the inception, Sparkonix has always been recognised for developing innovative solutions in EDMs. The indigenous development of EDMs for the tyre mould manufacturing is in line with Sparkonix’s vision to bring innovative technologies for Indian manufacturers. In the recent past, mould manufacturing for the tyres has seen a significant shift outside of India, especially to China. However, with increasing variants, greater costpressures and shorter timelines, tyre manufacturers have faced multiple challenges in sourcing tyre moulds. In addition to proven technology, performance and results, we have two distinct advantages over the imported tyre mould EDMs. First, Sparkonix offers

MACHINE TOOLS WORLD JULY 2016

huge savings in investments required for the tyre mould EDMs. Secondly, a nationwide network of support engineers ensures an assured service and spares availability for years to come. - Shailesh Patwardhan, Director, Sparkonix (India) Pvt. Ltd. There is a huge opportunity in Tyre mould manufacturing for mould manufacturers based in India and it is largely untapped. While the tyre mould manufacturing needs multiple technologies, availability of EDM

technology remains its key link. The launch of a ‘made-in-India’ EDM technology from Sparkonix bridges this key link for Indian mould manufacturers and empowers them to explore the huge opportunities in tyre mould manufacturing market. For more information, Sparkonix (India) Pvt. Ltd. B-4, H Block, MIDC, Pimpri, Pune - 18 Ph: +91 20 2747 0643 / +91 20 2747 6452 Email: info@sparkonix.com

TECH TRENDS

ROLLON for industrial machines: Automatically opening machine enclosures

ooling machines, manufacturing cells or packaging machines are usually operated in a protective enclosure. This prevents accidents, protects the surroundings from flying shavings or contamination and shields hygienically sensitive products against contamination from the outside. Sliding doors allow for loading and unloading, cleaning, repairing or maintenance. In order to open and close them automatically, the linear axes of the E-Smart series by Rollon, for example, can be used. If they are installed horizontally and tilted 90 degrees, the door can be mounted on the carriage and moved by the actuator. Power is transmitted by steel-reinforced polyurethane timing belts with an AT tooth profile. The axes are characterized by low friction, long service life and low noise. A Compact Rail roller

MACHINE TOOLS WORLD JULY 2016

guide safely accommodates the sliding doors at the bottom. The same solution can be implemented even cheaper with a bi-directional Smart axis. A B-Smart that is twice as long with two synchronously colliding and moving runners stops and then moves the machine doors. This saves an axis and requires only a transmission, a motor, an encoder for determining position and a servo amplifier. In handling and positioning systems

that used to require two horizontal axes, a Robot SP-2C axis with two independently positionable carriages may also be used instead. An SC-axis can be correspondingly mounted onto the trolley, which is provided in the Plus System family for performing vertical strokes. The design with two perpendicular axes on a transverse axis can save not just an axis, it is also a time saver for the user by being able to run parallel processing. For more information, Rollon India Pvt. Ltd. 1st floor Regus Gem Business Centre 26/1 Hosur road, Bommanahalli Bangalore 560068, INDIA Telefono: +91 80 67027066 Fax: +91 80 67027004 E-mail: info@rollonindia.in Web: www.rollonindia.in

TECH TRENDS

Cleaning for Oxygen Service Do we clean our components for oxygen service? It’s a question we hear all the time. Often it is because our customer will use the regulator or valve in oxygen service, but not always. Many times, our customers will request O2 cleaning even though their media is anything but oxygen. This level of cleaning has become a benchmark in the specialty gas market for the specific level of cleanliness of wetted flow path parts. Primarily, if a regulator or valve is cleaned for oxygen service, it means that all components in contact with the process media are free of hydrocarbons (oil, grease, and other contaminants), as well as particles large enough to causes pars that can lead to fires. ASTM G – 93 and CGA G-4.1 are standards defining what methods and equipment are suggested to achieve and verify a specific level of cleanliness for oxygen service. These standards do not attempt to identify a specific construction that is suitable for oxygen service (acceptable materials of construction for oxygen service are covered by other industry standards). Instead, they recommend the methods for cleaning, and specify the methodology for verifying the resulting level of cleanliness of piece parts and assemblies. ASTM G-93 defines several levels of cleanliness for various applications for equipment used in oxygen-enriched environments, along with the methods used to verify these levels of cleanliness. Tescom uses ASTM G-93 as its standard for cleaning. In fact, any component that we sell through the industrial division is packaged with a label that includes the following: “This product is cleaned in accordance with ASTM G – 93 and CGA G-4.1 (This assures removal of visible particles and combustible residues).”

MACHINE TOOLS WORLD JULY 2016

Kindling Chain Ignition So what does this all mean to the end user? Essentially, through a series of cleaning and evaluation steps, the component has been cleaned, assembled, and packaged in a controlled manner that assures the end user that no particles or combustible residues are present on the wetted surfaces. These particles and combustible residue can then act as ignition mechanisms for an oxygen fire under the right conditions. Every day, someone learns about the need for leaning components used in oxygen service the hard way Most common among the metal working industry, oxygen fires often occur in the regulator set of an oxy/acetylene welding rig. The welder may have carelessly tossed the regulator set on the ground when

TECH TRENDS changing cylinders, or perhaps didn’t cap the end of the cylinder after a long day of welding, allowing dirt to enter the outlet of the cylinder valve. When the regulator is connected to a cylinder of oxygen, and the cylinder valve is opened, high pressure oxygen flows into the regulator at a high velocity. The oxygen reaches the main valve of the regulator, which is usually in the closed position. In this situation two opportunities for an oxygen fire exist. The first is from the impingement of dirt and other particles moving at high velocity within the component. The second is due to heat of compression. Heat is generated from the conversion of mechanical energy when a gas is compressed from a low to a high pressure. High gas temperatures can result if this compression occurs quickly to simulate near – adiabatic conditions. This temperature rise may be high enough to cause the plastic seat or o-ring material in the regulator to ignite. Plastics and elastomers have what is called an auto-

ignition temperature that refers to the temperature at which the material will ignite in the presence of 100% oxygen. A seat fire or o-ring fire will promote consequential burn of the surrounding metal. This condition is often referred to as promoted ignition or kindling chain ignition. Avoiding a fire Impingement occurs when a particle or particles entrained in the gas are moving at a high velocity through the component, and begin hitting a wall or other fixed object in the body of the component. When the particle impacts the body of the component at high velocity, there is a chance that a spark is created at the moment of impact. This spark can trigger a fire, selected fueled by the body material, and supported by the oxygen - rich atmosphere. For metals, there is a property called Absolute Threshold Pressure that refers to the pressure at which the metal will support self-sustained combustion in oxygen atmospheres. All of the 300

series stainless steels have threshold pressures near 500 psi while aluminum supports combustion at pressures as low as 35 psi. + Once the oxygen fire begins, it continues until the system pressure is reduced to a point where combustion is no longer possible. This usually occurs when the fire has burned through the wall of the regulator resulting in a dangerous explosion of fire and material. When looking for a component to be used in an oxygen environment, choosing plastic parts with high auto-ignition temperatures and metals with higher threshold pressures will substantially reduce the potential for oxygen fires. Brass and Monel are commonly used metals while PCTFE and Viton® are commonly used soft goods. For more information about oxygen-compatible constructions, please contact Tescom engineers for assistance. We’ve discussed the need for special cleaning for oxygen service, but why would someone specify this level of cleaning for applications of other gases? There are no other industry standards that quantify a level of cleanliness as specific as cleaning for oxygen service. It is the benchmark of clean, you might say. So, rather than spelling it out in a long, windy text specification how the device should be cleaned, verified, and packaged, the customer simply requests cleaning for oxygen service. Of course, this by no means implies that any component cleaned for oxygen service is suitable for oxygen service, but we now know that the device is hydrocarbon and particle free, making it suitable for all manner of analytical, pharmaceutical, and industrial applications. Tescom’s Industrial Controls Division cleans and packages all pressure regulators and valves for oxygen service as a standard feature of our product offering. There is no need to specify it separately. [Courtesy: Shavo Technologies Pvt. Ltd.]

MACHINE TOOLS WORLD JULY 2016

TECH TRENDS

DMG MORI Systems

promises complete system competence

Top customized engineering: DMG MORI Systems combines technology, machine tool, automation and peripherals in holistically coordinated 360° solutions for production systems

lexible automation guaranteeing process reliability is an elementary factor of success for a universally digitalized production world. With this in mind DMG MORI Systems already offers its customers the possibilities and competences to produce successfully here and now. And this performance commitment applies to every segment of automation technology: to machineintegrated automation as well as standard automation and on to include flexible manufacturing cells and comprehensive turnkey production lines. The future is automatic In the age of “Industry 4.0” the automation of manufacturing processes is gaining dynamically in importance. At the same

MACHINE TOOLS WORLD JULY 2016

time the merging of virtual and real production worlds demands an integral communication capability of machines, systems and components. 360° system competence DMG MORI Systems meets this challenge of the future actively by offering a holistic range of services from a single source for technology, machine tool and automation solutions. This diverse service offer is based on the unique experience of DMG MORI in the sector of techno-logy design and automation that is bundled within DMG MORI Systems GmbH. Added to this is the engineering expertise and strong partner structure that together with its experience enable DMG MORI Systems to configure and

implement ideally aligned systems for every customer and every requirement. And it achieves this for a diverse range of workpieces, from a small precision part to tool moulds, and for a multitude of different lot sizes from single parts right through to serial production with automation solutions that range from standard to turnkey. The range is organized in four segments: Segment 1: Machine-integrated automation (Integrated in the machine, Universal production) Segment 2: Standard automation (Solutions for tool, workpiece and pallet handling Portal and robot solutions)

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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UNITY CONTROLS PVT. LTD

TECH TRENDS Segment 3: Flexible manufacturing cells (Implementation of customer-specific machining processes combined with automation of in-house machines and third party products) Segment 4: Production lines (Planning, simulation and implementation of turnkey solutions based on the DMG MORI corner-type solution) Process reliability with maximum productivity The interaction of different disciplines from technology, machine, automation and peripherals make turnkey projects the supreme disciple of automation and system technology. In addition to its wide range of products in the field of machine tools DMG MORI also offers proven expertise in all fields – in the engineering of technological applications as well as in material flow and the required peripherals. This consistent integration is in turn the basis for a high level of cost-efficiency, as Silvio Krüger, General Manager of DMG MORI Systems GmbH, explains: “The convincing features of the production lines include low unit costs, outstanding ma-

MACHINE TOOLS WORLD JULY 2016

chining performance, a high system availability of over 95% and high output. They achieve the shortest cycle times and offer impressive flexibility where workpieces are concerned.” Parallel manufacturing processes are also possible and flexible programming leaves considerable scope in the production process. Reliability and process stability are ensured by the use of advanced and proven technologies and products on the one hand and the global presence of DMG MORI on the other. “As a supplier for the globally organized automotive industry, it goes without saying that we draw on our worldwide service network and a specially setup top-level support team to help customers quickly whenever the need arises”, stresses Silvio Krüger, calling attention to the new Technology and Competence Center in Wernau near Stuttgart.

New technology centre in Wernau With the aim of bundling and focusing the system competences already mentioned with the resources of the DMG MORI SEIKI Group even more intensively for our customer we are currently constructing a future-orientated Competence Center for tool and equipment techno-logy, control system design and project management in Wernau. The company is building a completely transparent 47,000 m2 factory that has an air-conditioned production area of over 12,000 m², six independent central coolant systems, a central extraction system for emissions from the dry machining process and a measuring room for cmk and cpk production approvals of 450 m². Silvio Krüger sees the investment as a strategic milestone: “It is exactly here in the handling of turnkey projects that it is imperative to have the entire know-how ready to hand. The Technology Centre will allow us to optimize our structures and give customers the opportunity of getting a real impression of our engineering competence.” It will also be possible to coordinate the global activities of DMG MORI with Nara, Japan and Davis, USA perfectly from this central location.

PROJECTS www.mtwmag.com

Airport / Aviation Airports Authority of India (AAI)

Airport / Aviation Automobile

PROJECT

Gears Industrial Park Ports & Shipping Railways

UPDATE

Transport

AAI has chalked out an investment plan over the next four years towards the development and upgradation of airports in the country. The Civil Aviation ministry has approved this plan which mainly includes upgrade and expansion of 39 airports and revival / airport upgradation in smaller cities. The plans also includes installation of solar capacities at several airports.

Place: Delhi Contact: M. Amin, Dy. General Manager (PR), Rajiv Gandhi Bhawan, Safdarjung Airport, New Delhi-110003, T: 011-24629348, 24693417, E: amin@aai.aero Bhogapuram International Airport Company Ltd Bhogapuram International Airport near Visakhapatnam is proposed. HUDCO has agreed to release `650 cr to acquire land for this project. Around 2,400 acre will be acquired for the Airport in the first phase.

Place: Telangana Contact: G Shankar, General Manager (Admin), 1st Floor, FDC Complex, AC Guards, Hyderabad - 500028. T: 040-29803752-53/69, M: 9959920728,

E: mdbiacl@gmail.com, W: www.biacl.co.in

Airport Authority of India (AAI) AAI is considering plans to expand airport in Agra. Defence Ministry may allott 50 acre of Indian Air Force land for the expansion project. A new terminal building would be constructed on the leased land to scale up operations.

Place: Uttar Pradesh Contact: Shishir Jain, Asstt. Gen. Manager Engg. (C), Civil Air Terminal Kheria, Agra - Uttar Pradesh Pin-282008, T: 0562-2400844, M: 9412257561, E: shishirjain@aai.aero, PNC Infratech Ltd The company has been declared as the lowest bidder for a contract involving resurfacing the runway at an Air Force station, Bakshi Ka Talab, near Lucknow in Uttar Pradesh.

Place: Uttar Pradesh Contact: S.V Singh, Project Director, 3/22-D, Civil Lines, Bypass Road NH-2, (Near Omaxe SRK Mall), Agra-282002, Uttar Pradesh, T: 0562-4054400, 4070000 Airport Authority of India (AAI) AAI plans for a major revamp of the existing Lohegaon airport. The expansion would

JULY 2016

MACHINE TOOLS WORLD

PROJECTS

include increasing parking bays and terminals capacity. The plan to acquire Indian Air Forceâ&#x20AC;&#x2122;s 16 acre of land is approved and another 30 acre from Indian Oil Corporation (IOCL) is being worked out.

Place: Maharashtra

Place: Tamil Nadu Contact: M.Karnakaran, Head Operation, 304A, Shanthi Gears Road, Singanallur, Coimbatore 641005, Tamil Nadu, T: 0422-4545745, F: 0422-4545700, E: karnakaranm@ shanthigears.com

Contact: Vinay, Assistant General Manager (Civil), Pune Airport, Lohegaon Pune-411032, Maharashtra. T: 020-26685201, 26683232, F: 26685599, E: apdpune@aai.aero

Automobile Maruti Suzuki India Ltd The company is coming up with its car plant in Gujarat. The commercial operations is likely to start in 2017.

Place: Gujarat Contact: Puneet Dhawan, Senior Manager and Head Corporate Communications, Nelson Mandela Road, Vasant Kunj, New Delhi-110070, Delhi. T: 011-46781117, 46075414, 46781000, F: 46150275, E: pdhawan@maruti.co.in,

Gears Shanthi Gears Coimbatore-based company plans investment over the next four years for technology upgradation, expansion and sales promotion activities.

MACHINE TOOLS WORLD JULY 2016

Industrial Park Government of India The company has decided to establish three bulk drugs and three medical devices parks on the public private partnership mode.

Place: Nationwide Contact: Kamlesh Kumar Mishra, Deputy Secretary, Shram Shakti Bhawan, New Delhi-110001, Delhi. T: 011-23353320, E: kk.mishra@gov.in

Ports & Shipping Mumbai Port Trust (MbPT) The Port Trust intends to develop land and is likely to appoint a project management and implementation consultant who can create a detailed master plan enlisting development of road, marina and restaurant as part of the project. Bids will be floated soon.

Place: Maharashtra Contact: Gautam Deh, Senior Deputy Manager (Business

Development Sales), Port House, Mumbai. T: 022-66566565, 66566501, 66564521, Extn: 66566508, F: 23730611, 23744277, E: sskharche@mbptmail.com

Ministry of Shipping The Centre has planned development of Colachel, Kanyakumari, into a major port. The development would be taken up in three phases. The proposed transhipment port at Colachel involves reclaiming 500 acre of land from the Sea. The completion is targeted in three years.

Place: Tamil Nadu Contact: Rabindra Kumar Agarwal, Joint Secretary, Transport Bhawan, Sansad Marg, New Delhi -110001. Delhi. T: 011-23711499, E: rabindra.a@nic.in, W: www.shipping.gov.in Chennai Port Trust Plans investment to carry out major expansion plans which include construction of a coastal terminal, coal handling facility and EXIM godown. Apart from this the development of a barge handling facility is also planned.

Place: Tamil Nadu Contact: Madhavi S.V, Chief Engineer, Engineering Department, 1, Raja Ji Salai, Chennai-600001, Tamil Nadu. T: 044-25360646, 25393927,

E: ce@chennaiportgov.in,

Haldia Dock Complex (HDC) Development of Single Buoy Mooring (SBM) Facility for Handling Liquid Bulk Cargo at Deep Drafted Location for HDC, Kolkata Port Trust.

Place: West Bengal Contact: A Dutta, General Manager, Haldia Dock Complex, Kolkata, West Bengal. T: 03224 - 252110, F: 252740, M: 9434063171

Railways L&T Construction Transportation Infrastructure business of the company in consortium with Instalaciones Inabensa, S.A., Spain has bagged design & build order from Dedicated Freight Corridor Corpora- tion of India Ltd. The order involves electrification works for 417 km section of the Eastern DFC (Dedicated Freight Corridor) from Mughalsarai to New Bhaupur in the state of Uttar Pradesh.

Place: Uttar Pradesh Contact: Rajeev Jyoti, Chief Executive-RBG, 8th Floor, Tower-A, Railway Business Unit, Vatika Mind Scape Building, 12/3, Delhi Mathura Road, Faridabad-121003, Hariyana. T: 0129-4291000, M: 9582252061,

PROJECTS www.mtwmag.com

E: domanic@lntecc.com

Ministry of Railways The Centre has decided to lay the third line between Vizianagaram-Titla- garh at an investment of Rs. 2,356.68 crore. This would help in faster evacuation of cargo from Visakhapat- nam and Gangavaram Ports. The electrification on the second railway line is currently progressing in the fast track mode.

Place: Andhra Pradesh Contact: Anil Kumar Saxena, Addl. DG (PR), Rail Bhavan, Raisina Road, New Delhi-110001, Delhi. T: 011-23381332, 23383149, F: 23385215, M: 9868679525, 9810046241, E: dpr@rb.railnet.gov.in L&T Construction The company is executing the electrification works for two packages of the Western dedicated freight corridor (DFC) covering 1337 route km with over 3000 track km. The projects under implementation includes Rewari â&#x20AC;&#x201C; Vadodara Section covering 915 km and electrification works for a 422 km section of the western DFC from Vadodara in Gujarat to JNPT (near Mumbai) in Maharashtra

8th Floor, Tower-A, Railway Business Unit, Vatika Mind Scape Building, 12/3, Delhi Mathura Road, Faridabad-121003, Hariyana. T: 0129-4291000, M: 9582252061, E: domanic@lntecc.com

Transport Hyderabad Metro Rail Ltd Plans to assign Integrated Multi Parking with commercial space (MLP) and Skywalks for Hyderabad Metro Rail.

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: Telangana Place: Maharashtra Contact: Visnuvatan Reddy, SE, Metro Rail Bhavan, Saifabad, Hyderabad-500004, Telangana, T: 040-23388589, F: 040-23388582, M: 9959552473, E: mvvrhmr@gmail.com, cehmr2008@gmail.com Afcons Infrastructure Ltd Chennai Metro Rail Ltd (CMRL) has awarded the contract to complete the balance work of underground tunnel from May Day Park to North Shaft of AG-DMS to Afcons Infrastructure Ltd (AFCONS) which has already carried out tunnelling work in other parts of the city.

Place: Tamil Nadu

Place: Gujarat

Contact: Bivabasu Kumar,

Contact: Rajeev Jyoti,

Senior Manager (Corp Comm), 16, Shah Industrial Estate, Veera Desai Road,

Chief Executive-RBG,

Azadna- gar P.O., Andheri (West), Mumbai - 400053. T: 022-67191000, F: 26730047/ 26730026, bivabasu.kumar@afcons.com

Contact: R. Anand Kumar, GM (Procurement), Metro House, 28/2, CK Naidu Marg, Anand Nagar, Civil Lines, Nagpur-440001. T: 0712-2554217, E: anand.kumar@ metrorailnagpur.com, www.metrorailnagpur.com Bangalore Airport Rail Link Ltd Plans to implement 42-km of Light Rail Transit System (LRTS) under public-private partnership in Bengalu- ru. The project comprises two corridors: JP Nagar-Hebbal corridor of 32 km covering Bannerghatta Road, Kanakapura Road, Mysuru Road, eastern boundary of Jnanabharati campus, Magadi Road, Peenya Industrial Area, BEL Circle, Lottegol- lahalli and Hebbal; the second corridor comprises Vijayanagar

Tollgate-Ta- varekere corridor covering 10 km. The completion of this project is targeted in four years.

Place: Karnataka Contact: C Jayaram, Director (Projects), Bangalore Airport Rail Link Limited, KSFC Bhavan, No.1/1,Thimmaiah Road, Bengaluru- 560052, Karnataka. T: 080-22200110, E: barl.hsrl@gmail.com MP Group The Group has received contract from Noida Metro Rail Corporation (NMRC) for plying buses within Noida and Greater Noida. The bus network will traverse prominent areas with 13 different route plans. The company has developed a Special Purpose Vehicle (SPV) to implement its NMRC project for City Bus Service operation. The buses will be procured by the MP Group whereas infrastructural support in the form of ticket revenue collection and more will be provided by the NMRC.

Place: Noida Uttar Pradesh Contact: Ganesh Sumbhe, Accounts Manager, MP Group, 2nd Floor, Chiranjeev Apartments, Karve Road, Erand- wana, Deccan, Pune-411038, Maharashtra. T: 020-25442780, M: 8380021657 E: ganesh@etsl.co.in JULY 2016

MACHINE TOOLS WORLD

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

HIGH QUALITY FOR YOUR MACHINERY

MGM brake motor main features

VARVEL production lines

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

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

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

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

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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: • • • • • • 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

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

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.

Steady Volt Servo Voltage Stabilizers

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

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: • Intelligent microprocessor-based system(available in new digital models) • Digital interface with large LCD display and keypad

JULY 2016

MACHINE TOOLS WORLD

107

PRODUCTS • • • • •

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.

HSS Cutting Tool Indian Tool Manufacturers (ITM), is pioneer in HSS Cutting Manufacturers in India, it offers wide range of HSS Drills, Taps, Reamers, End Mills, Bore Type Cutters etc,. ITM is one of the largest HSS Cutting Tool manufacturers in India.

HSS Drill: ITM produces best quality of HSS Drills in its range, on latest CNC Machines like Karl Haux and Hertlein machines. The flute profile and geometries are unique and originated by the ITM in India.ITM have stringent manufacturing control methods to produce high quality drills, also have in-house facility of Heat treatment to get accurate handedness. In addition to that, ITM drills are made out of imported steels, to meet the standards of international market. We are serving to Indian and International customers, since 1937. due to highest quality of tools, on time delivery, availability of stocks etc., Only ITM HSS Drills can operate L/D ratio up to 100 times, where as in Carbide drills up to 3,5,7,10, times. We have drill series of Stub, Jobber, and Long Series, Extra Long series in both Parallel Shank and Taper Shank. ITM also can supply the Tools with TIN, TiCN, Ti(Al)N for better performance of Tools. Drills can be supplied in HSS M2, HSS M35, HSS M42 premium grades of HSS steels.

HSS Taps:

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: itmth@indiantool.com.

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Even in modern machining era, every CNC machine opts for only HSS Taps. Tapping is the final operation of every component; hence, they prefer to use HSS Taps to avoid any breakage in component due to tapping. if tap breaks / damages, component get rejected. Only HSS materials have the property of can with stand on heavy machine vibrations, interrupted cuts, inclination faces, and wavy faces, where as carbide Taps cannot work on these working conditions. ITM produces high quality of HSS Taps made out of from CNC machines like GT 77, Normac FT-80 flute grinders etc.,.ITM geometries are unique with difference cutting angles with different flute forms for different machining applications. And also our taps are made out of imported steels. ITM is one of the prominent supplies in Indian market due to its quality and on time delivery. ITM is offering H&S M/c Taps, LS M/c Taps, Spiral and SPPT Taps in both HSS and HSS-Co grades. Only HSS Tools can operate at moderate speeds either at low or high speeds, these formulae cannot applicable for Carbide Tools. Carbide Tools will work at only recommended speeds and feeds. Hence HSS Tools are only solutions for conventional machines as well as CNC machines.

PRODUCTS www.mtwmag.com

Dahanukar for Surface Grinding Machines

For Product Enquiry Contact Dahanukar Machine Tools College Road, Vadkun, Dahanu Road (W) Dist Thane – 401 602 Phone: 02528-224354 Email: sales@dmtindia.com Web: www.dmtindia.com

Dahanukar Machine Tools, established in 1983, specializes in manufacturing horizontal spindle reciprocating table and vertical spindle rotary table type Surface Grinding Machines. The company manufactures machines featuring high accuracy, high efficiency, very precise with a high degree of repeatability. The company also provides custom-made machines for specific grinding solutions for customers. Various machines from sizes as small as 4 inches x 6 inches job holding capacity to 40 inches x 20 inches are manufactured in hand operated, hydraulically operated as well as NC cut machines Machines with Auto Down feed, Auto Grinding Cycles, Linear Motion Guides,; Ball Screws are also manufactured as per customer’s needs. Dahanukar has recently launched PLC-based automated solutions for its range of Surface Grinding Machines. A dedicated team of service engineers for trouble shooting as well as servicing the machines is available on a 24 x 7 basis.

ELESA+GANTER wide range of Set collar specialties

For Product Enquiry Contact Elesa and Ganter India Pvt. Ltd. A-54, Sector -83, Noida 201 305 (U.P.) INDIA Tel. +91 120 472 6666, Fax +91 120 472 6600 E-mail : info@elesaganter-india.com Web: www.elesa-ganter.com

Set collars are still indispensable in modern mechanical engineering and plant construction projects: they secure axes and shafts, serve as fixed stop or as attachment option for additional functional elements such as limit switches. A multi-functional element, as it is, found in Elesa+Ganter’s product range in a number of different embodiments. The simplest design is version GN 705, basically complying with DIN 705 and made of blackened steel. If better quality grades are called for, versions made of stainless steel or corrosion-resistant, galvanised steel are the elements of choice. The same is true for the grub screw which Elesa+Ganter also offers in the traditional split variant, but recommends in the more rugged variant with DIN 914 hexagon socket with better fixing properties. While the fixing grub screw in standard set collars acts directly on the shaft and puts the surface under stress, the semi-split set collar GN 706.2 has no such damage potential. With the help of a grub screw featuring a hexagonal socket, the slot height is reduced such that the whole of the inner surface of the set collar creates a form-locking bond with the shaft. Unlike in the standard set collar, this configuration allows high clamping forces and higher safety levels. The same clamping principle is used in the threaded set collar GN 706.3, whose inside surface features a thread ranging from M8 to M30. One very special derivative is the set collar GN 706.4 which is also split, although the clamping force is generated by a clamping lever tightening the assembly without the need for tools. Essentially the same feature also characterizes the latest member of the set collar family: the quick release set collar GN 704 which functions without a big clamping lever. The element is slackened and tightened with a relatively small, yellow passivated handle which integrates itself with form-locking effect when fixed. Made of aluminum, the set collar reduces the mass moved and therefore the inertia of the rotating assembly. If a set collar cannot be mounted – or pushed over the shaft – in axial direction, the first choice would be the GN 707.2 set collar. This split set collar is assembled via two cylinder head screws and wedged against the shaft.

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PRODUCTS

Hangsterfer’s CC 10 - 22 Straight Cutting Oils For Deep Hole Drilling • CC 10 & CC22 oils are • Chlorine-Free • Non-Staining • Can be used safely on all materials • Non-Toxic • Non-Irritating • Non-Corrosive • Easy to recycle and waste treat • Lower misting • Fewer resi¬dues Hangsterfer’s neat cutting oil CC10 is recommended for Deep Hole Drilling /Gun Drilling application. CC10 (Viscosity 10) has all the capability to outperform. Hangsterfer’s neat cutting oils are recognized by various machine manufacturers around the world. These oil improves tool life and surface qualities to the large extent. In addition to the lubricity provided at the cutting zone, Hangsterfer’s cutting oils provide excellent lubrication for the machine’s slides, guide bushings, bearings, and spindles. For Product Enquiry Contact Hangsterfer’s Laboratories, Inc. USA Sanjay Tools & Adhesives Mobile : +91 9822028518, +91 9892516810 E-mail: hangsterfers@sanjaytoolsnsk.com Web : www.hangsterfers.com

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

Balaji Diamond Tools renowned for industrial diamond tools

For Product Enquiry Contact Balaji Diamond Tools # 1121, Trichy Road, Coimbatore - 641045, INDIA. Phone (Off.) : +91 - 422 - 4395244 . E-mail : balajibdt@gmail.com Web: www.balajidiamondtools.com

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Balaji Diamond Tools is one of the leading manufacturers of quality industrial diamond tools in India since 1986. Its manufacturing plant located at Coimbatore makes a wide range of standard and customized tools to meet the exacting customer needs and requirements. The range includes Single point diamond dressers, multipoint diamond dressers, Diamond grit impregnated dressers, Blade type diamond dressers, Forming & Chisel type diamond dressers, Diamond turning & boring tools, Hardness testing indentors, Diamond lapping compounds, Diamond Files, Diamond & CBN mounted points, Diamond & CBN resin and metal bond wheels, Diamond deep drills, Diamond & CBN honing sticks, PCD/PCBN brazed tools, PCD/PCBN inserts, PCD/PCBN Grooving tools and so on. Balaji’s products are available across 15 states in India through an extensive dealer network. The company also exports its products to countries like USA, UK and Latin America to name a few. “Our workforce comprises a highly trained, experienced and motivated team of engineers who work with our clients to deliver excellent results,” says Mr. B. Praveen Kumarr, CEO. Its Management consists of highly qualified hardcore engineers, technocrats and personnel with rich and varied experience in the field for over three decades. The company takes utmost care at every stage of manufacture right from selection of raw materials to the finished tool. “Cent percent quality is ensured by our quality control engineers before final dispatch,” pinpoints Mr. Kumarr. The company strives to constantly improve the quality of its tools and to ensure that the best quality is provided at the most competitive price.

ADVERTISERS INDEX COMPANY NAME

PG. NO.

ACCUSHARP CUTTING TOOLS PVT. LTD.

ACE MICROMATIC GROUP

BACK PAGE

ADOR WELDING LIMITED

ANCA MACHINE TOOLS PVT. LTD.

ASIAMOLD - 2016

105

GRIND MASTER MACHINES PVT. LTD.

GROB MACHINE TOOLS INDIA PVT. LTD.

H HEIDENHAIN OPTICS & ELECTRONICS INDIA PVT. LTD.

B BIRLA PRECISION TECHNOLOGIES LIMITED

COMPANY NAME

IMTOS 2017

103

C JYOTI CNC AUTOMATION LTD.

CNC SERVICING & SOLUTIONS (I) PVT. LTD.

CNC SOFTWARE, INC.

INSIDE BACK COVER

LAPP INDIA PVT. LTD.

74-75

DELTA ELECTRONICS INDIA PVT LTD

DOWEL ENGINEERING WORKS

MARPOSS INDIA PVT. LTD.

PG. NO.

ROLLON INDIA PVT. LTD.

S SANJAY TOOLS & ADHESIVES

31 & 67

SEE LUBE TECHNOLOGIES PVT. LTD.

SHAVO TECHNOLOGIES PVT. LTD.

SOLITAIRE MACHINE TOOLS LTD.

SPARKONIX (INDIA) PVT LTD

SPRAYMET SURFACE TECHNOLOGIES PVT. LTD.

T TSUGAMI PRECISION ENGINEERING INDIA PVT. LTD.

COMPANY NAME

U UCAM PRIVATE LIMITED

UNITY CONTROLS PVT. LTD.

MGM-VARVEL POWER TRANSMISSION PVT. LTD.

101 INSIDE FRONT COVER

E EFFICA AUTOMATION LIMITED

MMC HARDMETAL INDIA PVT LTD

ELECTROTHERM (INDIA) LTD.

EMAG INDIA PVT. LTD.

RAJKOT MACHINE TOOLS SHOW - 2016

102

ENGIMACH - 2017

104

RENISHAW INDIA (PUNE)

ERWIN JUNKER MASCHINENFABRIK GMBH

ROHIT POLISHER

W WIN INDIA - 2016

100

Y YAMAZAKI MAZAK INDIA

10-11

YASKAWA INDIA PVT. LTD.

YG CUTTING TOOLS CORPORATION PVT. LTD.

FRONT GATEFOLD

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Mr.

Inside Story

Ravi

Raghavan CEO & MD, Bharat Fritz Werner Ltd.

My Life’s Goals

Aim & Ambition: My passion in life is to play a role, however small, in making India the Engineering and Manufacturing Hub of the world. I believe that innovation and customer centricity are the drivers for every business, with steadfast commitment to well-defined goals, and swift actions. I would like my company – BFW to transform itself into one of the most loved & respected companies for all its stake-holders – vendors, customers, employees and shareholders. Vision: To make the best of myself as possible and to always have the interests of my company at heart, and to influence others to act accordingly through good leadership and mentoring. Social Goal: To make BFW one of the most socially responsible organizations in the country, by giving back to community - with special focus on people development, ecology (by making BFW the greenest campus in the manufacturing community) and by caring for the under-privileged sections of our Society. Business Goal: To partner our customer in their journey of growth – we always win by making our customers win.

My Leisure Choices Favorite holiday spot: I always prefer Safari spots like Kenya’s Masai Mara; that allows me to be closer to nature. Music I like : I like Carnatic (soul) music and old Hindi film songs – which take me back to the bygone era, when India was at the cusp of a Social & Financial transformation. Sports I Love : Like a regular Indian, I enjoy Cricket & Football among other sports. I am always up for a good game of Badminton & heaving in the beautiful game of golf.

Ask my Taste Buds Favorite food: Mexican, Italian and of course Indian Food. And I have to mention my wife’s home-made cooking – I just have to make a special mention of it! Favorite Drink: Definitely coffee – it helps me streamline my thoughts and also unwind after a tedious day.

In Awe of I Admire: Lots of individuals, but people who fight and stand by their beliefs; and transform the society for the better of humanity. In recent times, I have come to admire our Hon’ble Prime Minister – Shri Narendra Modi, for his steadfast commitment for our Nation’s cause; which I believe will change the course of the Indian Economy from days to come. Also our Late Former President Dr. A P J Abdul Kalam would always remain an idol for me, for espousing a great mix of simplicity with high thoughts.

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RNI No. MAHENG/2015/64267 Postal Reg. No. THC/173/2015-2017. Posted at Mumbai Patrika Channel Sorting Office G.P.O. Mumbai 400 001 on 15th of every month and Published on 10th of every month

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