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

www.mtwmag.com

Executive Publisher

Contents

Vol 2 Issue 03 | AUGUST 2016

Shirish D.

BUSINESS NEWS

CEO Shekhar D.

Editor Shilpa Dongre

CNC Software unveils Mastercam 2017

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

Designer & Layout

Gleason to demonstrate new solutions for advanced gear production

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

Online Division Ganesh M., Pradeep M. Pillalamarri

Circulation Executive Satish Kadam, Amol Ranshur

Renishaw debuts all-in-one optical incremental encoder

Branch Offices (Zonal)

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

ExxonMobil collaborates with Micromatic Machine Tools

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

COVER STORY

Ace Micromatic : Powering the success driven growth Mr. TK Ramesh, CEO Micromatic Machine Tools Pvt. Ltd.

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

INTERFACE

VIEWPOINT

Seco Tools celebrates 20 years in India

MAPAL relies on Safe-Lock system from HAIMER

Shell Lubricants announces ‘The Future of Hydraulic Oils’

Three Taiwanese companies heed ‘Make in India’ call

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

MACHINE TOOLS WORLD AUGUST 2016

CSR Report from Hypertherm shows growth in community engagement

Revolution in Cutting Oil Technology

Industry’s response to Automation is lukewarm: Satish Bhat

CII Automation Conference calls for a change in the way we manufacture

S O L U T I O N S Getting the right answer depends on asking the right questions.

Horizontal Machining Centres Vertical Machining Centres Special Purpose Machines Vertical Turning Centres Horizontal Turning Centres Knee Type Milling Machines

Complete Solutions for Machining and Turning

German Subsidairy

BHARAT FRITZ WERNER

www.bfwindia.com

Contents INDUSTRY FOCUS

Vol 2 Issue 03 | AUGUST 2016

TECH TRENDS

66 72

48 Synetics aims to be in the top league in automation

52 Gala, deep-rooted in Surface Engineering Solutions

How the VM 9 turning center gives maximum flexibility

CASE STUDY

Indian Die & Mould makers can confidently compete with global players

Moto2 pushes the boundaries using Metal 3D printing

PROJECTS

PRODUCTS 8

MACHINE TOOLS WORLD AUGUST 2016

Trusted Family-Business Trusts in Haas

Editorial Board

Editorial Index A

Accusharp Cutting Tools

101

ACE Micromatic Group

Ador Welding

60, 98

AMTEX 2016

B 99

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

Jyoti CNC Automation LTD

Lantek

MAPAL India

Mastercam

Mitsubishi Electric

D DMG MORI

28, 88 30

N NUM

EMAG India

Renishaw

ExxonMobil

S Seco Tools India

Renishaw Metrology Systems Ltd.

FARO Technologies

Effica Automation Ltd.

KOMET Group

Cortec

Mr. MIHIR Baxi President – Global Sales

Kasto

CII Automation

Ms.Samina Khalid Marketing Manager

Dormer Pramet

Mr. Arjun Prakash Managing Director

101

Birla Precision

Mr. A.P. Jayanthram Managing Director

JIG Engineering

24, 82 28, 68, 100

See Lube Technologies

Shell Lubricants

32 102

Gala Precision

SIC MARKING

Gleason Works

Sparkonix

Grind Master

Synetics Automation

Haas Automation

Taipei World Trade Center

Haimer India

Hangsterfer’s

100

Unity Controls

34 99

Heidenhain

Hypertherm

Zenith Industrial Products 102

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

AUGUST 2016

MACHINE TOOLS WORLD

TECH PROFILE

MAPAL Actuating Tools - maximum

rationalisation & optimisation

potential in machining The MAPAL TOOLTRONIC with an additional CAT (Contour Actuating Tool) actuating tool is the ideal tool for producing almost any required cylinder shape, for example contour drill holes, reliably, flexibly and quickly.

MAPAL actuating tools

MACHINE TOOLS WORLD AUGUST 2016

hether for special machines or for complete machining on flexible machining centres â&#x20AC;&#x201C; if the issue is to machine complex contours, noncylindrical bores, face surfaces or recesses on cubic parts, actuating tools offer the optimal tool. The product range includes mechanical actuating tools, which on the machine side are driven by pull/push rods or U axis systems, as well as NC-controlled tools, and the particularly flexible mechatronic tool system TOOLTRONIC, for machines without an additional feed unit. An application for actuating tools can be found in many branches. Especially in the automotive industry there are many applications which require highest precision. For example the machining of the crankcase bearing journals, the contour machining of the cylinder bore before the fitting of the cylinder liner, the trumpet form of the con rod, the sealing groove and the connection of the electronical brake of the caliper, the taper turning on the pivot bearing or the spherical machining on the coupling device. The range of application is nearly unlimited. The MAPAL TOOLTRONIC with an additional CAT (Contour Actuating

When something exceptional develops between us: ThatÂ´s the MAPAL effect.

You

want a production that is more efficient, less time-consuming and more cost-effective.

Discover tool and service solutions that will bring you forwards: www.mapal.com | Your technology partner for machining

Get there faster

supply you with modern tool solutions tailored to your specific production concept.

TECH PROFILE

TOOLTRONIC-CAT: Machining of trumpet form with an oval and elliptic profile in AlSi-alloy.

Tool) actuating tool is the ideal tool for producing almost any required cylinder shape, for example contour drill holes, reliably, flexibly and quickly. This is because the production processes for eccentric turning can be carried out on just one machining centre using the TOOLTRONIC-CAT. The controlled, oscillating movement of the turning tool produces the required geometry, namely deliberate non-roundness. Complex, exactly calibrated mechanisms and the numerous different parts inside an actuating tool require the highest accuracy and care during every production step. To safeguard the high precision of the tools, they are assembled manually. To commission the tools as quickly and efficiently as possible at the customer, complex actuating tools are comprehensively

MACHINE TOOLS WORLD AUGUST 2016

tested in advance under extreme loads and real application conditions. Commissioning at the customer is then undertaken by a MAPAL application specialist. MAPAL in India have trained professionals to provide application and service support for these tools. In October 2015, MAPAL expanded its operation in new production site for actuating tools and ISO special tools. A 5000 square meter modern Administration, Design and production facility building in Eppingen, BadenWürttemberg has been built which combines the previous locations of Sinsheim and Vaihingen. MAPAL has significantly increased its production capacity for actuating and ISO special tools to meet the large demand and the customers‘ request for shorter delivery times. The newly built production hall

in Eppingen is equipped with the latest manufacturing technology and has a modern CNC machines. The production and logistics processes have been optimized during the course of the strategic realignment and adapted to the new capacity. This has resulted in a sophisticated, highly efficient overall concept which ensures higher production volumes, quick response times and highest precision. In addition, there is sufficient capacity for further growth of the Competence Centre. For more information, you are requested to contact National Sales Manager – Mr Rajesh Kumar.K.G Phone: 9741499824 Email:rajeshkumar@in.mapal.com Website.: www.mapal.com

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

CNC Software unveils Mastercam 2017

CNC Software has announced the release of Mastercam 2017. Mastercam 2017 brings a new suite of programming tools focused on delivering speed, automation, and efficiency for all machining jobs. Mastercam 2017 introduces a more efficient workflow, improved usability, Dynamic Motion improvements, and so much more. 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 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. Mastercam’s Dynamic Motion

MACHINE TOOLS WORLD AUGUST 2016

technology can slash machine time by as much as 75% or more. And, Dynamic Motion will help you get the most out of any machine in your shop—new or old. Mastercam’s Dynamic Motion technology maximizes material removal rates, 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 that are more efficient, less complex, and travel a shorter distance resulting in shorter cycle times.

EuroBLECH 2016 presents online competition After the great success of the first online competition in 2014, EuroBLECH 2016 is presenting this year “The New Generation of Sheet Metal Working”. The online competition will reward six organisations or individuals in the sheet metal working industry for best practice, innovation, excellence and outstanding performance in six categories. Following this year’s main theme at EuroBLECH, “The New Generation of Sheet Metal Working”, the competition categories are focussing on recent developments and trends in the sheet metal working industry. The first category, “Factory of the Future”, will reward organisations or individuals for the clever implementation of smart manufacturing methods. The second category,“Women and Innovations”, is focussing on cutting-edge projects and accomplishments initiated by women in sheet metal working. The best university projects in science and engineering involving sheet metal technology can

compete in the category “Academic Excellence”.The category “Original Design” is open to companies producing unusual products made from sheet metal. Finally, “The Young Generation” is seeking for outstanding performance of junior employees and young inventors, and “Clean Technology” will rewardeco-friendly solutions and sustainable manufacturing methods. The six winners will be formally presented with an award during a ceremony held at EuroBLECH 2016, 24th International Sheet Metal Working Technology Exhibition, which will take place from 25 – 29 October 2016 at the Hanover Exhibition Grounds in Germany. Detailed information about the competition and the entry requirements are available on the show website www.euroblech.com/ english/competition. All organisations and individuals in the sheet metal working industry are invited to enter if their company or project is setting an extraordinary example in one of the categories. Closing date for entries is 31 August 2016.

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

BUSINESS NEWS

Lantek makes new appointment to promote factory in UK To promote the Lantek Factory concept to sheet metal and structural steel companies in the UK, Lantek has appointed Adam Ball as Sales Manager for the company’s ERP products. More companies are realising that they can gain some very significant efficiency benefits from integrating all their manufacturing systems allowing them to measure performance, in real time, of the key aspects of their business. Adam Ball says, “I have been involved in supporting and supplying software for the sheet metal industry for a considerable time and there is a clear move

towards automation to optimise productivity. Integration of software systems is part of the automation process, enabling users to have an accurate picture of all areas of their business including costs, manufacturing status and customer relationships.”

The Lantek Factory concept is achieved through the integration of Lantek Workshop and Lantek Integra products with the Lantek Expert and Lantek Flex3d CAD/ CAM products which handle CAD data, unfold parts, create nests and generate CNC code for the cutting process. Starting with a customer enquiry, CRM software makes available the complete history of a customer’s orders. Quotation software then makes it very quick and easy to generate an accurate cost to include material, and all the manufacturing operations such as cutting, bending, painting

and assembly. At the same time the production schedule can be interrogated to make sure that material is available and that there is sufficient production capacity to deliver parts on time. Once the order is placed, delivery dates, manufacturing stages and material requirements are all specified and scheduled. These are then synchronized with the other work going through the factory, enabling engineers to create dynamic nests of parts for each material type where appropriate, manage remnant material and prepare parts for cutting while keeping to the delivery dates.

Gleason to demonstrate new solutions for advanced gear production Gleason will demonstrate brand new solutions in advanced gear manufacturing technology on Booth #N-7000 at IMTS 2016, covering a wide array of processes for the complete production and inspection of all types of bevel and cylindrical gears. Among the technologies to be exhibited will be the Genesis 260GX – New Threaded Wheel Grinding Powerhouse. The 200/260GX machines are the most recent addition to our Genesis® machines series. The GX series features a two spindle concept for maximum productivity with minimized idle and set up times. You can also witness Hard Power Skiving on the Gleason 300PS for the first time at IMTS. The Gleason Power Skiving Simulation Software

MACHINE TOOLS WORLD AUGUST 2016

depicts the cutting cycle for every cut and ensures that cycle times are minimized and tool life is maximized. The 500CB Cutter Build Inspection Machine for automatic, accurate and repeatable builds will also be exhibited. Genesis® 400HCD Gear Hobbing/Chamfering with the new GEMS® Software Package is the newest addition to the Genesis® line of hobbing machines features a newly developed time-parallel chamfering process. The brand-new GMSL series of machines offers the latest advancements in metrology systems within a compact and smart design. Gleason will present its complete gear manufacturing tool program including modern tool servicing concepts with integrated connectivity via RFID. Products featured will include tool materials like G90 and advanced carbides, optimized with the latest wear coatings. Power Skiving Tools are now available in solid carbide and with inserted blades for the exciting Hard Gear Power Skiving process. For bevel gears Gleason will show the innovative Pentac®Plus RT cutter head which makes blade setup and checking more reliable and faster than any current solution on the market. Gleason will also present its latest line of hard finishing tools including dressing tools for grinding and honing applications. Quik-Flex® Plus, Gleason’s next generation of modular, quick-change workholding systems requires a single tool, less time and minimal operator experience. Customers are invited to stop by and participate in the Gleason Quik-Flex®Plus Challenge to experience how easy it is to change the modular components.

BUSINESS NEWS

FARO® Expands Metrology & Factory Automation Offerings with Acquisition of BuildIT Software & Solutions Ltd. FARO® (NASDAQ:FARO), the world’s most trusted source for 3D measurement and imaging solutions for Metrology, Factory Automation, Product Design, Public Safety, BIM/ CIM and 3D Services applications, announces the acquisition of BuildIT Software & Solutions Ltd., a leader in process-configurable 3D metrology software solutions with hardware agnostic interfaces. FARO will introduce the configuration power of the BuildIT software in a new “Your Product, Your Process, Your Solution” campaign aimed at providing major customers with customizable, in-process solutions that integrate metrology

devices and sensors from multiple manufacturers. Located in Montreal, Canada, BuildIT’s software is used daily on the production lines of 5 of the 10 largest aerospace and defense manufacturers. BuildIT’s software is hardware independent, giving

customers the flexibility to utilize different hardware offerings to maximize productivity and efficiency. “The acquisition of BuildIT bolsters FARO’s complementary suite of software solutions for our metrology customers,” stated Dr.

Simon Raab, FARO’s President and CEO. “By adding BuildIT to our metrology portfolio, our customers now have even greater software options for use in a variety of 3D metrology manufacturing applications to reduce inspection and assembly times and increase productivity. The BuildIT software suite is hardware agnostic. FARO recognizes that its Factory Automation and Metrology customers often integrate equipment from multiple vendors, and we are committed to providing valuable and configurable customerspecific solutions irrespective of metrology manufacturer mix.”

Renishaw debuts all-in-one optical incremental encoder VIONiCplus is Renishaw’s new highest performance optical incremental encoder system that has been launched as part of the VIONiC™ digital all-in-one encoder series. The VIONiC design combines all necessary interpolation and signal processing inside the readhead and eliminates the requirement for additional external interfaces. To this end, Renishaw developed a new Versatile Interpolation ASIC (VIA) chip to perform all of the functions originally executed by the interface. Other features, working in conjunction with the Advanced Diagnostic Tool (ADT), bring the enduser wide-ranging monitoring and diagnostic feedback. The VIONiCplus incremental encoder is the culmination of research into the latest fine compensation architectures and advances in modern optimisation algorithms leading to unparalleled heights of performance. By leveraging advances in digital interpolation and signal processing techniques, Renishaw has

MACHINE TOOLS WORLD AUGUST 2016

built an encoder with Sub-Divisional Error (SDE) below ±10 nm – unprecedented from a 20 µmpitch scale. VIONiCplus is the first conventional optical encoder to deliver the performance advantages of ultra-fine pitch (<4 µm) systems with the additional benefits of better yaw and ride-height tolerance, easier installation, smaller system size, higher speeds, more flexible scale options including longer lengths, better dirt immunity and lower cost. An example application is scanning, for instance 3D LiDAR, which relies on precise constant-velocity control of a rotary motor in order to limit measurement errors at long range.

The VIONiCplus incremental encoder is the ideal solution as it provides exceptionally low SDE that minimises velocity ripple. Furthermore in motion control, the encoder’s high 2.5 nm resolution and low 1.6 nm RMS jitter reduce position settling time and increase stage repeatability. The VIONiC series of incremental encoders has CE approval; is manufactured by Renishaw, using strict quality controlled processes that are certified to ISO 9001:2008; and, like all Renishaw encoders, is backed by a truly responsive global sales and support network. The VIONiC encoder series is available to order from August 2016.

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

PRECISE

PRODUCTIVE

HIGHLIGHTS

+ + + + + +

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

EMAG India Private Limited I “Technology Centre” I No. 17/G/46-3 · Industrial Suburb I 2nd Stage · Yeshwanthpur I Bangalore · 560022 I Karnataka · India Phone: +91 8042544400 I Fax: +91 8042544440 I E-mail: sales.india@emag.com I Website: www.emag.com

FAST

BUSINESS NEWS

ExxonMobil collaborates with Micromatic Machine Tools ExxonMobil Lubricants Private Limited is the official lubricant partner of Micromatic Machine Tools Private Limited, the marketing and service company of the 1,200 crore Ace Micromatic Group that is India’s largest machine tool conglomerate. Through this partnership, Mobil Industrial Lubricants will support Micromatic with its advanced range of industrial lubricant products and services, backed by its leadership and expertise in the lubricants market. Through this collaboration, ExxonMobil aims to offer Micromatic customers its high quality products addressing application needs supported by the Solcare program for coolant management. Mobil distributors’ ability to collaborate with the Micromatic service team will ensure customer satisfaction

through technical services and on time product deliveries. Glen Sharkowicz, Industrial Lubricants Marketing Manager, Asia Pacific, ExxonMobil Fuels & Lubricants, said, “Our partnership with Micromatic, one of the leading machine tool developers, will help us push the boundaries of lubrication formulation and performance”. TK Ramesh, CEO, Micromatic Machine Tools

Pvt. Ltd, said, “We look forward to leverage our collective knowledge and expertise to bring improved performance and productivity to our customers. We also look forward to Mobil’s expertise in selection of appropriate fluids which is in line with our commitment to promote Green environment.” “Mobil Industrial Lubricants is proud to partner Micromatic to better understand the needs

of Indian component and equipment manufacturers, provide them with customized solutions that will help them achieve a winning advantage,” said Shankar Karnik, General Manager, Industrial,ExxonMobil Lubricants Pvt. Ltd “As part of our partnership, we have developed a program, which includes a quick reference guide for customers on lubricant management and ensures all Micromatic customers across India have access to the right lubricants at the right time, resulting in customer delight and assurance. This allows both Mobil and Micromatic to bring their combined capabilities to achieve new heights of equipment productivity and efficiency,” added Imtiaz Ahmed, Asia Pacific Mobil SHC Brand Manager, ExxonMobil Lubricants Pvt. Ltd.

NUM and Feng Chia University develop intelligent CNC machine NUM (NUM Taiwan Ltd) and Taiwan’s Feng Chia University have jointly developed an intelligent CNC gear hobbing machine with an advanced electronic gearbox that completely eliminates the time overheads of changing mechanical gears on traditional machine tools. Development of the machine began in 2014, under the initiative of Professor Ruihong Xu, who works for the Bachelor’s Program in Precision System Design at the College of Engineering in Feng Chia University. Professor Xu is responsible for a number of industry-university collaborative research and development projects at the university. Following detailed discussions between NUM and Professor Xu about the potential machine control possibilities of its latest Flexium+ CNC system – which offers an advanced precision electronic gearbox – the company donated a series of CNC controllers to the university in 2014. With the assistance of other providers, the

MACHINE TOOLS WORLD AUGUST 2016

intelligent CNC gear hobbing machine, which utilises five-axis electronic gear synchronisation techniques, is now complete. It is currently being exhibited in the first floor laboratory of Feng Chia University’s College of Engineering. The open architecture of NUM’s Flexium+ CNC makes it an ideal platform for research and development projects such as this. The humanmachine interface (HMI), together with loop programs for gear machining, have been specially created by Professor Xu, who was previously in

charge of HMI development at HOTA Industrial Mfg. Co., Ltd. He continues to foster tight collaboration between the university, HOTA, Hiwin Technologies Corp. and NUM. The new intelligent gear hobbing machine is based on a significant upgrade to a traditional NC gear hobbing machine that featured a mechanism provided by Chang Feng Gear Machinery Co. Ltd. Developed under the Industry 4.0 planning and design concept, it offers powerful expansion capabilities through use of a CNC-PC communication framework. Facilities for monitoring parameters such as spindle speed, temperature and motor current have been added. Transmission of network data, calculation of cloud data, analysis and prediction can be performed via suitably equipped tool wear monitoring systems. This facilitates online compensation and product measurement, to provide optimal cutting parameters & precision.

BUSINESS NEWS

Seco Tools celebrates 20 years in India Seco Tools India Private Limited, a wholly owned Subsidiary of Seco Tools AB, Sweden located at Koregaon Bhima on Pune-Ahmednagar National Highway, has completed 20 years of operation in India on May 27, 2016. The company inaugurated its new office and factory building on May 27, 2016 at Koregaon Bhima. Internationally acclaimed industrialist Baba Kalyani, Lars Bergstrom, President and CEO of Seco Tools, Andreas Fritz, Managing Director and Sr. Vice President Asia Pacific alongwith Seco employees and other

distinguished guests were present during the event. Seco is a global business, based on shared values that extend across cultural and geographical boundaries. Seco strives to be perceived by customers, suppliers and employees in a consistent manner, regardless of where in the world you meet the company. “We have been able to live up to the high standards that we and our customers place on us through our shared values: Passion for our customers, family spirit and personal commitment”, says Lars Bergström President

and CEO. “These three common values help us make the right priorities and act in a manner that has become Seco’s hallmark for decades” he continues. The shared values are of great importance for the governance of the global operations. Decisions are based on values and goals, which means that Seco, despite its size, can continue to be fast and flexible. “The information age has had a profound effect on the industry. From the need to compete globally to an ever-increasing pace of technological evolution, today’s manufacturers, we as

well as our customers, face constant challenges to reduce cost and increase productivity,” says Andreas Fritz, Managing Director, Seco Tools India. “At Seco, customer relationships have always been a cornerstone of our operations. By choosing Seco, you get more than just a comprehensive portfolio of advanced metal cutting solutions and expert services. You get a partnership based on trust, respect and communication and a team that is always ready to help you gain the competitive advantage,” he adds.

DMG MORI meets target forecasts DMG MORI AKTIENGESELLSCHAFT completed in a volatile market environment the first half year 2016 according to plan: Order intake was € 1,158.2 million (previous year: € 1,203.3 million). This decline is mainly attributable to cancellations made by us due to non-receipt of advance payments. Without this measure, the order intake figure would be above the previous year’s level. Sales revenues amounted to € 1,092.5 million (previous year: € 1,090.2 million). EBITDA totalled € 94.2 million (previous year: €94.9 million), EBIT was € 65.3 million (previous year: € 68.4 Mio. €) and EBT amounted to € 61.2 million (previous year: € 65.7 million). As of 30 June 2016, the

MACHINE TOOLS WORLD AUGUST 2016

group reports earnings after taxes of € 42.8 million (previous year: € 45.3 million). Sales revenues in the second quarter reached € 551.1 million (previous year: € 551.8 million). For the half year, sales revenues were slightly above the previous year’s value at € 1,092.5 million (previous year: € 1,090.2 million). International sales revenues amounted to € 729.4 million and were thereby at about the previous year’s level (€ 733.3 million). Domestic sales revenues increased to € 363.1 million (previous year: € 356.9 million). The export quota amounted to 67% as in the

previous year. In the second quarter, order intake amounted to € 566.6 million (previous year: € 616.1 million). This decline is mainly attributable to cancellations made by us due to non-receipt of advance payments. Without this measure, the order intake figure would be above the previous year’s level. In the first half year order intake amounted to € 1,158.2 million (previous year: € 1,203.3 million). Domestic orders were € 371.9 million (previous year: € 397.9 million). International orders amounted to € 786.3 million (previous year: € 805.4 million). Thus the share of foreign business is 68% (previous year: 67%).

BUSINESS NEWS

MAPAL relies on Safe-Lock system from HAIMER Within a wide range of markets, such as the aerospace industry, cutting tools from MAPAL have successfully established themselves for high-performance machining operations like trochoidal milling. In order to offer users even greater protection against tools being pulled out of the chuck during machining operations, & to prevent damaging single workpieces or the machine itself, MAPAL is going to rely on the Safe-Lock pull-out protection system from HAIMER. The two companies recently signed a corresponding licensing agreement. HAIMER and MAPAL have reached a partnership and licensing agreement. The tool holding specialist from Igenhausen near Augsburg and the precision cutting tool manufacturer from Aalen are combining their strengths to form a new partnership. In the future, they will work strategically closer together on the progression and further development of

technologies and their applications in the manufacturing market. The two companies have signed an agreement that has contractually solidified their partnership. “We are proud and happy to have a strong partner at our side in MAPAL that is one of the world’s leading tool manufacturers,” emphasizes Claudia Haimer, managing partner of HAIMER. And the managing partner of MAPAL, Dr. Dieter Kress, is also looking forward to the future cooperation. “The Safe-Lock system has

proven itself both in the market and during our in-house trials. Consequently we have decided to use this leading system,” Dr. Jochen Kress, Member of the MAPAL Senior Management, says. “It is very frequently used for modern machining strategies. With Safe-Lock, the productivity and tool life can be significantly increased,” Andreas Haimer, Managing Director and President of the HAIMER Group explains .When it comes to high-speed cutting, absolute safety is

especially crucial. Considering the high value of the single workpiece or an unmanned production, scrap parts and machine downtime have to be avoided in order to guarantee process reliability. Through special drive keys in the tool holder and grooves in the cutting tool shank, the Safe-Lock system from HAIMER ensures high accuracy frictional clamping with the security of a form fit between grooves on the cutting tool and the drive keys in the chuck.

Dormer PFX drill well suited for deep-hole drilling Dormer’s PFX range offers the versatility and productivity to meet most deep-hole drilling needs. Providing a cost-effective option for a wide range of applications, all PFX drills are manufactured from high speed cobalt steel and suitable for use in a variety of materials for drilling depths from 3xD to 25xD. This includes 3xD stub (A920, A921), 6xD jobber (A900, A901), 10xD long series (A940, A941) and 15xD to 25xD extra length (A976, A977, A978). All feature a straight shank and parabolic flute design for increased chip space and improved evacuation. This design allows greater hole-depths to be achieved in some cases without the need for pecking. A thick web increases the structural strength of the drill for greater rigidity and minimizes the

MACHINE TOOLS WORLD AUGUST 2016

risk of tool breakage. In addition, a special point geometry provides additional benefits including excellent centering - eliminating the requirement for a pilot hole and reducing the cycle time of the application. Also, it reduces thrust force and power requirements, ensuring accuracy is maintained throughout the depth of the hole. Available in bright finish across the full range, a SmoothFlow coating option is available on stub, jobber

and long series drills. This AlCrN-top coating reduces friction, increases wear resistance and, in combination with the parabolic flute, eliminates chip packing at greater depths. The merger of round tools manufacturer Dormer Tools and cemented carbide tooling specialist Pramet Tools was instigated in 2014. The combined product programme now encompasses a comprehensive range of rotary and indexable drilling, milling, threading and turning tools for the general engineering sector. An expanded sales and technical support service extends to over 30 offices serving more than 100 markets worldwide. These are supported by stateof-the-art production facilities in Europe and South America and a global distribution network consisting of five strategically placed hubs.

BUSINESS NEWS

Shell Lubricants announces ‘The Future of Hydraulic Oils’ Shell Lubricants, the global market share leader in finished lubricants, announced the launch of Shell Tellus S2 MX and Shell Tellus S2 VX- ‘The Future of Hydraulic Oils’ in India, at a press conference. India marks the first leg of the global product launch which shall be followed by unveiling of the new products across Singapore, Thailand, China, S Korea, Malaysia, Indonesia, Germany, Australia and France markets to name a few. The Shell Tellus range of hydraulic oils have been developed to enable equipment operators to select the fluid that will help to deliver optimum value to their operations through: wear protection, long fluid life, and system efficiency. The company has invested in R&D to

upgrade the previous formulations and is now ready to roll-out the next generation hydraulic oils that offer significantly improved performance in these three areas. Shell Tellus S2 MX and Shell Tellus S2 VX are the upgraded formulations of the Shell Tellus S2 M and S2 V hydraulic fluids respectively. For customers, this amounts to more reliable and

efficient equipment operation, which can help reduce unplanned downtime, lower maintenance costs, and contribute to savings in total cost of ownership (TCO)1. Speaking about Shell Lubricants’ latest offerings, Hans Gerdes, Shell Tellus Brand Manager, said, “As a global leader in hydraulic oils, at Shell, we take great pride in working

closely with the leading OEMs, and developing products to fit their needs.” “We work closely with OEMs, academic groups and industry bodies to understand the challenges faced by our customers. With this understanding, we invest in R&D of products that can help customers to reduce ‘Total Cost of Ownership’ of their equipment, by upgrading their lubrication. The new generation of Shell Tellus S2 hydraulic oils - Shell Tellus S2 MX and Shell Tellus S2 VX – are a result of our continuous efforts and we are proud to introduce these to the market. In particular, our team is pleased to have India as the first leg of this global launch”, added Mr. Akhil Jha, Vice President Technical, Shell Lubricants India.

Cortec launches grease for longer corrosion protection When it comes time to lubricate bearings, fans, chassis, or other metal areas where grease is applied, Cortec’s CorrLube VpCI Lithium EP Grease offers longer lubrication enhanced with superior corrosion protection—even for use on electrical connections. CorrLube™ VpCI®Lithium EP Grease is a lithium complex grease formulated with premium quality, severely hydro treated base stock. It provides excellent resistance to oxidation and has high temperature stability; it is suitable for both operating and lay-up conditions. This lubricant’s formula is specifically designed with superior corrosion inhibiting properties against salt water, brine, H2S, HCl, and other corrosive agents. In addition, it incorporates Vapor phase Corrosion Inhibitors for areas not in direct contact with the grease. It lubricates for longer periods of time and increases the effectiveness of seals to keep out contaminants. The grease remains effective even in extreme operating conditions and aids in the

MACHINE TOOLS WORLD AUGUST 2016

suspension of solid additives such as graphite, molybdenum, disulfide, etc. Its thicker film consistency allows it to operate on worn parts, provide surface protection against movement, and reduce noise level. Specific applications of the grease include the following: Metal-to-metal, Lubricating sleeves, Ball and roller bearings, Vehicle/equipment chassis, Fans, Bushings, Pulley bearings, sliding high-friction areas and generator end bearings. The grease has been under successful use by a major mining equipment manufacturer in Finland.

The company had been using grease from one of Cortec’s competitors to protect electrical connections in control boxes. However, the grease was not performing well, and several areas were still corroding. Cortec’s representative was able to offer CorrLube VpCI Lithium EP Grease as a more effective product that would meet requirements of a dielectric test while being flame retardant (control boxes are located in mining equipment where burning chemicals cannot be used). Test results according to the ASTM D149 Dielectric Strength and Breakdown Voltage method exceeded expectations. The product was applied to vulnerable areas from a custom-designed tube at different coating thicknesses, depending on the extent of an area’s corrosion exposure. Excellent results were obtained in the field. Cortec®CorrLube™ VpCI® Lithium EP Grease was easily applied, easily removed, and continues to give long lasting reliable performance.

BUSINESS NEWS

Three Taiwanese companies heed ‘Make in India’ call Taipei World Trade Center (TWTC), a Taiwanese government body to promote bilateral trade among countries, announced that three Taiwanese Machine Tool companies are investing in India,Tongtai Machine Tool Company, Fair Friend Group and Chain Headway Machine Tool Company. Post the Taiwanese Machine Tool Trade Showheld in Chennai, this has generated on-site business and attracted industrial players from Taiwan. Following the huge success,Tongtai Machine Tool Company; the biggest manufacturer of special machineswill be setting up a Technical Research Center in North India and open the India office in Hyderabad. The Fair Friend Group, the world leading industrial holding conglomerate with over 80 companies to invest and tie-up with India based local company to expand its operation in the Indian market. Chain Headway Machine Tool Company, the leading tools

and accessories suppliers will collaborate with local dealers to develop high speed toolbars and cutters in the country. Speaking on the occasion, Charles C. Li, Director General, Taipei Economic and Cultural Center said, “The AIEMA, Taiwaneseexpo generated keen business interest and attracted the best Machine Tool companies from Taiwan to invest in India. Through TWTC we are enabling the best of India and Taiwan to correspond and engage through strategic alliances that will benefit both the nations. We are extremely keen on supporting the Indian government’s programme on ‘Make in India’.” In the year 2015, the top ten destinations for Taiwan’s machine tool exports were China (including Hong Kong), United States, Turkey, Thailand, Germany, Vietnam, the Netherland, India, Japan and Russia.

AMTEX 2016 exhibition retained a huge success The AMTEX Exhibition (Asian Machine Tool Exhibition) was held from 8th to 11th July 2016 with a bang at Hall Nos. 8, 9, 10, 11, 12,12A & 14 at The PragatiMaidan, New Delhi, (India). An array of Machine Tools, Machineries and Allied Products were displayed in an expanse of over 2,00,000 sq.ft Besides giants in the Machine Tool and Engineering segment from the length and breadth of the country, the event had participation from 67 other countries like Germany, Japan, USA, Spain, Turkey, UK among others with separate pavilions from China, Taiwan, Singapore & Korea being the major highlights. The efforts of the organizers in giving a start to AMTEX from 2001 helped the manufacturing and tooling sectors in the country.

MACHINE TOOLS WORLD AUGUST 2016

The Indian Machine Tool sector stands 13th in production and 6th in consumption of Machine tools. The present Governments manifesto considers the MSME sector as crucial for the development of the country. Cyril Pereira- MD, Reed Triune Exhibitons Pvt. Ltd. while expressing that in the wake of the successful prelude in New Delhi in 2008, the Exhibition has grown to be the largest show in the region. He also thanked one and all for their contribution to the success of AMTEX. He was joined by Michael Mandl- CEO of Reed Exhibitions India- who announced the success of the joint venture of Triune & Reed to bring international best practices

in India through Trade Shows and conferences with participation of several European Countries. AMTEX-2016 was supported by NSIC(National Small Industries Corporation) demonstrating strength of Medium and Small Scale Industries of the country. The visitor response for AMTEX-2016 was overpowering with a healthy attendance from sectors like Automobiles & Auto Components, Defence, Railways, Capital Goods and General Engineering Industries. Prominent delegations visiting AMTEX-2016 were from Maruti Suzuki India Ltd, Hero Honda Motors Ltd., BHEL; New Delhi, SAIL, Escorts limited, Ashok Leyland limited, Eicher Motors ltd., JCB India Ltd., Indian Institute of Technology; New Delhi, Indian Railways etc.

SNIPPETS

32%

In Past 3 years Machine Tools Industry Production increased in value terms at a 32 % Compounded Annual Growth Rate (CAGR)

58%

The consumption of metal working tools has increased considerably, at a CAGR of 58 %

$35 bn

(US$ 35 billion) The automotive industry is one of the largest consumers of machine tools in India

75%

75% of the Indian machine tool producers are ISO certified.

160

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

13%

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

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BUSINESS NEWS

CSR Report from Hypertherm shows growth in community engagement Hypertherm, a U.S. based manufacturer of plasma, laser, and waterjet cutting systems, is out with its annual Corporate Social Responsibility report, measuring 2015 progress on Hypertherm’s social and environmental goals. The report covers three different CSR disciplines: the community, the environment, and Associate wellbeing. Highlights from 2015 include an increase in hours spent volunteering, success engaging more students in STEM fields, the opening of a regional recycling center, and the hosting of Hypertherm’s first ever Supplier Sustainability Summit to discuss shared challenges and best practices. “Last year served as a pivotal year for our initiatives. Most notably, it marked the halfway point on our path toward our 2020

environmental stewardship goals,” said Jenny Levy, vice president of corporate social responsibility for Hypertherm. “In evaluating our journey over the past five years, we’ve learned that although our organization is transformed by this work, continued partnership with our suppliers, customers, and community is critical.” The report, available at www. hypertherm.com/CSR, shows that 81 percent of Hypertherm Associates volunteered in 2015 serving an average of 15.5 hours in the community. Combined, that amounts to more than 18,000 volunteer hours donated to nonprofit organizations in 15 different countries. The Hypertherm Owners’ Philanthropic Endeavors (HOPE) Foundation meantime awarded 107 grants, 20 more than

in 2014, in support of strategic focus areas including health and wellness, food and shelter, and education and the arts. As a manufacturer with a long history of engineering innovation, engaging future generations in Science, Technology, Engineering and Math (STEM) fields is of particular importance. To that end, Hypertherm reports

reaching more than 7,000 students through its support of STEM programs. This support includes both time and money with Hypertherm Associate-volunteers providing STEM related coaching and also welcoming more than 700 students to Hypertherm for educational tours, job shadow days, and hands-on workshops.

KASTO to showcase innovative line of products for machining At AMB 2016 (Stuttgart, 13 to 17 September) the metal sawing and storage technology specialist KASTO will be showing its innovative line of products for machining and storing bar stock and sheet metal. The presentation at Stands B11 and B12 in Hall 6 will also feature efficient solutions for energy recovery & storage. In addition, for the first time the company will be presenting a newly designed high-performance band sawing machine that is optimised for bimetallic & carbide blades. Users will be impressed by its short cutting times & long tool life. All storage systems sold by KASTO are optionally available with an energy recovery system and an

MACHINE TOOLS WORLD AUGUST 2016

integrated energy storage unit. The system can convert surplus energy, such as that produced in braking of a gantry crane or lowering of lifting gear, into electricity and store it

temporarily for later use as needed. This reduces the electricity costs for operation of the storage system while at the same time improving the mains quality because power is drawn more continuously. Thanks to the lower power requirement, operators may even be able to use smaller transformer stations in their planning, in this way reducing their investment costs. At AMB KASTO will be demonstrating its expertise with a UNITOWER tower storage system that is equipped with energy recovery. Visitors to the KASTO stand can also look forward to a premiere: The company will be presenting its newly developed high-performance

band sawing machine for efficient use of bimetallic and carbide blades, which is distinguished by short cutting times and long tool life. But the company will also be displaying long-used solutions. KASTO will also be displaying its KASTOvertical semi-automatic vertical band sawing machine for longitudinal cutting. It can cut square or flat materials with different cross sections from rolled blocks or rolled plates. A moveable material support table ensures fast and safe handling of heavy workpieces. The cutting speed and feed rate are continuously adjustable, and it has a cutting range of 600 millimetres.

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

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17.03.2016 15:51:15

BUSINESS NEWS

CII Automation Conference calls for a change in the way we manufacture “Quality is not difficult to attain, but quality consistency is hard to achieve. So if you need consistent quality, volume and productivity, you have to switch to Automation,” said Mr. Ramakant Joshi in his keynote address at the CII Conference on ‘Automation for Profitability’ held at Hotel Residency Towers, Coimbatore on 22nd July. “Automation also reduces fatigue and helps the workforce to be more productive. In order to make automation achieve the desired goals, it is imperative that the buyer is equally knowledgeable and is fully involved, rather than leaving things entirely to the seller and his capabilities. At the buyer’s end, people at all levels should also be trained to assimilate the new technologies and the processes involved,” remarked Mr. Joshi. Mr. P. Ravichandran, President, Danfoss Industries was the Chief Guest on the occasion. In his address, he dealt with the after-effects of digitalization. He said that the mega trends in the domain are disrupting the world. Larger companies are fast disappearing and smaller ones are growing bigger in no time. The use of IOT technology and software are eating into every business including the kirana stores. In industries like food processing, automation is helping in close control of parameters, enabling traceability of the processes & products and also bringing down the costs. Automation is also bringing productivity, safety and sustainability through conservation of energy, water

MACHINE TOOLS WORLD AUGUST 2016

and other scare resources.” He said the industry should have the capacity and ability to deploy automation. Small and medium size companies must focus on knowledge and skill development so as to be able to embrace the sweeping changes. Earlier, Ms. Nethra J.S. Kumar, Chairperson, CII Coimbatore Zone & CMD, Lakshmi Electrical Control Systems Ltd. delivered the welcome address and Mr. Arjun Prakash, Event Chairman & CoConvener- Manufacturing Panel, CII Coimbatore Zone & DirectorEffica Automation Ltd. delivered the theme address. The Conference discussed as many as 16 well researched papers under four Technical Sessions viz. Automation for Higher Productivity & Flexibility; Quality in Automation; Materials Handling; and Advanced Technology in Automation. The eminent speakers represented well-known automation

companies like Beckhoff, Rockwell, Festo, Hirotec, Ace Manufacturing, Lucid Imaging, Karma Innovations, Pricol, Bastion Solutions, ABB, Gudel, Arkkays National Engineering, Robert Bosch, Siemens and Fanuc India. Dr. B. Vinod, Member-Steering Committee and Head, Robotics & Automation, PSG College of Technology summed up the proceedings.

Nearly 160 delegates from the manufacturing sector from across the country attended, took part in the day-long deliberations and derived benefit. The Conference was organized by CII with a view to addressing the twin challenges of adopting new technologies for manufacturing firms: big investment and scarcity of skilled manpower to handle automation. – P.K. Balasubbramaniian

BUSINESS NEWS

P90CD & P90iC Horizontal Hobbing Machines Gleason Corporation introduces the P90CD and P90iC Horizontal Hobbing Machines. Now, two new machines from the P-Series enhance the current model line to provide optimized solutions for specific applications which require high productivity and efficiency. Based on the well known P90 Hobbing Machine, the new P90CD Hobbing Machine with integrated Chamfering/Deburring Module has been designed for disc-type workpieces, like automotive pinions and short shafts. The P90CD features an integrated CNC chamfering/deburring station which works in parallel to the cutting process; hence productivity is not compromised by the added auxiliary process. The P90CD can hob parts up to a diameter of 60 mm and module 3 mm; larger diameters are available on request. Cycle times are as short as 10 sec for planetary pinions. The chamfering/

MACHINE TOOLS WORLD AUGUST 2016

deburring station includes an auto-meshing feature which avoids tooth-on-tooth cut workpieces and chamfering tools for consistent cycle times and to avoid damage to workpieces. The new P90iC Hobbing Machine with integrated Chamfering/Deburring Unit has been specifically designed for the hobbing and quality chamfering/deburring of geared shafts, but can be used for disc-type workpieces as well. The P90iC features an integrated chamfering/deburring unit which eliminates burrs and creates even and precise chamfers. The P90iC handles any workpiece up to a diameter of 100 mm and module 3 mm; larger diameters and modules are available on request. The P90iC is an excellent solution to employ one or two-cut processes for finish hobbing or to create a quality base for subsequent hard-

finishing operations. The two-cut process in particular is executed in a single setup (cuttingchamfering/deburring-cutting) and eliminates secondary burrs and residue on the gear flanks. This process is very beneficial for subsequent hard-finishing processes, protecting the tool life of expensive finishing and dressing tools, especially if a honing process is applied. For both machines direct-driven hob head options are available which offer the optimum adaption to many applications. For both machines Gleason provides hobs from state-of the-art materials, with the latest wear coatings and high quality rotary chamfering/ deburring tools with extremely long tool life as well as clamping fixtures to secure high machining quality.The P90CD and P90iC are supported by the Gleason Global Service network with strategically located spare parts centers and

over 250 service professionals in all major markets worldwide.

About Gleason: Gleason Corporation’s mission is to provide “Total Gear Solutions” to its global customer base. Gleason is a leader in the development, manufacture and sale of gear production machinery and related equipment and automation solutions. The Company’s products are used by customers in automotive, truck, aircraft, agriculture, mining, energy, construction, power tool and marine industries and by a diverse set of customers serving various industrial equipment markets. Gleason has manufacturing operations in the United States, Brazil, Germany, Switzerland, India, China and Japan, and has sales and service offices throughout North and South America, Europe and in the Asia-Pacific region.

BUSINESS NEWS www.mtwmag.com

Hydrosila Ukraine celebrates 100th Haas machine tool.

On June 15th 2016, during a special celebration event, Ukrainian company Hydrosila marked the delivery of its 100th Haas CNC machine tool. Several VIP guests attended the event, including Mr. Jens Thing, Haas Automation Europe managing director, Mr. Wojciech Ratyński, member of the board at Abplanalp Engineering, Mr. Nikolaj Skripnik, general director of Abplanalp Ukraine, and Mr. Vitaliy Khnustudinow, managing director of Haas Factory Outlet in Ukraine. Hydrosila is made up of five factories located in Ukraine, three of them in Kirovograd, 250km south from Kiev, and the other two in Melitopol, in Sourthern Ukraine. All of the factories are owned by Hydrosila Group, which currently employs over 4000 people. The holding company has been a Haas customer since the purchase of its first two machine tools, in 2000. By mid-

summer 2016 it had increased the number of its Haas machines across all factories to over 100 (currently 114). All the machines are supplied and supported by Abplanalp Ukraine Haas Factory Outlet (HFO), a member of Abplanalp holding company, the most successful Haas supplier in Central and Eastern Europe. “We are very proud to be the supplier of Hydrosila and its affiliated companies,” said Mr. Jens Thing. “The facility and operations we have seen during our visit are extremely impressive. The company is very well organised and motivation is excellent. In fact, Hydrosila is one of the best volume-manufacturing plants I have ever seen, anywhere. We look forward to a common, successful future together. And, through the local HFO, we also look forward to supporting the growing Ukrainian manufacturing economy with our very reliable

CNC machine tools.” Hydrosila’s general director, Mr. Yuri Titov, emphasized the importance of cooperation with Haas for the development of the company’s business: “Global market conditions require all manufacturing businesses to be competitive in terms of productivity and the quality of their products” he states. “We began a full, technical modernisation of our company in 2000, by purchasing our first machine tools from Haas. The decision to invest in Haas turned out to be a very good one. We have a very reliable manufacturing base and we can make parts to consistently high standards. The support we receive from the HFO is excellent.” During the event, Mr. Wojciech Ratyński said that the Hydrosila group, with its excellent technical abilities and its exceptional organisation, is able

to manufacture very complicated products, which will enable the company to grow in Western European markets and beyond. “We look forward to coming back again when the company has 200 Haas machines,” he said. Hydrosila is specialised in the manufacture of gear pumps, hydraulic cylinders, high-pressure hoses and other agricultural spare parts. The products are not only exported, but also used to assemble complete machines, including drills, cultivators, seeders, sprayers and more in the historical Chervona Zirka factory. In 2011 the company met a milestone by reaching production capacity of over 1 million pumps per year. The company’s long history began in 1874 when British brothers Robert and Thomas Elvorti established the factory, which many decades later became the largest and oldest manufacture of agricultural parts in Europe. Across two centuries, the Chervona Zirka (Red Star) factory has successfully made its way from simple mechanical workshop to the leading supplier of fluid power machines and hydraulic system components for agricultural, construction and road-building equipment.

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MACHINE TOOLS WORLD

COVER STORY

Ace Micromatic :

Powering the success driven growth Q1. Ace micromatic has gained substantial market share in Indian machine tool industry, please elucidate the success story of the company? Ace Micromatic Group is India’s largest machine tool conglomerate with a market presence in several countries across Asia, Australia, Middle East, North & South America and Europe. Intent is to provide its customers a one stop shop for all machining needs, the group specializes in the manufacturing of CNC turning, milling and grinding machines along with subsystems like tool turrets, ATC etc. The group offers its customers a wide and comprehensive range of machine to suit a broad spectrum of applications. It also offers turnkey solutions, tooled up options, innovative work holding, Cp/ Cpk evaluation, TPM friendly machines and more. Building on its expertise in machine tool manufacturing, the group also offers products to enhance its customer’s productivity through real time machine monitoring and OEE. Our success can be attributed to our collective ability to convert design’s to making products cost effectively. Looking back at the three decades of our operation,

we can confidently say that Micromatic played a key role in nurturing the SSI’s & the SME’s to adopt CNC technology and move towards global quality levels, through providing them with affordable CNC technology and close hand holding. Our customers feel comfortable to work with us and place repeat orders. With an installed base of more than 30000 machines across the globe, we are the largest Machine tools group.

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? We have global market presence of our machines in several countries including United States, Germany, France, UK,

Russia, Canada, Brazil, Saudi Arabia and China, etc. We are currently concentrating on the Chinese, South East Asia, Turkey and European markets. We have set up our own offices in China and Germany to cater to the needs of the local customers in the region. In addition to this we have a strong dealership network in other major markets where we have supplied machines. Around 10 % of our sales are through exports and it is increasing year on year. As far as global alliance is concerned, we are a truly Indian company and have been actively “Making In India” since last three decades. All the technology development is done in-house in tune with the changing requirement of our customers. Our product development is in line with the market requirements and enables our customers to produce their components in a cost effective manner.

Q3. What are the market prospects for the Ace micromatic products in India and How do you plan to position these products? We have standard machines and also provide value added products and services to all our customers. Ace Micromatic group companies are uniquely positioned to

Mr. TK Ramesh, CEO Micromatic Machine Tools Pvt. Ltd.

MACHINE TOOLS WORLD AUGUST 2016

COVER STORY www.mtwmag.com

closely knit the entire team together and paved way for Ace Micromatic group to aspire to be among the Top 25 players in the global machine tool fraternity

Q7. Please comment on the current machine tool scenario in India ? provide end to end solutions to a large number of industry sectors through its wide and comprehensive range of machines to suit a broad spectrum of applications in Automotive & Auto component, General Engineering, Aerospace & Defence, Energy, Railways, Construction equipment and off road vehicles, Die & Mould, Medical & Orthopaedic implants etc. Starting from process optimization, fixture and work holding solutions, tooling selection, automation and complete prove out, the machines are built to suit the customer needs. In addition we have also expertise in integrating automation solutions through Robotics and gantry system providing an error free and highly productive solution.

Q4. Can you brief us about the marketing strategies that were applied in order to stand out in the competition of machine tool industry? The key differentiator that keeps Ace Micromatic group ahead of the curve is our high productive solutions at competitive price and the unmatched pre sales and post sales application and service support that adds great value to the customers. Our customers are served through the extensive and widely spread sales and service network of Micromatic machine tools the marketing arm of Ace Micromatic group. With 35 plus offices and six technology centers spread across the country, and with a strong team of 550 trained engineers, we believe we are at the door steps of our customers when they need us.

Q5. Please elucidate in brief about the Ace micromaticâ&#x20AC;&#x2122;s infrastructure & What are the measure that are being taken from the product manufacturing to distribution? Ace Micromatic group is truly powering

the growth of the nation through its strong workforce of about 2,400 committed employees across India and more than 120,000 sq mts of built up facility. We have the best in class manufacturing facility for production of Castings and then machining them to the fine accuracy required for building high class machines. The assembly of Jobber series CNC turning centers takes place on Assembly lines which yields very high levels of consistent products. Separate temperature controlled room with automated test beds for the test running and stabilisation of Spindle ensures very high accuracy and life of the spindle. Calibration and measuring equipment of world class standards are available at all production units to ensure thorough testing of our machines to international standards.

Q6. Brief us about the R&D and Quality policy for your business? Design and development is the key strength of Ace Micromatic Group. Some of the core strengths of the group are the rich engineering experience of its leaders, who are considered pioneers in the development of several technologically advanced products and a very strong shared value system. A healthy synergy among the group companies has facilitated cross learning and rapid growth and enabled us to be the front runners in machine tool development. Further, as new developments happen, we bring out products needed for the sector. For eg. Our Government is giving stress on the development of the electronic sector in India through the â&#x20AC;&#x153;Digital Indiaâ&#x20AC;? initiative; we are internally developing new products that will cater to the needs of this sector. Managing a large organisation and driving sustainable growth requires a strong vision which motivates the people. The twin pillar of Ethics and Values has

Green shoots of growth are being observed, though the pace of growth is not up to the expectation. Also, as we are beginning to see automotive sales, especially the passenger car segment increasing, the capacity utilisation is also improving. Sooner or later the new investment plans will also kick in. The order book for most of the machine tool manufacturers in the first quarter of the current financial year has been positive, and with the same trend continuing, we should hopefully end with a double digit growth rate.

Q8. Could you brief us on Indian & Global perspective of machine tool industry? What are the distinguishing factors? The key requirement of Quality, Cost & Delivery remains the same whether in India or abroad. Machine performance and reliability are the basic requirement for all manufacturing industries. The major difference in the expectation from the manufacturing industry which ultimately influences the machine tool design also is the way in which the machines are tended. On account of the low cost work force in India, we tend to have higher percentage of machine which perform single function and are generally manually operated or with simple automation. Where as in the European and other countries, due to non-availability of labor, the machines generally tend to be multi-tasking and fully automated.

Q9. In your opinion how can the Indian machine tool industry become globally competitive ? In my opinion, some of the machine tool manufacturers of India are already globally competitive. Not only are they effectively facing the onslaught of foreign machine tool manufacturers in India, rather they are also taking up the

AUGUST 2016

MACHINE TOOLS WORLD

COVER STORY challenges on foreign soil. We already have our presence in China and in Europe through our own offices and are regularly selling our products in face of competition from local and other international manufacturers. India can be competitive in the total solutions space as we have competitive engineering strength.

Q10. What are the key technological trends that are driving machine tool industry? Machine tool industries have to learn to be responsive to higher uncertainty and chaos in the market in this new dynamic era. The throughput time has to be cut down in order to be able to deliver to the fast changing needs of the user industry. Rather than stocking and selling manufacturers have to move to the mode of build to the requirement in shorter time in order to be responsive to the changing needs of the market. We at ACE Designers have implemented systems to produce our standard machine within five days and this has helped us to trim our finished goods inventory. A serious effort to show case Life time & life cycle costs and working to reduce it is beginning to happen.

Q11. How do your perceive the future of the Indian machine tool industry ? The future for Indian machine tool industry is very bright for those companies which are willing to keep pace with the changing market needs. India has a large captive market for machine tools and the Make in India initiative will definitely increasing the Manufacturing activity in India. We have the required products to meet the demands of the emerging markets and are also actively creating new prod-

MACHINE TOOLS WORLD AUGUST 2016

ucts looking at the new growth opportunities that the â&#x20AC;&#x153;Make in Indiaâ&#x20AC;? initiative is throwing at us.

Q12. How far the factors like government norms, excise duty, taxation, exim policies are affecting your business? We all know very well, and have continued to grow our business over the past years irrespective of the government policies and norms. Hopefully with the new focus on Manufacturing and the clearing of the GST bill, things will improve in the coming period.

Q13. What are the best possible remedies you can advise in order to maintain the high profitability in the shrinking margins market of India? There are always cost pressures when the competition is high as many players would be fighting for the same pie. Managing cost to the price pressures is always a challenging act. Working with the customer holistically across the value chain to provide value is a key challenge in tough times

Q14. What is your vision for Ace micromatic? We at Ace Micromatic have set our goals to be among the top 25 machine tool manufacturers in the world and are moving towards that aim with planned initiatives.

Q15. Please address the issues that are affecting the machine tool industry? Machine tool manufacturers in India have to adopt to Global specification, Aesthetics, Reliability and high end features in order to compete with the imported machines. We have to provide cost competitive solutions to be able to compete. Brand building and local service support is very important, however, we are very strong in this area as we have worked upon these factors even before the competition came in. Availability of local vendors for many of the critical components needed for our Machine tool is a long standing issue. We have to endure longer lead time and price fluctuation as these products are imported. With the dynamic market condition which requires fast deliveries, this becomes a major constraint in quickly meeting the surge demands.

Every chip tells a story

Compact system for in-process tool breakage and tool wear monitoring on cutting machines

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INTERFACE

Revolution in

Cutting Oil Technology Mr. Munish Garg Managing Director, See Lube Technologies (P) Limited

Q. What are the latest advancements in technology and product upgrades that you have introduced? Expected growth of Industrial lubricants stands at 3.5% CAGR and this growth is technology based. To compete in this market, adoption of new technology is inevitable. With the increase in demand, there is a big problem of disposal of used lubricant is becoming a big challenge. To counter this problem, we are working towards biodegradable Lubricants. We have developed cutting oils with vegetable oils which are biodegradable using nanotechnology. These oils will have lesser problem of disposal.

Q. How do you see the coolants & lubricants market performing in the next few years? High demand in engineering sectors, mainly automobile sector, pulling the requirement of coolants & lubricants. The expected CAGR is at around 3.5%. Opening up of FDI in defence sector is also going to push the demand upside.

Q. Which sectors will impact demand & sales the most? How do you plan to capitalise on these opportunities? Automobile sector will impact the most. We are working towards to penetrate in more OEMâ&#x20AC;&#x2122;s and their ancillaries. Opening up of aviation and defense sector will also

MACHINE TOOLS WORLD AUGUST 2016

increase the demand of Lubricants. We are also introducing the minimum quantity Lubrication where lubricant will be used less than 100 ml per machine in one shift in mainly cutting & milling operation. These lubricants are based on misting technology, thus giving relief in quantity buying and disposal too. We are also introducing complete range of products thus we become full line supplier for any industry. Apart from our main stream products, we are also moving in to value added product and services like regeneration of used lubricants at customer premises only. We are also introducing equipments for the same, which will be available off the shelf from July 2016. Last year we have launched Total Lubrication management system, where we take responsibility of Lubrication needs of our client through single window system. We manage, test & optimize the lubricants at clientâ&#x20AC;&#x2122;s premises. There is couple of customers who got benefitted with our efforts in terms of reduction in consumption. This year we are increasing our sphere to Coolant Management services too. We will be taking responsibility of coolant management for procurement, usage & disposal, thus giving a much relief to our customers. This activity will not only help customers in systematic way to optimize the usage of coolant ( cutting oil),

but also reduce the cost of operation.

Q. Do you see a requirement to scale up operations in the coming years? Yes, this is requirement of time. Operations in terms of optimization in production house as well as scaling up marketing, is to be done. Now a days, conventional methods of growth are old story, one has to be very creative to sustain growth. New avenues to be dig out, new concepts to be launched and utmost is adoption of energy conservation systems to be introduced in manufacturing set up.

Q. What are the challenges that stand in the way of success? Today world has become very small. Biggest challenge is over use of technology. One has to be open for change in technological concepts. Today along with demand, competition has also become manifold. Unless one is not working on the concept of cost reduction, he will be out of the race. Cost reduction is not only at your location even at your customer location has become your responsibility. One has to be on foot continuously to work in this direction. More and more companies are coming to India with their products, but in my opinion, unless you become complete solution provider for your customer, success will be a distant dream.

INDUSTRY FOCUS

Synetics

aims to be in the top league in automation Coimbatore-based Synetics Automation Solutions Pvt. Ltd. is in the forefront of automation, providing innovative and cost-effective solutions to the manufacturing sector. Six years down the line, the company has proven its engineering prowess and innovativeness in the areas of its core competence namely CNC auto-loading, assembly automation and robotic solutions, and added an impressive list of customers to its portfolio. Reduced dependence on labour, reduced overheads, increased throughput, increase in quality and consistency and ultimately increased customer satisfaction are some of the benefits of automation the user-industry should take advantage of, says the top brass of Synetics in an interview with Mr. P.K. Balasubramanian. Excerpts: Q. Could you explain the beginnings of Synetics?

“We have to convince the customer on the tangible and intangible benefits of automation.”Karthik Soundararajan, Director, Synetics Automation Solutions Pvt. Ltd.

MACHINE TOOLS WORLD AUGUST 2016

Vijayaram Balasundaram : Synetics is the brainchild of two engineers – me and Karthik Soundararajan. We both have done our Masters in Automation & Robotics from the Rochester Institute of Technology, in the US. After my MS, I joined General Motors and worked there for 10 years and got rich experience in automated car and truck body welding lines. Karthik joined Alliance Automation Systems as a Controls Engineer handling electrical design of machines, PLC and robot programming. After working for five years, he moved to Assembly & Test Worldwide (ATW) and stayed there for 1 ½ years. In 2007 he came to India to start and head their Indian Operations. Synetics was started by us jointly in the year 2010 with a view to serve manufacturing companies who wanted to reduce their dependence on labor and at the same time improve their quality and productiv-

“Government should encourage automation and provide loan subsidies for capital investment.”Vijayaram Balasundaram, Director, Synetics Automation Solutions Pvt. Ltd. ity. We started the factory with just two employees and today we have a dedicated workforce of 43 people.

Q. Who was your first customer and what’s your present range of manufacture? Vijayaram: Our first customer was Adulon Polymers based in Coimbatore. For them we developed a painting line using robots. After the initial order, we did two more projects for them – naturally because they were quite happy with our first project. Our current range includes robotic solutions, assembly automation solutions and CNC auto-loaders.

Q. So, what is your niche in automation today? Karthik Soundararajan: We are primarily full-fledged system integrators and machine builders providing end-to-end solutions. We have a very strong mechanical design team with experience in

INDUSTRY FOCUS www.mtwmag.com

A turnkey project done involving robotic automation

be used for turning centers, while the larger one is meant for machine shops with vertical & horizontal machining centers which need supply of more inserts. Our prototypes are ready and are getting perfected. We shall be launching these machines in a couple of months. The ASRS we have developed for food vending is also a novelty in retail outlets and public places. We have already supplied about 20 such systems. They are now being launched in Singapore.

Q. How do you convince the prospect of the fast realization of ROI.

3D modeling and analysis, backed up by a controls team with vast PLC & robot programming knowledge. We do the entire assembly, integration and testing in house to achieve ultimate customer satisfaction.

Q. What are your capabilities and major strengths in turnkey automation? Vijayaram: We are highly creative and we apply our automation experience to come up with innovative solutions that address the customers’ problems. We use high quality and reliable automation components for our systems integration. We focus on building operator-friendly systems also taking care of ergonomics. We have a thorough understanding of OSHA safety standards and lay greater emphasis on the safety of our systems. Our systems are also designed with serviceability in mind and are very maintenance-friendly. When it comes to aesthetics, our products are world-class.

Q. Which are the major projects you have executed recently? Vijayaram: We have executed five robotic projects – one for machine tending, a large overhead gantry system for welding and two for painting. We have a steady stream of orders for our CNC Auto-loaders.

Q. Which are the innovative products you have developed for automation? Karthik: Our CNC Auto Loader needs

A carbide insert vending machine from the crucible of Synetics special mention. With auto-loaders attached to 4 CNC’s, one operator can run four (4) machines. So across three 8 hour shifts, the auto-loaders can replace 9 operators. They are less expensive(40% less) when compared to robotic solutions and can be easily retrofitted to existing machines. Another revolutionary product is our Carbide Insert Vending Machine – Pro-Crib, which is a boon to machine shops. Inserts are costly and hence their issue and proper usage should be monitored and controlled. We have come up with two versions. The smaller version is designed for single insert vending to

Vijayaram: When it comes to automation and calculating the return on investment, the customer should consider reduction in manpower, and also the improvement in productivity. With automation one can expect at least 15-30% improvement in productivity. The savings can be worked out as follows: Suppose you have 7 CNC machines. If you attach auto-loaders to 6 machines and achieve a 15% improvement in productivity per machine, you can achieve a cumulative 100% increase. So instead of running 7 machines, for instance, you can achieve your production with 6 machines. This obviates a capital investment of Rs.20 lakhs and also saves on floor space and power required for the 7th machine. On the other side, with manpower, one can achieve only 85% efficiency. When you implement Automation, you can get closer to 95% efficiency and realize several tangible and intangible benefits. And most important, you have peace of mind. One of our customers has realized a huge increase in production. In 12 hours, with manual loading they used to get 1100 components. Now with an Auto Loader, they get 1440, a gain of 30%. At this rate, the 4th CNC machine can be used to produce other components!

Q. What are the do’s and don’ts in Automation? Karthik: People generally have a bad impression about Automation. This is because the requirements are not defined and customer may not be aware of the

AUGUST 2016

MACHINE TOOLS WORLD

INDUSTRY FOCUS Do’s & Dont’s. In order to reap the full benefits of Automation, the end-user should work very closely with the supplier and have a complete understanding of what they will get. Both should get involved and make things happen.

vendors who keep us informed of the product developments. We read technology journals, attend seminars and conferences, meet people, visit exhibitions and also access Internet for knowledge and information.

For implementing Automation, the following factors should be considered: a. Identify areas that provide maximum value addition. b. Select areas which are easier to implement and bring ROI faster. c. Select projects where the process is stabilized and less complex d. The input component quality should be consistent, automation cannot handle parameter variations e. Areas where cost of labour is more (or) hazardous environments. f. Take time to define the scope thoroughly.

Q. Which are the major industry segments you serve and who are your major customers?

Q. These days all are talking of low cost automation. What are your views? Vijayaram: Yes. People say they have achieved low cost automation. But in effect, it may not be true. While working out the cost, one should also include the cost of time invested by their employees and the cost of failures. People should go for cost-effective automation, based on ROI calculations.

Q. How do you keep yourselves abreast of the latest trends? Karthik : We interact with various

Karthik: Automotive industry, pump industry and materials handling are some of the key industry segments we serve. We want to get into assembly automation in a big way. That’s our core strength.

Q. Which is the most challenging development you have handled? Karthik: It is the food vending machine we have developed. First we developed with pneumatic automation. Later it was switched to all electric. It is materials handling in a different form. The development was quite exciting and satisfying.

Q. What’s your vision for Synetics and how do you look at the future of automation vis-à-vis Synetics? Vijayaram: We want to be one of the top 10 players in the automation industry in India by 2025. Our national agenda is to make India a manufacturing hub for the world. But this is possible only if we implement automation and take our manufacturing to the next level. Look at Ford. They have

put up a plant in Gujarat with 85% automation in their bodyshop, the highest in Asia-Pacific. Automation has to be taken seriously and implemented by our tier-2 and tier3 companies. The fact remains that China is way ahead in automation in manufacturing. That is why they are able to mass produce components at cheaper prices. In the days to come there will be more compulsions to go in for automation. The semi-skilled labour cost which stands at a level of Rs.350/- per day is likely to touch at least Rs.800/- per day by 2025. Today most of the components for automation are imported – PLC’s, servo motors and robots for instance. With the “Make in India” campaign gaining momentum, some of these products will also be manufactured in India and their prices will come down. A combination of increased labour costs and reduced automation component prices will be a big enabler and ROI will be much quicker. In the 80’s the machine tools industry was comfortable with conventional lathes. There was inertia on the part of manufacturers to go in for CNC machines. But in 90’s transition did take place. Today everyone wants only CNC’s because they realize the benefits. Similarly automation is also going through a transition phase in India and the country has to embrace it on a much larger scale so as to keep pace with the industrial growth envisaged.

Assembly automation in progress

Synetics’ CNC autoloader

MACHINE TOOLS WORLD AUGUST 2016

INDUSTRY FOCUS

Gala, deep-rooted in Surface Engineering Solutions The Gala Group, headed by Mr. Kirit Gala, believes that ‘Innovation is about challenging conventional wisdom and finding creative solutions, challenging the obvious and combining discipline and competency in precision engineering.‘ It proclaims that it is engaged in engineering next generation solutions for a world on the move. Gala is a leader in manufacturing torque fatigue disc springs, regular springs and strip springs catering to the globe. The company is also a name to reckon with in providing surface engineering solutions galore. Mr. P.K. Balasubbramaniian converses with Mr. Anand Kaundanya, Chief Operating Officer- Surface Engineering at Gala Precision Engineering Pvt. Ltd. to get a ringside view of the company’s innovations and engineering solutions which help the customer achieve superlative quality and excellent performance of his end products. Excerpts: Q. What are the prime activities of the Gala Group? We are a technology leader in Springs offering a wide array of Springs for applications in Automotive, Off Highway Vehicles and the Power Sector. We also make precision assemblies where Spring is the main component. In Surface Engineering, we offer integrated solutions in the area of finishing and cleaning of metal parts. We provide end-to-end solutions for Deburring, Polishing and Washing & Gala’s Multi-Stage Ultrasonic Cleaning System revolutionizing cleaning

Cleaning of parts. Moving one step ahead, we offer Finishing and Cleaning solutions using Robotics where safety, reliability and performance are of paramount importance. For deburring and polishing of parts, we offer Vibrators, Centrifugal Barreling and Disc Finishing machines with complete automation. For cleaning of parts, we provide different types of Spray cleaning, Multi-stage ultrasonic cleaning and Special purpose customized parts cleaning systems. In order to complete the spectrum, we also offer high quality media and compounds which are essential to achieve the required level of performance in finishing & cleaning processes.

Q. What are the different types of Springs you offer? Our range includes Disc Springs, Strip & Spiral Springs, Coil Springs, Special Springs & Assemblies. With our design capability and application engineering, we have become a preferred partner for OEMs.

MACHINE TOOLS WORLD AUGUST 2016

Mr. Anand Kaundanya, COO – Surface Engineering, Gala Precision Engineering Pvt. Ltd.

A typical Disc Finishing System engineered by Gala

Q. What are the Surface Engineering Solutions you offer? We at Gala see surface refinement as an art in engineering that we have developed with decades of experience and continuous innovations. Today we offer sophisticated, customized Surface Engineering solutions in the fields of Deburring, Finishing, Washing & Cleaning. Finishing is a proven, highly effective form of surface engineering. It occupies an important place in the production process. Our deburring & finishing solutions are tailored to suit the ever-increasing demands of modern manufacturing environment. We provide customized integrated solutions suitable for specific products and production requirements.

Q. What is precision cleaning of parts? The parts cleaning process which results

INDUSTRY FOCUS in achieving stringent milipore values and particle size and particle count is known as precision cleaning of parts. This also calls for complete oil free surface.

Q. What solutions do you provide to achieve precision cleaning of parts? Precision cleaning of parts can be achieved with a combination of cleaning processes such as Spray, Deep Spray and Ultrasonics. This is supported by basket dunking, basket rotation, basket tilting and agitation. Filtration at multiple levels is equally important. We provide all types of cleaning solutions under one roof. This includes all types of spray cleaning machines such as conveyorised, rotary basket, indexing station and customized. Tabletop ultrasonic to multistage ultrasonic cleaning systems up to 5000 ltr work chamber with complete automated basket handling mechanisms are provided. We also offer: • Single chamber multiprocess aqueous cleaning machines. • Rotary screw type Immersion and Spray cleaning machines up to a capacity of 1250 Kg / hr • Customised cleaning machines like Single piece flow ultrasonic cleaning, high pressure cleaning and Robotic cleaning, etc.

Q. Could you throw some light on your manufacturing facilities? We have our manufacturing facilities in Wada, Maharashtra, some 40 kms from our corporate office in Thane. The plant spread across an area of 31,000 sq. mtrs, houses our Machine Manufacturing Division as well as our R & D Centre. The R & D Centre conducts pre-sales trial to develop finishing & cleaning solutions to achieve the desired results. The Centre is equipped with a dozen machines for pre-sales trials; 85 varieties of media and

20 varieties of chemicals, and a plethora of instruments to measure various parameters like surface finish, critical dimensions, milipore value, etc. In the Design Office, we have facilities like AutoCAD, 3D modeling and modern work stations. We also have in-house facilities for SS & MS fabrication and machining.

Q. What’s your marketing / service setup? We have a team of highly trained sales engineers stationed in Mumbai, Bangalore, Chennai and Delhi. We also have an extensive service network covering major industrial belts across the country to attend to service calls. Service is crucial in our business.

MACHINE TOOLS WORLD AUGUST 2016

c. Manufacturing of precision parts cleaning systems to achieve Millipore value of less than 1 mg d. Successful completion of 5,000 ltr capacity Ultrasonic cleaning system for a PSU e. Successful completion of one of the world’s biggest Centrifugal finishing machines

Q. What are your new thrust areas?

Gala also offers Media & Compounds for Finishing and Cleaning

Q. Who are your major customers? We have customers representing various industry segments. These include: Auto Sector: Bosch, Bajaj Auto, Eaton, GKN, Pricol, Tata Motors, and Volvo Bearings: FAG, NBC, NRB and SKF General Engineering: Godrej, LMW and Sandvik Energy & Power: ABB, Alstom, Areva, BHEL, Crompton Greaves and Suzlon PSUs: Ordnance Factories, HAL, BHEL, MMTC, etc. These are some of our major customers.

Q. What are your significant and recent milestones? Gala’s wide array of Vibratory Finishing, Washing and Auto Dosing Systems

Screw type Rotary Washing System A boon to the industry

Following are some of our recent achievements: a. Export of finishing & cleaning systems b. Turnkey projects in defense sector

Our thrust areas and new initiatives include: (a) Development of high technology Aqueous cleaning solutions for precision cleaning of parts at par with global standards; (b) Application based approach to offer customized precision cleaning systems; and (c) Building special purpose machines for defense sector for polishing of non-ferrous parts.

Q. What’s your vision for Gala Precision? Our core ideology is to be Genuine, Trustworthy, Sincere, Innovative, and Committed to continuous learning and spreading knowledge. Our vision is to be No.1 in every market we serve and build the sinews of this organization to have the strength of a big enterprise and at the same time the leanness and agility of a small company. The Group will be driven by entrepreneurship and professionalism and will offer great opportunities to deserving and dynamic individuals to make their mark in the world of scientific management. Furthermore, Gala will remain committed to spiritual orientation and peaceful co-existence of all stakeholders.

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INDUSTRY FOCUS

Indian Die & Mould makers can confidently compete with global players Mitsubishi Electric shares its perspective on the booming Die & Mould industry, and the opportunities and challenges for players in India Q. How is die & Mould making industry shaping itself in India? What kind of opportunities and challenges you can see? The Die and Mould making industry in India has evolved over the years and today competes in a global arena. With an increasing demand from industries such as automobiles, auto components, packaging, plastics, electronics, electrical, healthcare and machine tools, we see a huge opportunity in the Die and Mould making industry in India. High quality and high precision are the buzzwords of any Die-Mould business. The tool room industry is undergoing a change in manufacturing practices. Where earlier, only few important components were manufactured using the CNC machine, now the industry is switching over entirely to CNC to gain a competitive edge.

Q. How can you describe the growth Indian die & mould industry has seen in the span of 10 years? Die & Mould makers in India can today confidently compete with the global market and over the years have recorded transformational and all-round market growth. It has now considered as the ‘Mother of the Manufacturing’. Die & Mould Associations in India is looking forward to gain engineering excellence with an aim to establish India as global manufacturing hub. With the globalization within the die & mould industry, we are seeing qualitative improvement in

MACHINE TOOLS WORLD AUGUST 2016

the type of moulds being used in various industries. The Indian tool room is also rapidly changing by using CNC machining to manufacture.

Q. What kind of technologies are present in the die & mould making industry? Lot of technologies are coming up in die & mould making industry. The segment requires best surface finishing of the Die Mould machines. Below we list some of the technological trends that the die and mould manufacturers can try their hands on: 1. “SSS” (Super Smooth Surface) Technology: SSS controls to provide an optimal speed control function for machining die mold with smooth surface. It also ensures high machining stability and quality with virtually no effects resulting from cutting shape or speed. As a result, the following effects can be obtained in the SSS control. 1. A stabilized and High-quality processing is realized • Irrespective of the speed and shape command to achieve high quality processing in a stable. • There are no streaks on the processing surface even in the command shape that changes consecutively 2. Reduction of processing time • Conventional ratio 5:30% of time reduction (Comparison with the same accuracy) • Especially the effect is remarkable when feed rate is higher

3. Easy parameter setting • Parameter adjustment for correction of shape is not required • Easy adjustment such as Efficiencyoriented and Accuracy-oriented 2. Right CAD/CAM solutions: Right design is necessary for a success of any product. With the use of proper CAD/CAM solutions, the risk of errors drastically goes down as it automated eventually reducing human intervention. Generally, in CAM to create a machining program, the motion curve of the tool relative to the workpiece is calculated by approximating the minute line segments. Therefore small error is more or less included in the data of minute line segment. For example, as shown in Fig.1, there are many cases like the minute error of the zig-zag shape or the shape of a level difference is contained within the limits of the permissible error (tolerance) on CAM processing, to form the process originally. 3. High Speed Machining: HSM is considered to be most promising technology as it helps in reducing the production time and cost of producing high precision surface finishes. The tool life is also extended, though proper care must be taken to tailor and balance the tool. 4. Rapid Tooling: Rapid tooling aims to reduce cycle times by 40% as compared to conventional machining. The use of conformal cooling, bimetal layering and better mould materials, like aluminium,

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INDUSTRY FOCUS allow quicker thermal conductivity in moulds. Also, the rapid processes allow for production of inserts and mould tooling in less than 48 hours. Rapid processes are also capable of producing modifications in the tool, like undercuts or side-action easily.

Q. What does Mitsubishi Electric India offers to the die & mould makers? Mitsubishi Electric offers new generation controllers that are developed with many standard functions to suit the current market requirement and excel in years to come. A number of specially-developed control functions, such as “SSS” (Super Smooth Surface) -- the high-grade Mitsubishi Electric CNC M70/M700V Series delivers Super Smooth Surface (SSS) Control. SSS flexibly supports various compound machining, including multipart system/multi-axis machining centres, milling and hobbing. Mitsubishi Electric provides the control necessary for high-performance milling. With fully developed 1 nano precision -machining technology, range of special

MACHINE TOOLS WORLD AUGUST 2016

high-speed, high-accuracy functions all come as standard, resulting in faster block processing time and ensures the highest level of precision therefore resulting in shorter machining time . This functionality improves the accuracy and better productivity in machined parts. Built in Power failure Vertical axis drop prevention function which prevents tools breakage and machined component rejection. 10/100Base-T High speed, Ethernet interface for communicating with PC, IC card interface to run big capacity programs direct from CF card and support on-line big capacity program edit in CF card. Easy one touch Power fail program restart function reduces the operator error. System memorizes the Block number when power is interrupted with MSTB history. The following original processing modes are adopted in SSS control. • The global shape judgment based on prediction of instruction form

determines the optimal feeding speed. • Efficient acceleration and deceleration without waste even in shape • Processing a uniform that does not depend on the speed and shape instruction

Q. What are the initiatives from Mitsubishi Electric India in terms of improving the competitiveness of India Die & mould industry? Mitsubishi Electric emerges as a leading CNC controller supplier in this segment beating all the competition. Mitsubishi Electric CNC products are engineered with cutting edge solutions and technologies to meet the highest quality requirement of the precision industries. The consistent quality offered by Mitsubishi Electric CNC reassures and attracts customers in die and mould segment. Mitsubishi Electric India has always been providing opportunities to the tooling industry by improving competitiveness through spreading awareness and building exposure through domestic and international visits, seminars and exhibitions.

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Industry’s response to

Automation is lukewarm: Satish Bhat Q. What’s your area of Specialization in Automation? ADOR Welding Limited offers standard and customized Automation solutions for different types of Industries, like Ship building, Power Process, Automotive, Heavy Fabrication, Infrastructure and road building, structural work, pipe and pipe mills, wind turbine manufacturing, conveyor roller manufacturing etc. The wide ranges of ADOR Products include: 1) Standard welding automation products: • Column & boom • Welding positioners • Welding rotator • Trolley for linear GMAW welding (MIG AUTOMATION) • Trolley for circular shell welding (MIG) • Fume extractor 2) Application wise customised products: • Square axle welding SPM • Robotic welding • H beam welding SPM • Idler roller welding • Cylinder welding SPM • Weld Seamer 3) Multi-level automated welding lines: • H beam fabrication system comprising of CNC cutting machine for 3.5 – 15 mtr profile cutting (1+8 oxy fuel); H beam assembly machine; Flange & web Assembly and Tack welding with MIG process; H beam full joints welding with SAW process; Beam conveying,

MACHINE TOOLS WORLD AUGUST 2016

Mr. Satish Bhat, Managing Director, Ador Welding Ltd. turning & tilting arrangement through Beam rotation & transfer; Beam straightening machine for straightening of the flange with respect to the web • Twin head welding gantry comprising of welding gantry for idler roller welding; Vision system to observe the process and provide correction feedback; 5 Ton capacity Rotator for job rotation

Q. What are the latest trends in automation in your domain? The latest trends in Welding Automation are 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 – MIG, Laser – MIG and

VIEWPOINT major advances in the cutting processes (Precision Plasma, Laser Cutting, Water-jet cutting etc.). ADOR Welding is actively involved in absorbing the advanced technologies and processes through state-of-the-art in-house R & D set up, technical collaborations, mergers and acquisitions etc.

Q. What are the benefits of automation to the end-user? 1. Consistency in weld result - Error 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. 2. 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. 3. 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. 4. 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. 5. 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. 6. Quicker Weld-Fault diagnostics â&#x20AC;&#x201C; lower

MACHINE TOOLS WORLD AUGUST 2016

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-of-tolerance conditions. This enables the operator to perform timely functions and take necessary steps to prevent the deposit of faulty welds.

Q. How does the user industry react? Is there inertia in switching to automation for reasons other than the investment involved? The response from Indian Industries â&#x20AC;&#x201C; especially the medium and small scale ones towards Automation is still lukewarm, due to the availability of skilled welders at low wages. But the rising labour costs are driving these industries towards nominal, low-scale partial automation. It is this area where ADOR has a major advantage over many others, having an elaborate team of designers, welding process specialists, application engineers, and their own advanced welding power sources to complete the whole package of jigs, fixtures, handling arrangements, weld torch manipulators and welding power sources, backed up with the abundant range of high quality and productivity welding consumables to suit any process, productivity norms and most stringent quality demands. ADOR is capable of offering low cost automation, specifically customized for the end-user requirements, which not only calls for minimal investment in terms of capital purchase, but extremely high ROI in terms of enhanced productivity, quality and minimizing rejections.

Q. Are we in step with the world by using contemporary technologies? In fact, to achieve the perfect qualities and higher levels of productivities, most manufacturing processes involving metal joining and cutting are moving towards Automation, partial or complete process lines. Complete Robotic Work cells (unmanned) with intelligent handling, vision control and anti-collision systems have been developed both for automobile as well as other heavier fabrication

industries like shipbuilding, heavy structural fabrication etc. In addition to enhanced performance characteristics, the ability for direct digital control has also markedly expanded the automation possibilities of difficult welding processes. This direct control allows these supplies to become an integral part of the complete system and all of their capabilities to be accessed and controlled from a single controller. With the ability to enable/disable the supplies, change modes between DC and AC, vary current, voltage, and AC phasing, all based on part or torch position, automated continuous root-to-cap multipass welds are achievable. Waveform Control TechnologyÂŽ is adapted for Root Pass MIG and submerged arc welding. The power supplies provide constant current or constant voltage operation and allow variable frequency and amplitude for AC output. The software-driven AC, DC-positive or DC negative output allows the user to control the deposition and penetration. The result is a more consistent, smoother arc at a wider range of parameters, increased weld speeds, consistently higher-quality welds, and improved efficiencies in a single- or multiarc environment. The sophistication of the software based inverter design allows a significant ability to be integrated into an adaptively controlled dynamic system required for the challenging narrow groove environment. Newer, more advanced power sources and seamless integration into the overall narrow groove system architecture have dramatically enhanced the operating envelope and flexibility of the welding process. It is important to note that the efficiency of these inverter-based power supplies yields significant savings in operating costs over traditional transformer/rectifier designs. In a typical industrial operating environment fabricating pressure vessels, each machine can potentially save up to 7,00,000 per year in operating costs due to its unique design and use of energyefficient, high-speed inverters.

TECH TRENDS

The secrets to

moulding perfect pens! B ehind every well moulded pen body, lies a perfect cooling mechanism within the mould. Sparkonix’s EDM Drills are leading the way in core pin drilling applications, which is critical to perfecting the cooling mechanism in pen moulds. Plastic Pen moulds have multiple cavities and come with a cooling assembly. The quality, in terms of strength and finish of the pen body, is a direct result of the effectiveness of cooling mechanism for the moulds. Typically, pen and pencil bodies need a deep hole with very small diameter for the core pin to enable faster, efficient cooling of the mould. Sparkonix’s EDM Drills are trusted by leading pen/ pencil mould makers/manufacturers for the critical core pin drilling process. Core pin drilling in moulds The core pin drilling for pen moulds needs a 2.0 mm + diameter hole over a depth of 250-300 mm. The fine tolerances and narrow wall thickness in the mould means a very high level of precision in drilling the core pin holes. The slightest deviation in drilling can adversely affect the quality of core pins and ultimately the quality of final product. The Challenges In the core pin drilling process, insufficient flushing often heats-up the core pin and can lead to its deformation. This also affects the perpendicular position of the electrode drilling the hole which must be strictly maintained over the entire drilling depth. Sparkonix EDM Drill - the ultimate solution for core pin drilling Sparkonix’s EDM Drills offer a proven

MACHINE TOOLS WORLD AUGUST 2016

technology for core pin drilling application. Two unique features in Sparkonix’s EDM Drills make it highly effective in addressing the challenges in core pin drilling process. The EDM Generator Sparkonix has mastered the EDM Generator technology for drilling deep cavities. Whatever be the work piece material, hole oversize can be achieved within required tolerances. Sparkonix’s EDM Drills offer the same consistency for drilling length of up to 300 mm. The right pumping pressure When Drilling very deep cavities, the disintegrated powder has a tendency to accumulate or get stuck in the hole leading to its deformation. The pump capacity

and design of flushing mechanism is very critical to precision EDM drilling. Sparkonix’s EDM Drills uses a specially designed plunger pump that provides the most accurate pressure for water used in flushing. The pump is manufactured in-house with Sparkonix’s stringent quality benchmarks and provides far better consistency in pressure when compared to conventional pumps. A well designed bypass mechanism with pressure relief valve completes the flushing cycle. With advanced EDM technology and specialized pumping system, Sparkonix’s EDM Drill is a zeromaintenance solution, in core pin drilling applications, that performs as promised for years together. For more information, Email: info@sparkonix.com

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

HIGH QUALITY FOR YOUR MACHINERY

MGM brake motor main features

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• 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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TECH TRENDS

KOMET® Tools for

cost-effective machining Machining tools are becoming increasingly efficient. This is what the KOMET GROUP is demonstrating at AMB 2016, where the precision tools manufacturer is presenting numerous innovations under the trade fair slogan “TOTAL PRODUCTIVITY SOLUTIONS”. Highlights include the growing range of milling tools that can also be used in generative manufacturing processes, as well as a completely new indexable insert reaming tool and unique expansions of the KOMET KUB Pentron® drill. Other attractions include the numerous innovations in mechatronic tools and ultra-hard cutting tool materials as well as the KOMET® ToolScope assistance system, which bridges the gap from machining to Industry 4.0.

enowned as a leading innovator in high-precision drilling, reaming and threading, the KOMET GROUP presented a significantly expanded range of milling cutters just last year that transformed the tool manufacturer into a singlesource supplier. Alongside the KOMET® solid carbide milling cutters for all requirements in the diameter range of 3.0 to 25.0 mm, the KOMET® indexable insert milling cutters have primarily been subject to further improvements. The cutter holders in the completely redesigned

MACHINE TOOLS WORLD AUGUST 2016

KOMET® PCD milling cutters are manufactured using the generative process of laser melting, which means that these new tools can offer feed rates up to 50% higher than before. 3D printing enables up to twice as many cutting edges to be created – regardless of diameter. KOMET® is also utilising the structural flexibility provided by the additive manufacturing process to create a perfect design for the course of the coolant channels inside these milling cutters. Curved channel routes now reduce pressure loss in the coolant and are positioned precisely in

TECH TRENDS www.mtwmag.com

such a way that every cutting edge is supplied with coolant from a separate channel. Aside from the new production process, KOMET® is also expanding its milling range with new designs, such as the KOMET® hi.aeQ 45° face-milling cutter, which has a feed rate of up to 40% higher than a shoulder milling cutter. KOMET® is also launching new PCD milling and thread milling tools to standard versions that can be particularly productive when used in applications involving lightweight construction materials. Dimensionally accurate – even for large drilling depths For years, the KOMET KUB Pentron® solid drill has stood for precise drilling under extreme conditions. This tool was previously only available in the 4xD and 5xD length/diameter ratios, but the Besigheim tool specialists have now also developed 2xD and 3xD versions so that the high-performance indexable insert drill can be used in an even more versatile manner. The CS (Custom Solution) variant has drawn particular attention with its diameter/ length ratio of 6xD. As a result, the KOMET KUB Pentron® CS, which has been optimised for Key Account and industry segment requirements, does without guide elements and is extremely competitive compared to its guided counterparts on the basis of its performance data. Indexable insert reaming: Simplified index exchange Indexable insert technology has revolutionised reaming with multiple cutting edge

reamers and has set new standards in terms of cost efficiency and functionality. The KOMET GROUP has now successfully developed new high-precision indexable insert reaming tools that are even easier to operate. In previous tools, each insert was assigned a specific insert seat identified by the letters A, B, C, etc., but this positioning has now become redundant. Users can fit the indexable inserts into the new KOMET® indexable insert reaming tool in any order – making errors virtually impossible and reducing the logistical effort required. Increase in performance with diamond cutting materials As already mentioned with milling, the KOMET GROUP is focussing on developing tools with ultra-hard cutting materials. One example of this

is the expansion of the range of ISO indexable inserts with diamond cutting edges to a total of more than 900 items. In addition to KOMET® PCD products, CVD thick film diamond-tipped inserts can now also be supplied. All variants are manufactured using the latest production technology, such as laser machining and high-vacuum soldering, which results in high-quality cutting edges and variable geometries as well as improved cutting results and longer tool life. Facing head with direct position measuring system Mechatronic tools such as precision adjustment heads, facing heads and the KomTronic® U-axis systems, available in several variants, are one of the specialities of the KOMET GROUP. A patented direct encoder has been available as

an optional extra for U-axes and the purely mechanical KomDrive facing heads for two years. In order to enable encoding to take place directly on the slider, the encoder also takes disturbance variables of mechanical elements into account, such as the drive element tolerances, the temperature range and wear. The control system can respond to the measurement data immediately, providing accuracy to +/- 3 µm and thereby enabling outstanding machining quality to be achieved. Tool and process expertise from a single source KOMET BRINKHAUS GmbH has been part of the KOMET GROUP for more than three years. As a result of the interaction between tool experts and process monitoring specialists, it has been possible to further develop the ToolScope process monitoring system into an integrated assistance system in terms of Industry 4.0. It monitors the internal signals from the machine, detects events such as tool changes or machine stoppage and is able to calculate parameters and deduce trends. At AMB 2016, KOMET® is demonstrating how easy ToolScope is to use: Customers can select the solutions they require from the broad range of applications – from tool monitoring to an automatic tool change log through to adaptive feed control – and license them individually. Operation of the system has also become more flexible: Users can now view and operate their custom assistance system on mobile terminals such as tablets and smartphones.

AUGUST 2016

MACHINE TOOLS WORLD

TECH TRENDS

Solid-carbide end mills increase application range The Jabro-Solid2 JS554 range of solid-carbide end mills gains further utility and versatility with smaller neck diameter options

he new range of tools provide greater clearance when machining complex components, such as those found in aerospace, medical and general machining applications. Smaller neck dimensions make it easier to access parts clamped in complicated fixturing arrangements, as well as enable users to take full advantage of 4-axis and 5-axis machining capabilities. The neck sizes are optimised to retain tool rigidity while providing full compatibility with standard toolholder connective systems. The tools maintain their ability to productively machine materials in the ISO P, M, S and other material groups. High stability JS554 end mills provide high stability and low deflection. They also bring an excellent price-performance ratio to a range of applications, and these latest additions further expand the line’s advanced capabilities. The range of JS554 end mills covers tool diameters from 3 mm to 20 mm and typical cutting lengths 2xD + 2 mm. Reach lengths are 3xDc. The range also includes corner radius and 45˚-chamfer versions, for both Cylindrical and Weldon shanks. Seco Tools is a leading manufacturer of high performance metal cutting tools. Seco’s product range includes a complete programme of tools and inserts for turning, milling, drilling, reaming and boring as well as complementary tool holding systems. With more than 25,000 standard products, Seco is a complete solutions provider for the metal cutting industry and equips machine tools from the spindle down to the cutting edge. The company is headquartered in Fagersta, Sweden and represented in more than 50 countries worldwide with 40 subsidiaries, distributors and channel partners.

MACHINE TOOLS WORLD AUGUST 2016

Benefits • Smaller neck dimensions make it easier to access parts clamped in complicated fixturing arrangements • Ability to take full advantage of 4-axis and 5-axis machining capabilities • Optimised to retain tool rigidity • Full compatibility with standard toolholder connective systems

TECHNOLOGY @ work

19th International Exhibition of Cutting Tools, Tooling Systems, Machine Tool Accessories, Metrology & CAD / CAM

18th Indian Metal-Cutting Machine Tool Exhibition with International participation

26 Jan - 01 Feb 2017, Bangalore Venue

Organiser

Indian Machine Tool Manufacturersâ&#x20AC;&#x2122; Association

T: +91-80-66246600. F: +91-80-66246661. E: info@imtex.in

www.imtex.in

TECH TRENDS

VM 9

How the turning center gives maximum flexibility Massive workpieces and small batch sizes – in wind energy plants, commercial vehicle production or the aircraft industry these extremes can clash. The VM 9 turning center from EMAG not only provides a productive solution to these industry sectors, but also has the functionality to be loaded and unloaded automatically or manually based on the customers’ demands

he main question in heavy-duty machining is how can large, heavy components be efficiently and precisely machined when batch sizes vary so much? With the VM 9 the EMAG designers have provided an extremely productive answer. The solution is to bundle a number of performance indicators – from an extremely powerful main spindle and turret with up to twelve tools, to quality management with a measuring probe. “These performance indicators are rarely present in other turning machines, and

MACHINE TOOLS WORLD AUGUST 2016

in the rare cases they are present only one is offered. We, however, offer the whole package”, explains Achim Trommsdorf, Head of the “Modular Standard Machines” Product Group at EMAG. Cycle times cut by 50% The first VM 9 machines are operating in a German OEM’s facility. These particular machines are automatically loaded with gantry systems, however, they can also be loaded through the large front door if desired. Changeovers are a breeze and can be taken care of with

TECH TRENDS www.mtwmag.com

a few clicks at the control panel. This process allows the German company to produce approximately 250 transmission components for a number of different commercial vehicles, making more flexibility hard to imagine. Adding to its efficiency is the extremely powerful main spindle of the machine which guarantees decreased cycle times. For some of these components cycle times were times were reduced from two minutes to just one.

features a hinged housing that prevents the entry of chips and dirt. The tool turret adds to the fully integrated process, as it can also be equipped with driven tools for drilling and milling operations. The precision of the machining process is guaranteed by an axis control system that features direct, linear measuring systems, and a machine base made of MINERALIT polymer concrete with vibration damping qualities that guarantees excellent surface finishes.

Precision and process integrity built in The required process integrity is verified by the integrated measuring probe, which

Meeting the Demand of Heavy-Duty Machining “With the VM 9 we have a multi-

functional solution that makes sure we are well prepared to handle component diversity and process variety”, adds Mr. Trommsdorf. “It’s why we expect a lot from this approach. The machine fulfills all the requirements that users in the heavy-duty machining sector have brought to us over the last few years.”

AUGUST 2016

MACHINE TOOLS WORLD

TECH TRENDS

High-Performance Robots Thanks to Encoders with EnDat 2.2 Robots are only as productive as their controls and components allow, and transforming this simple wisdom into specific products requires a wide range of expertise. Itâ&#x20AC;&#x2122;s for this reason that the Italian manufacturer Comau places its trust in encoder solutions with EnDat-2.2 interfaces from HEIDENHAIN for its new robot control and 3-D laser system. As a result, users now have the handiest control currently available on the market and a high-precision, dynamic laser system for mid- to large-size robots.

omau Robotics & Service, a subsidiary of the Comau Group, develops and produces robot cells for welding, handling and palletizing in addition to several other products. These robots are used in a wide diversity of industrial applications, and technologically superior solutions are needed to set themselves apart from the wide spectrum of other robot manufacturers. As a consequence, HEIDENHAIN encoders equipped with the bidirectional EnDat 2.2 interface are used on the new C5G robot controls and 3D SmartLaser laser welding systems. Completely updated The new C5G control has been completely reworked from its previous design, and upgrading to a new generation of inverters meant that the encoders had to be re-specified as well. A further reason was that previously used encoders not always fulfilled expectations in terms of reliability. The new C5G robot control brings together the expertise of three companies: Software developed by

MACHINE TOOLS WORLD AUGUST 2016

Comau for controlling the robot axes and technological processes, position encoders with EnDat 2.2 digital interfaces from HEIDENHAIN, and the B&R hardware platform. The result is a product with extremely high innovation. With its compact design, the C5G is currently the handiest robot control for mid- to large-sized robots, and compared to the previous model has improved performance, higher processing power, superior reliability and reduced energy consumption. Absolute rotary encoders with EnDat 2.2 The ECI 1118 range of absolute rotary encoders from HEIDENHAIN with inductive operating principle for generating absolute serial signals has proved to be the ideal solution for this application. 262,144 positions per revolution (18 bit) can be measured with the ECI 1118 absolute singleturn rotary encoder, and this high resolution guarantees controllability of the drive system at all speeds. Oscillations in control loops are also reduced to a

The new C5G control

TECH TRENDS www.mtwmag.com

the subsequent electronics. In addition to the position value, the signal also provides supplementary information (temperature specifications and performance reserves for example) and enables monitoring and online diagnosis of the encoder. With a greater voltage range of 3.6 V to 14 V, there are also no problems caused by voltage drops in longer cables. A further benefit of the digital EnDat 2.2 interface is that evaluation numbers can be called during drive operation without sacrifices to the performance of the control. The diagnostic system generates error messages and warnings and therefore makes an important contribution to ensuring the availability of the overall system.

Integrated design of the Smart Laser system for 3-D laser welding

minimum. Thanks to its modular design with no ball bearings, coupling or transmission, the encoder has a very short construction length of only 12.3 mm with an outer housing diameter of just 36.83 mm. Singleturn scanning without additional mechanical components also improves resistance to shock and vibration loads. As a result, the low-noise rotary encoder is predestined for use in highly dynamic, compact servo motors for automation technology and industrial robots.

The ECI 1118 rotary encoder is equipped with the EnDat 2.2 digital interface. This purely serial interface permits fast and secure data transmission at clock-pulse rates of up to 8 MHz for high drive dynamics, even in environments with potentially high electromagnetic interference potential. The scanning signals are digitalized directly in the scanning head and calculate a position value with high resolution that is transmitted synchronously to the clock signal set by

3-D laser system completes the product spectrum To round off its portfolio, Comau Robotics & Service has also completely upgraded its 3D SmartLaser laser welding system, equipping these with HEIDENHAIN encoders. The patented system consists of a laser source with focusing module that is set completely without robot motion, achieving a laser welding system uniting the agility of a robot with the outstanding performance of extremely precise laser technology, while being controlled merely by the C5G. The 3-D laser system also features very good dynamic characteristics over its complete range of operation. Positioning the system is via a linear motor that can be accelerated up to 8 g, and repositioning the Z axis is therefore 10 times quicker than with standard robots, which in turn achieves extremely low cycle times (only 11 s for welding a vehicle door for example). The laser beam is deflected (in X and Y) by positioning lenses and reflectors, and these are operated via direct drives with speeds in excess of 1000 m/min. With linear motors there is principally no additional rotary encoder for measuring the speed, and position and velocity are therefore determined

AUGUST 2016

MACHINE TOOLS WORLD

TECH TRENDS

The LIC 4017 exposed absolute linear encoder is used for feedback operation with the four linear motors controlling deflection of the laser beam in the new 3D SmartLaser laser welding system

The new ECA 8412 is based on the functional principle of optical linear encoders without integral bearing

through the position encoder. Linear encoders that generate a high-quality position signal with only small interpolation error are therefore essential for the meaningful operation of linear drives. Encoders that use photoelectric scanning such as the LIC 407 linear encoder are particularly suited for this task since very fine graduations can be used as measuring standards by this method. These encoders provide benefits in the positioning, speed stability, and thermal behavior of linear drives, and absolute position value calculation and the associated availability of the position value immediately after encoder switchon are further positive features. As a consequence, Comau Robotics & Service took the decision for HEIDENHAIN’s LIC 4017 exposed absolute linear encoders, with these being installed on the four linear motors regulating deflection of the laser beam. A resolution of 1 nm and accuracy of up to ±5 μm together with a maximum traversing velocity of 480 m/min provide the laser beam focusing system with the required dynamics and precision. The two ROC 425 absolute singleturn rotary encoders with 25 bit resolution and the ECA 8412 angle encoder have

MACHINE TOOLS WORLD AUGUST 2016

the task of guiding the laser beam onto the workpiece in the remaining two axes. The ECA 8412 exposed angle encoder with segmented geometry and absolute position measurement was used as a prototype in this project to achieve overall consistency with EnDat 2.2. The outlook For HEIDENHAIN, the project reflects the successful application of a diversity of encoders together with EnDat 2.2. The next step is currently being implemented—the manufacturer from Traunreut in Southern Germany will soon be presenting encoders with functional safety and mechanical error

The ECI 1118 rotary encoder

elimination for coupling, products that will also provide the Comau robots with a further development boost. High-precision encoders for sophisticated positioning tasks DR. JOHANNES HEIDENHAIN GmbH develops and manufactures linear and angle encoders, rotary encoders, digital readouts and numerical controls for demanding positioning tasks. In addition to automation technology applications, products are used primarily in high-precision machine tools as well as in plants for the production and processing of electronic components. Since 1948, when the company began anew in Traunreut, HEIDENHAIN has shipped over 5 million linear encoders worldwide, over twelve million rotary and angular encoders, almost 470,000 position displays and nearly 240,000 TNC controls.

By Abhilash Tripathi, Associate Director-Sales & Service, Heidenhain India

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TECH TRENDS

Chamfering & Deburring gears precisely to achieve smoother gear transmissions

The chamfering and deburring of gears is often an undervalued process in gear production. However, it has a great influence on the usage characteristics of the work piece. Improvement in rating for gear shifting in vehicles also depends on the process used for this operation. This article explains the sophistication required in tools using plastic deformation for chamfering and rolling and cutting action for deburring

Sameer Kelkar, CEO, Grind Master Machines Pvt. Ltd.

ears need to be Chamfered and Deburred with a controlled, high quality process for the following

reasons : • To avoid breakage – Excessive carburizing along the tooth edges can often cause breakage when the gear is running • To avoid damaging gears and bearings – If burrs are not removed, they may chip off during the running cycle and cause damage to the other gears and bearings. • To avoid poor tool life in the finishing processes • Removal of very sharp burrs reduces the risk of tool handling injuries

MACHINE TOOLS WORLD AUGUST 2016

Francesco Grippo, Chief Technical Officer, Samputensili Machine Tools Srl Types Chamfering Specified on Gears is of following types : in only one or in both flanks, with a constant size along the profile, with or without chamfer in root diameter. Sometimes a further Rolling Operation is required (refer section on Rolling below) Chamfering with Plastic Deformation / Compression Tools Advanced Chamfering Tools use Compression (as against cutting) for creating chamfers on the edge. The pressure and the deformation of the material may modify the structure of the steel. The chamfering tool is like taper gear, with a width of roughly

TECH TRENDS

Gears require a rolling operation after chamfering due to the plastic deformation caused by this operation and to eliminate the “burs” or swellings that form on the material 10 - 15 mm, and normally is very well finished, with a surface like a mirror in order to prevent a quickly wear. The key benefits of Chamfering with such tools are stronger gear tooth due to better material flow and accurate chamfer angles. The angles of the chamfers are definite by the tool drawing, but the size depends on the rolling time and the pressure of the tool against the gear. If the contact time between the tool and piece increase the chamfer becomes bigger. The pressure which defines the deformation force is generated with a pneumatic cylinder. This method guarantees an “elastic force” that prevents some breakages. Further the Tools are Self Centering, thus guaranteeing symmetrical chamfer on both sides of the work piece. Rolling Operation Gears require a rolling operation

MACHINE TOOLS WORLD AUGUST 2016

after chamfering due to the plastic deformation caused by this operation and to eliminate the “burs” or swellings that form on the material. Whilst burs on the gear face may be removed by deburring tool, those on the lead remain. These burs, usually in the range of 0.05 – 0.07 mm, cause problems in subsequent grinding phases and actually put the grinding wheel at risk. At this point a rolling operation on the gears becomes necessary. The Samputensili method of Chamfering-Rolling uses a common chamfering/rolling tool (Patented) and a deburring tool to complete the Chamfer-Roll-Deburr simultaneously. Gears that are chamfered and rolled have been tested after heat treatment 1. Cracks do not form in the rolled area. 2. The structure is normal and corresponds to all the structural

characteristics of the material. Tool Configuration – Options Chamfering/Deburring tools can be organized in various configurations for different types of gears, geared shafts and sprockets. For example, cluster gears can be processed in a single operation with multiple chamfer/deburr tools organized as shown below. Conclusion Gear Chamfering/Deburring is a Key Process Technology in Automotive Powertrain for achieving smooth gear transmissions. Capability to produce strong accurate chamfers is essential. In addition for gears that are later finished, a rolling operation can be integrated with Chamfering/Deburring. Multiple Configuration options in tooling enable a solution for a wide variety of automotive gears.

AUGUST 2016

MACHINE TOOLS WORLD

CASE STUDY

M. BOUDINOT Team owner

Moto2 pushes the boundaries using

Metal 3D printing

In the high-octane world of MotoGP motorcycle racing, technical enhancements can have a big impact. Moto2 team TransFIORmers is using cutting edge metal additive manufacturing (3D printing) technology in an unconventional front suspension system to gain a significant competitive advantage.

otorcycles ridden in the MotoGP World Championships are special; the general public can’t buy them and they can’t be used on a public road. As prototype racing bikes they are custom-built to outdo their rivals and maximise performance on the track. Moto2, the second of the three MotoGP classes, was created in 2010. Its official engine is a 600cc four-stroke production engine, currently supplied by Honda. The French Moto2 team TransFIORmers, based in Perigueux, South West France, is revolutionising front suspension design in order to stay ahead of the pack. TransFIORmers is led by former 250cc World Championship rider Christian Boudinot, and the team’s unconventional suspension system was inspired by the seminal work of the legendary French

MACHINE TOOLS WORLD AUGUST 2016

motorbike designer Claude Fior. Boudinot’s former friend and mentor, Fior, recognised the gains to be made from isolating the front suspension from steering forces. Resolving issues of ‘brake dive’, the design enables later braking into a corner and faster acceleration out. Instead of the more traditional telescopic front fork suspension, the TransFIORmers motorcycle employs a rigid front fork suspension system separated from the chassis using two wishbones. To further advance the development of its innovative design, TransFIORmers approached I3D Concept,

a world-class expert in metal additive design and manufacturing techniques. Using Renishaw’s AM 250 additive manufacturing system, I3D Concept worked in partnership with the TransFIORmers team to optimise the design of its upper wishbone component, one of two attaching the front fork to the chassis and critical to the bike’s steering. Challenges

In the development of new components in Moto2 bike design, achieving a weight reduction is a priority. In particular, reducing the ‘unsprung mass’ of the bike

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CASE STUDY is a key consideration. The lower the unsprung mass, the better the suspension is in terms of vibration management and responsiveness to both braking and acceleration. Of equal importance is the speed with which the design of a new component can be modified, and how long it takes to remanufacture. Achieving perfection in a highly competitive environment demands fast, accurate component iteration. In a high reliability environment, mechanical strength is a further prime consideration. The TransFIORmers’ wishbone component needs to assure best possible rigidity, while handling significant levels of dynamic steering force. “To improve overall motorcycle performance, reducing the weight of all components located behind the shock absorbers is absolutely vital. Failure to optimise component weights can have an adverse effect on vibration, braking and acceleration, so weight reduction is a really high priority,” says Jérôme Aldeguer, Mechanical Engineer, TransFIORmers. Solution

TransFIORmers’ original wishbone component was hand-fabricated in steel, with the assembly comprising twelve separately machined and welded parts. I3D Concept consolidated the design into a single piece component, greatly reducing assembly time. The company produced the metal 3D printed wishbone using a Renishaw AM 250 additive manufacturing system; initially prototyping in stainless steel

MACHINE TOOLS WORLD AUGUST 2016

(inox) and finally manufacturing a lighter weight part in titanium. Key to the new 3D component design was an iterative process of topological optimisation, whereby the wishbone layout was successively rationalised in software within tight space constraints to withstand a set of predefined front fork loading conditions. Once the final component design was validated using digital CAD software, the build preparation file was prepared offline prior to export to the additive manufacturing system. Within the CAD software, I3D Concept was able to assess whether the parameters were effectively predetermined or whether they required tweaking to match the specific metal powder characteristics and the complex target geometries of the TransFIORmers wishbone. Importantly, using the AM 250’s dedicated Optical Control System (OCS) software, I3D Concept was able to very accurately control laser steering which helped to enhance precision, definition of features and surface finish. Results

By taking an additive manufacturing approach to Moto2 bike design, TransFIORmers succeeded in

dramatically reducing the weight of its critical wishbone front suspension component by a factor of 40%. Comparing the one-piece titanium component with the original welded steel component, a weight saving of 600 g was achieved. Metal 3D printing has also provided TransFIORmers with much finer control over component tolerances and the flexibility to very quickly iterate wishbone geometries to match specific chassis and kinematic requirements. “The weight reduction that metal 3D printing has achieved for us in our wishbone component has enabled us to bypass traditional weight transfer phenomenon and the problems associated with ‘brake dive’. More than that, it’s allowed us to design a part that is not only lighter, but far more rigid at the same time,” explains Jérôme Aldeguer, Mechanical Engineer, TransFIORmers. With an ultimate tensile strength in excess of 1100 MPa when processed using additive manufacturing, and near perfect 99.7% densities, the titanium Ti6AI4V alloy used has delivered a radical new wishbone offering far greater rigidity than the original multi-part, hand-assembled steel component. Thanks to additive manufacturing, TransFIORmers’ prototype wishbone development has become a highly efficient & cost effective process. Extensive part machining and assembly time overheads have been removed and design iterations and manufacturing have been made many times faster. In June 2016 the team won its first ever Moto2 GP race at the FIM CEV event in Barcelona.

CASE STUDY

GTECH is a family run business, having started in the 1970s by the family grandfather

Trusted Family-Business Trusts in Haas Having invested in the first Haas CNC machine in 2007, G-Tech has continued to trust the capabilities of Haas machines

t seems there’s always a need for general-purpose machine shops, wherever in the world they find themselves. These are companies, often family-owned, that make a specialization out of being generalists. Usually they don’t have their own product lines; they maybe don’t even have a preferred industry sector or a particular technology that sets them apart from other job shops. What they do have, however, is their reputation. Italy has its fair share of such companies, and G-Tech CNC, based near Reggio Emilia, is one of them.“We are here for what the market needs, when it needs it,” says Davide Gherpelli, company front man. “We can supply prototype parts in small quantities, or we can provide parts

MACHINE TOOLS WORLD AUGUST 2016

in high volume – large batches of series production. No particular sector; we think of ourselves as a 360 degree company.” From the 1970s until 2011, Davide’s father, Giorgio Gherpelli, ran G-Tech. In fact, the company actually began with his father, Davide’s grandfather. It was 2004 when Davide joined and almost a decade later when they welcomed Mirko, his younger brother, whom they call the ‘mago’ (the magician), for his skill with the Haas CNC. Now, there are 5 employees at G-Tech. But between them, they run a very busy machine shop. “We invested in our first Haas CNC machine in 2007,” remembers Davide: “An SL-10 turning centre. We then bought a Super MiniMill, an ST-10Y turning centre

The SL-10 turning centre was the first Haas CNC machine that GTECH CNC (Italy) bought in 2007

with live tooling, a VF-2SS high-speed mill, and a VF-1, which is our generalpurpose machine. In fact, we have a Haas machine tool for almost all our machining needs. We have a very good selection!” Trusted capabilities

Davide claims that his early experience with Haas helped make up his mind about the capabilities of the machines, and their

CASE STUDY www.mtwmag.com

Davide Gherpelli, company front man, comments that GTECH can supply prototype parts in both small quantities & in high volume – within no particular sector; they think of themselves as a 360 degree company suitability for a growing job shop. “It’s not just me, though,” he says. “You can look around the workshop and see how much we all love these machines. We eat, sleep and breathe Haas!” Projects vary as much in type and industry sector as they do in volume of parts required. The company’s Haas VF-2SS, equipped with an HRT210 is, says Davide, always busy. “We use this machine a lot for more complex parts – typically, prototypes. We use TopSolid CADCAM and programme off-line, whereas, with the ST-10, we usually programme at the machine. We’re currently using the ST to make bearing housings for the Airbus A350 and Ti rear wheel hubs for the Politecnico di Torino hyper-mileage car. The VF-1 is being used to machine parts for a drone used to measure contours of the land in 3D.” Around the workshop are various other projects that the company isn’t at liberty to discuss openly. One component in particular looks like the inner part of a steering wheel for a highperformance sports car. “I can’t tell you anything about that,” smiles Davide. “Secrecy is important for some of our customers.” Good reputations are hard to come by but very easy to lose. “We’ve built our reputation on delivering good parts on time,” says Davide, “but also for being trustworthy and discreet, at the same time. “The automotive sector in particular is very sensitive, especially in this part of Italy. There are some big names nearby.” As proud Italians, that’s work the Gherpelli family intends to keep and may well be the key to the company’s future growth. “As our assignments become more complex, and we attract more big-name customers, we already know we will need more Haas machines; the UMC750, for example.” For more than 50 years, five axis machining was simply too expensive for small to medium sized job shops like G-Tech CNC. Not anymore. “The UMC750 is an affordable 3+2 machine tool,” concludes Davide. “Like the Haas machines we already own, if we buy one it will allow us to expand and build our business for years to come.” And with its reputation preceding it, perhaps this family will stay in business for many more generations, as is the Italian way.

AUGUST 2016

MACHINE TOOLS WORLD

CASE STUDY

Apogee Industries transforms with the

DMG MORI NTX 1000 The firm is getting ready for a step change in productivity when it takes delivery of a DMG MORI NTX 1000 2nd Generation mill-turn centre

pogee Industries has been growing organically for ten years at the rate of 15-25% per year and is getting ready for a step change in productivity when it takes delivery of a DMG MORI NTX 1000 2nd Generation mill-turn centre after the MACH show. From its factory based Pewsey, Wiltshire the company supplies complex parts to the oil & gas, aerospace, motorsport and defence industries. William Chappel, Director at Apogee Industries says, “We produce components for companies around the world, working in partnership with them to develop a lean and efficiently manufactured product. In every case we need to achieve high quality and accuracy, whether it is a single one off prototype or a production run of thousands.”

MACHINE TOOLS WORLD AUGUST 2016

The challenge

Apogee Industries currently utilises 4-axis machining centres and driven tooled turning centres together with a high level of engineering input. Apogee has built a reputation for making complex, intricate and high tolerance parts in exotic materials to an exceptionally high standard. However, the current methodology requires numerous set ups and many bespoke fixtures which take a considerable amount of time and skill. William Chappel adds, “Many of the parts require between four and nine setups along with the associated jigs and fixtures for each operation. The result is an unacceptably low level of overall spindle run time offering very little optimisation and hence resulting in limited output. We anticipate that the increase in productivity by the

implementation the NTX 1000 2nd Generation will allow an additional up time of 70%.” Discovering the benefits of automation

The acquisition of a laser cutting machine at its second factory helped Apogee to realise that automation and advanced production methods could help the growth of the company and enable it to fulfill the customer’s requirements while keeping all aspects of production in house. In one instance, a part that would normally be machined from solid billet was laser profiled first before being machined to its final specification. This not only reduced material wastage but dramatically reduced the production time of each part leading to a cost saving and lead time improvement. Applying this experience to machining helped the company to understand the improvements it would gain from investing in the NTX 1000 2nd Generation. William Chappel says, “The NTX 1000 2nd Generation will replace four ageing machines and is expected to dramatically increase spindle run time. This is where we gain critical revenue to invest in new equipment. The NTX1000 2nd Generation is scheduled to run our monthly batch requirements through the evenings while the small quantities of complex jobs can be watched and manned during the daytime. In addition to the extra machining time, savings will be made on maintenance, associated running costs and duplication of tooling packages.” The NTX 1000 2nd Generation has 65mm (an option) through bar capacity and can throw a 430mm diameter by

CASE STUDY www.mtwmag.com

800mm long billet. It is also equipped with a B-axis head rated at 20,000 rpm (an option), and a 10 station lower turret with a built in motor giving 10,000 rpm. Due to the machines unique capabilities Apogee is able to bring a number of process in house, that it would normally subcontract, from gear cutting, broaching keyways and splines to deep hole drilling and a limited amount of gun drilling thanks to the 7.0 MPa coolant pressure. The automation comes from the addition of a bar feed and in machine travelling work piece unloader, this will allow Apogee to run the machine lights out and unattended, without an operator having to handle components mid production, gaining an extra 60% of production per week. Taking advantage of advanced features

To ensure quality, repeatability and reliability the machine is fitted with linear scales, a Renishaw probe and tool breakage detection. This allows Apogee to probe in cycle, validate the parts, and update tool offsets automatically before removal from the machining cycle. The advanced systems can also switch to sister tooling if needed, and ensure parts are rejected if there is a tool failure. William Chappel elaborates, “British manufacturing is based upon high technology. As a company we should always strive to invest in the latest equipment to increase efficiency, productivity and overall value for the customer, this predominately leads to an

advanced and automated manufacturing space. The NTX 1000 2nd Generation is the start of this transformation for Apogee.” Fitted with CELOS, the NTX 1000 2nd Generation will integrate well with Apogee’s existing job management system. The company will also have the CELOS PC version enabling its engineers to access drawings, images of the setup and notes and to schedule jobs from the office. William Chappel says, “CELOS will be very important to us as we work in a dynamic environment where we have to respond very quickly to our customers’ needs and requests. It will enable us to rapidly re-tool and setup for repeat jobs. Previously we had to take immense care on the multiple setups, produce spare parts for each operation and endure an overly high scrappage rate but, with the NTX

“With the NTX 1000 2nd Generation, the requirements for jigs and fixtures will be effectively removed and we will be given the ability to manufacture the precise amount of components required.” - William Chappel, Director, Apogee Industries

1000 2nd Generation, the requirements for jigs and fixtures will be effectively removed and we will be given the ability to manufacture the precise amount of components required.” “The machine already has a full production schedule on arrival due to ongoing projects. Naturally, reliability and service will be of paramount importance and DMG MORI’s transparency in service and repair times as well as the obvious build quality and precision characteristics of the machine is very reassuring.”

AUGUST 2016

MACHINE TOOLS WORLD

PROJECTS Airport / Aviation Airport Authority of India (AAI)

Airport / Aviation Automobile Industrial Cluster

PROJECT

Industrial Park Personal Care Power Railways

UPDATE

Transport

MACHINE TOOLS WORLD AUGUST 2016

Plans expansion of the terminal building of Jayaprakash Narayan International Airport, which is located 5 km southwest of Patna. The terminal would be converted into a two-storeyed structure, complete with aerobridges and a bigger parking bay. The airport hangar and the IOC depot would be shifted to pave way for the terminal.

Place: Bihar Contact: M M Francis, GM (Engg.), J.P.N.I. Airport, Patna-800014, Bihar. T: 0612-2220683, E: apdpatna@aai.aero Bhogapuram International Airport Company Ltd Orvakal Airport is proposed to be developed which is situated 26 km from Kurnool.

Place: Andhra Pradesh 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 Bhogapuram International Airport Company Ltd Development of Greenfield Airport at Village Damavaram and KK Gunta, Mandai Dagadarthi, District Nellore.

Place: Andhra Pradesh 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) Plans to assign the construction of Inland Terminal Building and related work in Leh airport (area 16, 500 Sq Mtr) at Leh.

Place: Jammu & Kashmir Contact: Sonam Nurboo, Airport Director, KBR Airport, Leh-194101, Jammu & Kashmir, T: 01982-251783, F: 251781, M: 9419179020, E: apc_vilh@aai.aero Airport Authority of India (AAI) Plans to assign the construction of present terminal building, (Change and Expansion) Area 33, 474 Sq Mtr in Srinagar airport at Srinagar.

Place: Jammu & Kashmir Contact: Sharad Kumar, Airport Director, Sheikh ul Alam Airport, Aerodrome Road, Srinagar-190007, Jammu and Kashmir. T: 0194-2303000, 2303311, F: 2303313, M: 9419000910, E: apd_visr@aai.aero

Boeing International Corporation India Pvt Ltd US based aircraft manufacturer has tied up with Tata Advanced Systems Ltd (TASL) to set up a facility at the aerospace Special Economic Zone (SEZ), Adibatla.

PROJECTS www.mtwmag.com

Tata Boeing Aero- space Ltd (TBAL) is the joint venture firm that will produce Boeing AH-64 Apache helicopter fuselages and other aerostructures. The foundation stone was recently laid.

Kheria, Director, Agam Kuan, Patna - 800007, Bihar. T: 0612-2577836, M: 09431018503, 07070665423, E: a.v.ispatpvtltd@gmail.com

Place: Telangana

The company got in-principle approval of the Government of India in August 2015 for setting up Greenfield Electronics Manufacturing cluster at Village Tunda in Kutch district of Gujarat spread over 511.34 acre of land.

Contact: Amrita Dhindsa, Manager (Communi- cations), 3rd Floor, DLF Center, Sansad Marg, New Delhi-110001, Delhi. T: 011-46566000, M: 9654606067, E : ashmita.sethi@boeing.com

Mundra Solar Technopark Pvt Ltd

Place: Gujarat

Automobile Suzuki Motor Gujarat Pvt Ltd Setting up wholly owned car plant in Gujarat. The unit will begin operations from next year.

Place: Gujarat Contact: Bhavesh Shah, Company Secretary, B-3, 1st Floor, Safal Profitaire, Prahladnagar, Ahmedabad - 380015, Gujarat. E: bhavesh.shah@smgsuzuki. co.in

Industrial Park A V Ispat Pvt Ltd The company got in-principle approval of the Government of India in August 2015 for setting up Greenfield Electronics Manufacturing cluster at Village Abgilla, District Gaurichak, Bihar spread over 21.11 acre.

Place: Bihar Contact: Vinod Kumar

Contact: Kartik, Manager, Adani House, Near Mithakali Circle, Navrangpura, Ahmedabad - 380009. T: 079-25555801, M: 9426699871, E:amit.uplenchwar@adani.com Odisha Industrial Infrastructure Development Corporation (IDCO) Department of electronics and information technology (DeitY) has given nod for setting up of a greenfield electronic park within the Infovally complex, a dedicated IT hub, on the outskirt of Bhubaneswar. Odisha Electronics and IT Parks Ltd is the SPV created to take this project forward.

Place: Odisha Contact: Santosh Nayak, Divisional Head, IDCO Tower, Janpath, Bhubaneswar - 751022. T: 0674-2542456, 2542465, 2540820, F: 2542956, M: 9437005440, AUGUST 2016

MACHINE TOOLS WORLD

PROJECTS E: santosh.nayak@idco.in, W: www.idco.in

Personal Care Bio Veda Action Research Co. Ayurvedic cosmetics brand Biotique plans to double its production capacity by setting up manufacturing units in Himachal Pradesh & North East.

Place: Himachal Pradesh Contact: Arti, Head (Customer Support), D-105, Phase 2 Noida- 201305, Uttar Pradesh, T: 0120-4299700, 702, 704, E: contact@biotique.com

architectural works For 1x800 MW North Chennai TPS Stage III Thiruvallur District.

M: 9724093004, E: proeradi14@gmail.com

E: anujedcc@dmrc.org

L&T Construction

Place: Tamil Nadu

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

Expression of Interest (EOI) are invited from experienced Parking Solution providers for implementing automated parking system.

Contact: S Subburaj, Sr.Manager, 690 Annasalai Nandanam Chennai-600035, Tamilnadu. T: 044-28286766, F: 24335920, E: ssraj@bhelpssr.co.in Hinduja National Power Corporation Ltd (HNPCL) Setting up 2x520 MW coal-based thermal power plant at Palavalasa near Parawada. The first unit was synchronized in January, 2016 and the second unit is getting ready to go on stream shortly.

Place: Gujarat Contact: Rajeev Jyoti,

Power Rewa Ultra Mega Solar Ltd Plans construction of 33/220 kV pooling substations with associated 220 kV DCDS transmission lines (Route length 55 Km) on turnkey basis for power evacuation scheme of 250 MW Rewa Ultra Mega Solar Power (RUMS) project at Suwasra, District: Mandsaur.

Place: Andhra Pradesh Contact: Mohit Thapliyal, Head of Corporate HR, Hinduja House, 171, Dr. Annie Besant Road, Worli, Mumbai - 400018, T: 022-24960707, E: mohit.hnp@hindujagroup. com

Railways Indian Railways (IR)

Place: Madhya Pradesh Contact: Himanshu Joshi, Executive Engineer, Urja Bhawan, Link Road, No. 2, Shivaji Nagar, Bhopal-462016, Madhya Pradesh. T: 0755-2553595, 2556526, F: 2551439, M: 9406569391, E: mpnred.solar@gmail.com Bharat Heavy Electricals Limited Plans to assign construction of civil structural and

MACHINE TOOLS WORLD AUGUST 2016

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, E: domanic@lntecc.com

Transport Delhi Metro Rail Corporation (DMRC)

Indian Railways is undertaking the implementation of gauge conversion of 70 km Ahmedabad and Mehsana Railway Line. The foundation stone for this project was recently laid.

Plans to implement the proposed Metro line covering Dwarka sector 21, Palam Vihar, Kapashera, Udyog Vihar and IFFCO Chowk in Gurgaon.

Place: Gujarat

Contact: Anuj Dayal, ED (CC), DMRC, Metro Bhawan Fire Brigade Lane, Bara- khamba Road, New Delhi - 110001, Delhi. T: 011-23417910/12, 2341841, Extn - 534171,

Contact: Pradeep Sharma, PRO, Western Railway Ahmedabad Division, Near Chamunda Bridge, Naroda, Ahmedabad-380004,

Chennai Metro Rail Ltd

Place: Tamil Nadu Contact: R.M.Krishnan, General Manager (Planning and Business Development), Admin Building, CMRL Depot, Poonamallee High Road, Koy- ambedu, Chennai-600107, Tamil Nadu. T: 044 23792000, chennaimetrorail@gmail.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 Place: Haryana 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

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

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

PRODUCTS

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

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

The CNC Controller – Phantom:

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

MACHINE TOOLS WORLD AUGUST 2016

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

PRODUCTS www.mtwmag.com

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

Following are some of its unique features:

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

• • • • • • •

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

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

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

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

AUGUST 2016

MACHINE TOOLS WORLD

PRODUCTS

New Seco parting-off system

For Product Enquiry Contact Seco Tools India (P) Ltd. Gat no.582, Pune Nagar Road, Koregaon Bhima, Tal. Shirur, Dist.- Pune, INDIA. Pin - 412216 Tel no:- +91-2137-667406 Web : www.secotools.com/in

Designed with increased productivity, tool life and part quality in mind, the new Seco 150.10-JETI system streamlines the heat removal process in high-speed parting-off applications. The parting-off system comprises High Speed Steel blades, Jetstream Tooling® technology and tool blocks with coolant inlets. Together, these elements give high-pressure coolant a straight path to the cutting edge and provide an optimised means for effectively penetrating the friction zone between the cutting edge and workpiece. Thereby, manufacturers benefit from fast heat removal, proper chip evacuation and superior part surface finishes. Plus, the 150.10-JETI system is able to move freely in tight workspaces and operate closer to the spindle thanks to its compact assembly free of external piping and connections. The elimination of these external components also saves users on spare part costs and reduces their tooling inventory. Available in 15 mm 20 mm and 25 mm sizes, High Speed Steel blades ensure high insert stability. The blades accommodate insert widths from 2 mm to 6 mm and are compatible with a variety of tool blocks on the market. The square-shank blocks available through Seco come in metric and imperial sizes, with heights and widths that range from 10x10 to 32x32..

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

• • • • • • • •

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

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

For Product Enquiry Contact Hangsterfer’s Laboratories, Inc. USA Sanjay Tools & Adhesives Mobile : +91 9822028518, +91 9892516810 E-mail: hangsterfers@sanjaytoolsnsk.com Web : www.hangsterfers.com

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MACHINE TOOLS WORLD AUGUST 2016

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Creep feed Grinding Gear Grinding - Profile & Warm Crush Grinding ID and OD Grinding Center-less Grinding Cylindrical Grinding Diamond & CBN Wheel Grinding Tool & Cutter Grinding

PRODUCTS www.mtwmag.com

Metal Cutting Tools Our Product Cluster: Drills, Step drills, End-mills, Reamers, Cutters, Centre-drills, Form-Tools, Profile tools and Customised tooling solution in Solid Carbide and H.S.S.

For machining Components: Engine Head, Cylinder Head, Connecting Rod, Wheels, Crank-Shafts, Gears, CrankCase, Axles, Nozzle Ring, Wind-Mill Blade, etc.

In Work Material: Carbon Steels, Alloy Steels, Cast Iron, Stainless Steel, Inconel, Super Alloys, Titanium Alloys, Copper Alloys, Aluminium Alloys, Brass, Plastics, etc. For Product Enquiry Contact Accusharp Cutting Tools Pvt. Ltd. W-242, J Block MIDC,Bhosari,Pune-411026 Tel:020-27129016, Fax:020-27124857 Email: accusharp@accusharp.co.in Website: www.accusharp.co.in

For Industry Sectors: • • • • •

Automotive Energy Engineering Die & Mould Aerospace.

Orbit Head Applications Converts the Z-axis vertical movement to an orbital movement • The ORBIT HEAD forms the whole depth of the thread in a single orbital cycle. • No need for interfering with the machine’s electronic circuits – attach as an electrode holder and it’s ready to operate.

For Product Enquiry Contact JIG Engineering 103/A, Mandpeshwar Ind Estate, Opp.M.C.F. Sports Cluib, Gymkhana Road, Borivali (W), Mumbai 400092, Maharashtra, India Tel: 7666335362 Website: www.edmwirecutfilter.com

Maintains the EDM machine features of sinking and withdrawal • Withdrawal of electrode designed so it is always towards the center of the hole and not in the direction from which it came in order to achieve improved flushing. • Up to 3.2 mm (1/8”) horizontal movement in 0.02 mm (0.001”) increments. • Special flexible hose for spraying fluid directly through the electrode for blind threads. • Two positions for attachment of electrode. Orbital fixed angular movement for threads (as well as circlip slot, inverted cone etc.) • Orbital and rotating about its axis for circular symmetrical shapes. A special electrode attachment enables the removal and replacement of the electrode without losing pre-settings for threads (to prevent cross-threading).

The potential of Scribing Technology Scribing is a marking process whereby the mark (text or logo) is produced by a carbide or diamond tip that penetrates and indents the surface. This produces a deep groove that forms continuous lines across round, concave, flat, or arched surfaces, and on almost any material. Also called “drop and drag” or “scratch marking,” scribing technology is an ideal choice for applications where noise level limitations are imposed. If dot peen

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PRODUCTS markers are considered too noisy when used on steel pipe, for example, a pneumatic scribing machine might be preferred. SIC Marking’s scribing technology guarantees a high quality mark and is ideal for requirements that include Optical Character Recognition (OCR) or aesthetics concerns (logos, symbols…).

Product range SIC Marking’s product range runs from standard machines to custom engineered solutions. All systems are created with careful attention to bring functional design, quality, innovation, and performance to manufacturing lines. Every site, every job, and every customer is unique. As an example, one of our customers in the automotive industry has asked our engineers to set up a system adapted for eight of his exhaust pipe’s production lines. The traceability and identification of exhaust pipes can be a complicated task since the parts are hollow. Our customer’s main issue was compliance with the noise limits which is the reason why scribing marking systems were chosen. Our i113s marking systems have been easily integrated and implemented on each work station. Thanks to the reliability and flexibility of SIC Marking’s scribing systems, our customer was able to adapt the marking head’s position to fit each of his production lines.

New scribing marking machine

For Product Enquiry Contact SIC MARKING ZAC Bel-Air 195, rue des Vergers CS 80017, F-69480 POMMIERS Patrice BARTHOLLET Phone: (+33) 04 72 54 80 00 Fax: 04 78 47 39 40 Email: p.barthollet@sic-marking.com

To complete its scribing range SIC Marking launches a new i63s marking machine. This new scribing marking head complements the i113s machine dedicated to deep marking on steel and other hard materials. The i63s marking system has a compact yet robust design engineered for integration on production lines of all types of industrial environments. The marking quality is excellent with perfect continuous lines and very fast for materials of all kind, from plastic to hardened steel (up to 62 HRC). The mechanical system is much simpler which has for consequence reduced maintenance. Already equipped with full connectivity (digital I/O, Ethernet TCP/IP, RS232...). Our i63s scribing systems also offer many features to interact with all the elements that set up their environment. Our machines can be easily integrated on all production lines using Profinet, Profibus and Ethernet/IP.

Industrial Fasteners Components

For Product Enquiry Contact ZENITH INDUSTRIAL PRODUCTS ABC INDUSTRIAL FASTENERS E-122, Ansa Industrial Estate, 1st Floor, Sakivihar Road, Sakinaka, Andheri East, Mumbai - 400 072 Tel.: 022-2847 0806 / 2847 0705 / 6692 3987 E-mail : zenith@zip-india.com Web: www.zip-india.com

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We offer some Industrial Fasteners Components Cold Forged, Hot Forged & Turned process type, Hot forged process - Components are Eye Bolt, Stay Eye Bolt, Eye Nut, Foundation Bolt, Hex Bolt, Hex Nut, 16 to 56 mm & 5/8 to 2” dia, Allen Bolt, M 6to 24mm dia, Carriage Bolt, M 10 to 36mm dia, NIB Bolt, Wing Nut, Wing Screws. Cold Forged Process Components are Rivet 1.6 to 10mm dia, Machine Sc, Philips & Slotted Type 2mm to 8mm dia, Hex Nut 2 to 20mm dia, Lock Nut MM 4 to 16mm. Hex Socket head Allen Sc 3 to 16mm dia. Grub Sc MM 3 to 16mm dia. Carriage Bolt Commercial Quality MM 5 to 12mm and 3/16 to ½”Weld Nut, Flanged Nut, Nylock Nuts. Turned process components. (Lathe, Terrate or on Traub Machine) Hex hd Sc & Bolt, Coach Bolt, Nut Dome Nut, Nylock Nut, T-Nut Slotted & Castle Nuts. Long Nuts Allen Sc 2 to 16mm, Grub Sc 4 to 36mm. BSP, BSPT 1/8 to 1.1/2”, NPT 1/16 to 1.1/2”, Collar plug Allen plug Hex Tapper Plug 1/8 BSPT to 1.1/2” BSPT Sq head, T-Bolt, Set Sc 4mm to 10mm dia, etc. other job as per sample or drawing with on quantity basic. Above items possible to supply M.S. En-8, 8.8, En-9, 10.9, Brass Copper SS 202, 303, 304 & 316 quality, HTS RST & V grade.

ADVERTISERS INDEX COMPANY NAME

PG. NO.

A 53

ACE MICROMATIC GROUP

BACK PAGE

ADOR WELDING LIMITED

ANCA MACHINE TOOLS PRIVATE LTD

ASIAMOLD - 2016

CNC SOFTWARE, INC.

33 15

GLEASON WORKS (INDIA) PRIVATE LIMITED

GROB MACHINE TOOLS INDIA PVT. LTD.

HTS - 2016

I IMTEX - 2017

IMTOS 2017

PG. NO.

MMC HARDMETAL INDIA PVT. LTD.

INSIDE FRONT COVER

N NORD DRIVESYSTEMS PVT. LTD.

RAJKOT MACHINE TOOLS SHOW - 2016

RENISHAW INDIA (PUNE)

S SANJAY TOOLS & ADHESIVES

87 & 91

SPARKONIX (INDIA) PVT LTD

SYNETICS AUTOMATION SOLUTIONS PVT. LTD.

J INSIDE BACK COVER

L LAPP INDIA PVT. LTD.

COMPANY NAME

HEIDENHAIN OPTICS & ELECTRONICS INDIA PRAIVATE LIMITED

JYOTI CNC AUTOMATION LTD.

D DOWEL ENGINEERING WORKS

C CNC SERVICING & SOLUTIONS (I) PVT. LTD.

GALA PRECISION ENGINEERING PVT. LTD.

BIRLA PRECISION TECHNOLOGIES LIMITED

PG. NO.

ACCUSHARP CUTTING TOOLS PVT. LTD.

BHARAT FRITZ WERNER LTD.

COMPANY NAME

74-75

UCAM PRIVATE LIMITED

UNITED GRINDING GMBH

UNITY CONTROLS PVT. LTD.

EFFICA AUTOMATION LIMITED

ELECTROTHERM (INDIA) LTD.

MACHAUTO EXPO - 2017

EMAG INDIA PVT. LTD.

MAPAL INDIA PRIVATE LIMITED

YAMAZAKI MAZAK INDIA

18-19

ENGIMACH - 2017

MARPOSS INDIA PVT. LTD.

YASKAWA INDIA PVT. LTD.

MGM-VARVEL POWER TRANSMISSION PVT. LTD.

YG CUTTING TOOLS CORPORATION PVT. LTD.

FRONT GATEFOLD

F FATTY TUNA INDIA PVT. LTD.

WIN INDIA - 2016

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Inside Story

Mr.

Ramesh

CEO, Micromatic Machine Tools Pvt. Ltd.

My Life’s Goals

Aim & Ambition: Aim and ambition are important in every person’s life. I believe that I am ambitious and have goals not because I am unhappy with what I have, but because I am happy with who I am and enjoy the experience of raising beyond my perceived limitation and discovering new capabilities. Vision: We are all work in progress. We must learn for change continually, Life is a game and we must play to win fairly. Nobody else can do it for you and you must work to excel not to compete. Social Goal: Making a difference and giving back to society in every little way you possibly can. It starts with the small things like compliances and widening your circle of concern. Personally conservation of the environment is very dear to me and I consciously find time, ways and means to contribute in this direction. Business Goal: Delighting customers, finding innovative ways to contribute to their success and growth. Institutionalizing the process of customer delight.

My Leisure Choices Favourite Tourist Spot: Any good forest or national park.. I have spent many vacations at Nagarehole, Banidipur and Mudhumalai. Music I like : Classic Rock, Jazz and Carnatic. Jetthro Tull, Beatles are my favourite bands. Closer home Kishore Kumar is an all-time favourite. Sports I Love : Motor Sport and Rallying… Like watching a close tennis match or basketball game.

Ask my Taste Buds Favorite food: I am hard core South Indian foodie… Best food is home food… Favorite Drink: A Chilled beer in summer and an occasional Rum or Vodka.

In Awe of I Admire: Very many people have helped shape me and contributed significantly in moulding me. I admire people who are comfortable being themselves and transparent in their interactions… JRD Tata who happened to be my father’s boss many many years ago was an early influence.

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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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