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

BEING SOLD IN OVER

COUNTRIES!

ENDMILLS • DRILLS • TAPS • INSERTS • TOOL HOLDERS

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Being the best through Innovation

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IT OFFERS: Reliability & safety • Increased tool life • High productivity

Range

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Ballnose, Corner radius & Flat end mills

Coating

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Tel: +91 80 43543610, Fax: +91 80 43543613, Email: marketing@yg1india.com

www.mtwmag.com

Executive Publisher

Contents

Vol 2 Issue 05 | OCTOBER 2016

Shirish D.

BUSINESS NEWS

CEO Shekhar D.

Editor Shilpa Dongre

CNC Software partners with Edge Factor

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

Designer & Layout

Pune Machine Tool Expo 2016: Marked great success

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

Online Division

Ganesh M., Pradeep M. Pillalamarri

Circulation Executive

Renishaw launches FixtureBuilder 3D-modelling software

Satish Kadam, Amol Ranshur Branch Offices (Zonal)

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

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

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

WEST (Maharashtra & Gujarat) Pune Sandeep - 09822751645

DesignTech Systems organizes technology seminar

COVER STORY

ANCA : Leadership with Flexibility & Precision Jeffrey Foregard, General Manager - Asia Executive Director, ANCA Pty. Ltd.

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

WALTER launches new loading system

Altem introduces new 3D printers

FARO continues expansion of factory metrology offerings

TECH PROFILE

28 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 OCTOBER 2016

Hypertherm introduces new SilverPlus technology

Worldâ&#x20AC;&#x2122;s first: Additively manufactured hydraulic chuck

Dynaspede thrives in Mechatronics

Kennametal takes a giant step forward with DUO-LOCK

Robotic revolution: Indian company gets Japanese patent

ANCA Machine Tools Private Ltd 8/1 , Dr. M H Marigowda Road, Arekempanahalli , (Wilson Garden ), Bangalore - 560027, Karnataka, India T: +91 (80) 6759 2100, M: +91 96637 69911, E: indiainfo@anca.com, W: www.anca.com

Contents INTERFACE

Vol 2 Issue 05 | OCTOBER 2016

CASE STUDY Making the entrepreneurial dream possible

34 How lightweight design gives greater flexibility in automotive manufacturing

KMTC promotes quality standards of Chinese.....

Accusharp shows why it is special

TECH UPDATE

TECH TRENDS

A Tale of Two Cutting Tools – Rotary vs Indexable

PROJECTS PRODUCTS

Shrink Fit Holder Technology & Advantages

Missile Lube 1, 1XL, 1XXL, 1XXXL Straight Cutting Oil for HONING ®

A glimpse into the future of machine tool construction

Steady Volt Servo Voltage Stabilizers

LEGEX Series 8

MACHINE TOOLS WORLD OCTOBER 2016

Editorial Board

Editorial Index A

HEIDENHAIN

Accusharp

Hypertherm

Ador Welding

50 62, 94

Altem Technologies

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

Mr. GK Pillai Managing Director & CEO

Walchandnagar Industries Ltd.

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

Kennametal 91

Concept Laser

DesignTech Systems

DMG MORI

Dormer Pramet

Renishaw Metrology Systems Ltd.

Jyoti CNC Automation LTD

M 10

Mastercam

Mitutoyo South Asia

N NUM

R Renishaw

22, 48, 56

RoboPlazma systems 12

Effica Automation Ltd.

28, 66

MAPAL India

Mr. MIHIR Baxi President – Global Sales

Systems

Ms.Samina Khalid Marketing Manager

Igus K

Dynaspede Integrated

Mr. Arjun Prakash Managing Director

ANCA Machine Tools 40, 96

Birla Precision

78 28, 60

Elesa and Ganter

S Sparkonix

STUDER

FARO Technologies

26, 58

Unity Controls

Haas Automation

44, 76

Hangsterfer

WALTER

WIDIA

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

OCTOBER 2016

MACHINE TOOLS WORLD

TECH PROFILE

World’s first: Additively manufactured

hydraulic chuck

In the hybrid process, the functional area is applied to the conventionally manufactured tool body by SLM.

ith the HighTorque Chuck (HTC) with narrow contour, MAPAL has succeeded in combining the benefits of the hydraulic expansion technology with the 3° back taper known from the shrink chuck. This is made possible by the additive manufacturing process employed at MAPAL in the form of selective laser melting (SLM). SLM is a powder bed-based process. Loose metal powder is melted layer by layer onto the areas where material is required by means of a laser beam. The part is built up from bottom to top. During the production of the hybrid HTC with narrow contour, the functional

MACHINE TOOLS WORLD OCTOBER 2016

area is applied to the conventionally manufactured tool body by SLM. Thanks to the additive manufacturing, the clamping range can be positioned very close to the chuck tip which would not have been possible with conventional manufacturing. This provides an optimum radial run-out of < 3 µm at the location bore and < 5 µm at 2.5 x diameter, as well as high shape accuracy with good vibration damping. The damping in the system reduces microstructure cracking at the cutting edge. That in turn ensures longer tool life and less strain on the machine spindle. Furthermore, the additive manufacturing eliminates the need for the soldered joint that has always been a limiting factor until now. The HTC with narrow contour has all the benefits of the proven MAPAL HTC (HighTorque Chuck) technology, whereby the “T” stands not only for high torque transmission, but also for thermal stability. The wide operating temperature range up to 170 °C ensures additional process reliability. The balancing quality is G=2.5 at 25,000 revolutions per minute. The new chuck offers significant benefits not only for mould making, but also for applications in the automotive and aerospace sector. Why? The HTC with narrow contour is suitable for all machining operations in contour-critical areas. It allows quick & simple

clamping of the tool. That means: Neither training courses nor high retooling costs or expensive peripherals are required for implementation. The HTC with narrow contour is available in the clamping diameters of 6, 8, 10 and 12 millimetres for HSK-A63 and SK-40. Intermediate sleeves enable additional diameter ranges to be covered. In addition, the chuck is optionally available with dynamically balanced HSK. That again is something new: For the first time is has become possible to dynamically balance components with HSK connection, because the mass imbalance that has been caused by the different depths of the key block slots until now has been eliminated in the optimised HSK. For more information, you are requested to contact National Sales Manager – Mr Rajesh Kumar.K.G Phone: +91 9741499824 Email:rajeshkumar@in.mapal.com, info@in.mapal.com Website.: www.mapal.com

The HTC with narrow contour is the first additively manufactured chuck from MAPAL.

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

You

Cost reductions

are looking for an innovative partner for your drilling operations.

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

We supply the solution for ecconomical drilling processes.

TECH PROFILE

Dynaspede thrives in

Mechatronics

ynaspede Integrated Systems (P) Ltd. headquartered in Hosur specialises in the design and manufacture of electro-mechanical components and sub-systems for a wide spectrum of industries in the Mechatronics business sector. It has extended service offerings in Engineering design, Product development, Prototyping and Testing. Dynaspede also offers contract manufacturing facilities and distribution services for its partners through its network. The company’s facilities in Hosur, Tamil Nadu occupy over 100,000 sq. ft. area, employing over 260 people. Its manufacturing facilities are distributed across multiple locations supported by a mature and effective vendor network. Its manufacturing capabilities include Sheet metal fabrication and finishing, Tooling and Machining, Electronic assembly and Precision engineering. Dynaspede has eight branch offices across India managing its sales and service network and extending effective presales and after-sales to its customers. The strength of Dynaspede lies in its ability to synchronise skills in various disciplines of engineering and offer reliable solutions both in Design and Manufacture for its partners and customers. Dynaspede was started in the year 1978 with Mechatronics as its core competence. A wide variety of electro-mechanical components and sub-systems including electronic drives, clutches, brakes, gear transmissions, electronic sensors, and digital motion control products have been developed and manufactured. Its Electro-mechanical system engineering capabilities have grown over the years to include customized solutions in Machine assembly, Robotics and Plant engineering. Dynaspede is also manufacturing and distributing various Power Electronics

MACHINE TOOLS WORLD OCTOBER 2016

products namely Aluminum foil wound Transformers, Stabilizers and UPS at an affordable cost. The aluminum foil wound transformers are very cost effective product having very wider application in Power electronics products.. Dynaspede is funded by some of India’s largest private equity funds, Kotak Mahindra and SIDBI. Technology development is sourced through a combination of affiliations with specialised institutions of higher learning and investments in boutique research and development outfits. The company is managed by a team of experienced senior management staff headed by Mr. Mohan Ram, whole time Director and CFO presently encompasses a complete range of capabilities for

Machine Buidinga

Panel Building

Tool Room

designing and manufacturing complex machines and integrated systems from concept to installation. The in-house facilities like R & D, Machining, Gear Shop, Metrology, Electronics Assembly, Fabrication and Heat Treatment, form the backbone of the organization. The Design & Development Team consists of experts in machine design & control technology, academicians, application specialists, software and hardware engineers working in an institutional environment, supported by modern CAE facilities. From the simple design of a base plate to the complexities of automatic controls, every piece of equipment from Dynaspede reflects a commitment to excellence. The in-house metrology and calibration facilities provide for mechanical and electronic measurements with an accuracy traceable to international test standards. Dynaspede’s Repertoire includes superior engineering and development capabilities, robust manufacturing setup, Small enough to scale up and large enough to be agile, Focus on value creation and lasting relationships, and Strong global clientele spanning automotive, aerospace / aviation, defence, and other industrial sectors. What sets Dynaspede apart is the collaborative approach of its dedicated professionals. “We enjoy spending long hours to match customer expectations with our own. Within the family of Dynaspede, we keep driving a point or two… no hard selling in pre-sales matters, no matter what… and no soft pedaling in after-sales matters - all dictum geared towards maintaining our Business Ethics …to conduct our business with honesty, integrity and dependability, elucidates the company. - P.K. Balasubbramaniian

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

The Art of Grinding.

A member of the UNITED GRINDING Group

S11

The super-productive machine for small workpieces.

If space-saving is your priority, then the S11 is the right machine for you. In a space of less than 1.8 m2 the S11 produces extremely efficiently and reliably with a grinding wheel dia. 500 mm. The S11 can be set up quickly and easily thanks to the lean StuderWINfocus software, geared to the most important features. It can also be easily automated with an integrated loading/unloading device. www.studer.com – «The Art of Grinding.»

United Grinding GmbH – India Branch Office & Technology Center · # 487, D1 & D2A, 4th Phase, KIADB Main Road, Peenya Industrial Area, Bangalore – 560058 Tel: +91 80 3025 7600 · Fax: +91 80 3025 7603 · Email: prabhakar@grinding.ch · URL: www.grinding.ch

BUSINESS NEWS

CNC Software partners with Edge Factor CNC Software has partnered with Edge Factor to produce a professional, time-saving, turnkey package of exciting media and interactive resources, called the Rock MFG Day Kit, to help make events compelling, engaging, and successful. Spurred by record-setting participation last year, many activities are in the works for Manufacturing Day 2016, scheduled for October 7, 2016—the fifth annual industry grassroots event that is celebrated across North America and being promoted as “MFG Day.” Edge Factor has joined the organizers of Manufacturing Day as the Strategic Content Partner; creating a virtual event package that enhances MFG DAY events and makes it as easy as possible for event coordinators to host inspiring and interactive events.

Featured in the Rock MFG DAY Kit, Edge Factor’s cinematic Behind Closed Doors film weaves inspirational stories of women and men using advanced manufacturing technology to push back the edge of what’s possible. Based on the film, the kit contains interactive activities, CNC machining and 3D printing projects, looping videos, discussion activities, a customizable slideshow presentation, post-event parent resources, and more. “This Manufacturing Day, we invite you to host an event and become a leader in mobilizing your manufacturing community,” said Jeremy Bout,

Producer/Host of Edge Factor. “The turnkey Rock MFG DAY Kit provides you with tools to reach out to your community to change the perception of manufacturing and showcase the amazing accomplishments and people behind your shop’s doors.” “Mastercam has partnered with Edge Factor to produce materials to inspire young people to pursue careers in the incredible world of manufacturing,” states Meghan West, President of CNC Software, Inc. “This free, online events resource kit will help manufacturers connect with leaders and students in your community to change perceptions of manufacturing, involve kids and teachers, reach parents, spark conversations, and collect meaningful feedback on the success of their events.”

Pune Machine Tool Expo 2016: Marked great success The four-day Pune Machine Tool Expo, 2016 – Western India’s B2B exhibition, concluded on a positive note on 2 October 2016. With more than 100 exhibitors, the machine tool exhibition attracted 7,400 visitors and 62 trade delegations from various industries such as auto component, automobiles, capital goods, defence, aerospace and railways. Along with host city Pune, the event attracted impressive number of delegates and visitors from the Tier II and Tier III cities such as Aurangabad, Nagpur, Kolhapur, Mumbai, Satara, Ahmednagar, besides the neighboring state of Gujarat. Organized by the Indian Machine Tools Manufacture’s Association (IMTMA), the exhibition was held for four days from 29th September – 2nd October 2016 and

MACHINE TOOLS WORLD OCTOBER 2016

served as a platform to demonstrate the latest manufacturing technologies. The expo covered both metal cutting and metal forming technologies including automation and robotics, tooling systems, CAD/CAM and other technologies, which are essential for today’s manufacturing. The Pune Machine Tool Expo turned out to

be fruitful both for the visitors as well as the exhibitors and most of the exhibitors were satisfied with the quality of the crowd and the business opportunities that the exhibition provided them. The success of Pune Machine Tool Expo has given further impetus to the IMTMA’s idea of Regional Machine Tool Expos – to address requirements of the Original Equipment Manufacturers (OEMs) of the various industry sectors in the Tier II and Tier III cities in the various regions of India. Continuing with the idea, the next Regional Machine Tool Exhibition will be the second edition of Delhi Machine Tool Expo, which will be held from 10-13 August 2017 at Pragati Maidan, before returning to Pune in 2018.

BUSINESS NEWS

Renishaw launches FixtureBuilder 3D-modelling software FixtureBuilder is a 3D-modelling software package designed to allow the off-line creation and documentation of fixturing set-ups. The software can be used with a CAD model of the part to be inspected, which is imported into FixtureBuilder, so that the fixture can be built around it. The entire set-up, along with the part, can then be exported into inspection programming software, using universal file formats such as: IGES, SAT, STEP, etc.. FixtureBuilder offers a wide range of customer benefits, derived from Renishaw’s outstanding understanding of metrology best practice and part inspection. FixtureBuilder offers unparalleled ease of use thanks to clear

and well-organised component libraries; Intelligent ‘Drag and drop’ functionality; quick manipulation of parts; and easy-to-use constraint mechanism. User experience is further enhanced by the software’s full CAD compatibility and the

availability of custom libraries. The ‘Build it’ function is one of the key benefits available to all FixtureBuilder users. It automates the production of work instructions and Bill of Materials for every fixture set-up, to help ensure compliance with quality standards and assist with product ordering.

The software is available to all existing and future Renishaw customers to complement and further improve the productivity of their Renishaw fixtures and other inspection equipment. It is available for purchase through the Renishaw distribution network as well as the Renishaw Web shop.

NUM launches advanced control solution for CNC milling machines NUM has launched an advanced control solution for CNC milling machines that features a highly intuitive conversational style user interface. Known as NUMmill, the CNC hardware and software provides a fully scalable control system and is supplied as a complete ‘off-the-shelf’ package. NUMmill is designed specifically for CNC milling machine manufacturers and control retrofitters. It offers an extensive suite of canned cycles, ranging from simple centre drilling, boring and threading to pocket cycles and complex profile milling cycles. All with 3D simulation for pre-process verification. The package is suitable for a wide range of precision milling applications in markets as diverse as metal cutting, woodworking, plastic, and high precision machining. Based on NUM’s market-leading Flexium+ modular CNC platform, NUMmill is typically configured with 3 or 4 linear axes and a single

MACHINE TOOLS WORLD OCTOBER 2016

rotary axis, though it easily scales to suit any size and type of milling machine application. NUMmill Windows-based software provides graphical shop floor programming screens that depict the tool, the workpiece and all associated setup data in a concise and unambiguous manner. The operator is prompted to fill in the appropriate data fields presented by the human-machine interface (HMI), after which

the machine control program is generated entirely automatically and then stored, ready for execution. On-line help files and step-by-step video tutorials are included for ease of operation. This conversational style programming helps to save considerable development time, as well as significantly reducing the learning curve for new operators. NUMmill is supplied as a complete, readyto-run package that includes the Flexium+ CNC system, software, and a 19-inch touchsensitive machine control panel, together with all necessary drives and motors. The system is also equipped with NUM’s MTConnect interface, which simplifies the integration of CNC machine tools with third party manufacturing software. The NUMmill system also provides measurement and probing cycles, to help users meet precision and quality targets, as well as full 3D simulation with collision monitoring for preprocess verification.

Our Lean Selection cam reflects our own core values. Precision, reliability, high performance.

JUNKER Lean Selection cam High-performance non-circular grinding. The Lean Selection cam is an economical and flexible machine concept for grinding camshafts in any lot size. The wheelhead can be equipped with up to two high-capacity grinding spindles. The swiveling B-axis manages rough and finish grinding or the grinding of bearings and cam lobes in a single clamping. The Lean Selection cam CBN grinding machine combines simplicity in operation, precision and lowest total cost of ownership. Erwin Junker Maschinenfabrik GmbH India Branch Office

www.junker.in

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

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

BUSINESS NEWS

DesignTech Systems organizes technology seminar DesignTech Systems recently organized a technology seminar “Achieve Product Excellence through technology Impetus” at Hotel The Lalit in Mumbai. The aim of this event was to showcase the latest and most advanced technologies in product design, analysis, validation and manufacturing to help companies build better products faster, economical and better than before. Using these technologies the companies can not only achieve their product design and manufacturing goals, but through PLM solutions, they can also set-up well streamlined and optimized work processes to attain maximum efficiency. DesignTech Systems Ltd., being the strategic Business Partners with the world leaders and some of the biggest names in the product design and manufacturing industry, presented CAD/CAM, PLM solutions from Siemens PLM Software; Comprehensive CAE suite of solutions from

Altair Engineering; 3D Printing technologies from Stratasys; MATLAB Technical Computing software from MathWorks; and Metal 3D Printing Solutions from SLM. In this event, DesignTech Systems demonstrated technologies at every stage of product lifecycle starting from Concept development, 3D Modeling and Validation, Product Design analysis and simulation,

Rapid prototyping, Alternative Production technologies, to PLM for managing and optimizing the entire product design. Guest Speakers like Mr. J. Arul Regan, Executive (R&D) IFB Industries Ltd. highlighted on how they are utilizing Stratasys 3D Printing Technology to develop aesthetically appealing and functionally superior products in lesser time and costs. 3D Printed models help IFB identifying

design error and saving time in development cycle, which forms a major part of product design related decision process. Abdul Kalam S. from Sridevi Tool Engineers explained how Siemens NX technology helped build accurate mold designs, reduced design cycle time by 50 percent and increase profitability through improved mold making technology. Mr. Atul L. Godse – Technical Head – Ansycad Solutions presented on advantages of using Altair CAE suite of solutions for various product streams. Vikas Khanvelkar, Managing Director, DesignTech Systems Ltd. thrilled at the excellent turn out of engineering fraternity for this event stating, “It makes me happy to see the enthusiasm among the engineering industry to learn about, understand the advantages, and consider adopting new and advanced technologies to add more value to their engineering initiatives.

WALTER launches new loading system the working envelope of the machine. The “Top loader” is equipped with a swivelling arm with a single gripper and uses the standard WALTER robot pallets - one for the blanks and one for finished tools. Depending on the tool diameter, these pallets can be loaded with up to 500 tools. A tool change takes only 27 seconds. The set-up of the tool pallets is completed automatically through an electrical teaching routine (patent pending) for ease of use and simplicity of changeover. WALTER has launched a completely new type of loading system for new machines of the types: Helitronic Mini Power, Helitronic Diamond Evolution and Helitronic Essential.

MACHINE TOOLS WORLD OCTOBER 2016

The new space-saving and cost-effective automation solution “Top loader” is integrated directly into the machine - therefore requiring no additional floor space and no restriction of

VL 3 DUO – MULTI-SPINDLE TURNING MACHINE PRODUCTIVE

PRECISE

COMPACT

HIGHLIGHTS

19.6 m² SMALL

FOOTPRINT

MAXIMUM PRODUCTIVITY: Chip-to-chip time of 5 seconds*, two separate machining areas for OP 10 and OP 20 each with a 12-station tool turret and 18 kW working spindle

HIGH PRECISION: Machine base made of MINERALIT® polymer concrete, size 45 linear roller guides and direct position measuring systems in all axes

COMPACT DESIGN: The machine has a footprint of only 16.9 m2 including a parts storage area that can hold up to 400 workpieces and TrackMotion automation system for high-speed part transport between the parts storage and machining areas, as well as for turning the workpieces. *Depending on workpiece geometry

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

More information

BUSINESS NEWS

Altem introduces new 3D printers Altem Technologies recently announced the availability of their newest 3D printers, for orthodontic practices and laboratories. The new printers allow dental professionals to push the boundaries of digital dentistry right from their desktops. The goal with the 3D printer is to enable any lab or dental clinic to fabricate stone models from their desk tops for appliances, delivery and positioning trays, models for clear aligners, retainers and surgical guides . 3D printing technology enhances accuracy, eliminates risk and also reduces the need for messy, time-consuming procedures that are currently being followed. It can

160

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

help save more than 50 percent of a technician’s time in designing and manufacturing restorations, which means a substantial reduction in operational costs as well. Altem is leading the way in helping to advance patient care by introducing solutions that enable personalized surgical planning and mass customization. No more guessing or no more figuring-it-out

as we go only digital precision,” said Prasad Rodagi, FounderDirector – Altem Technologies. Altem will be able to unveil a number of other orthodontic solutions that have shown a high degree of success by the process of 3D printing. Altem helps make practices far more efficient by dramatically shortening delivery times, improving service levels with accuracy along with cost reduction.

FARO continues expansion of factory metrology offerings FARO recently announced the acquisition of Laser Projection Technologies, Inc., a leader in high-speed, long-range 3D laser projection and measurement systems designed for use in manufacturing applications requiring precise component alignment. Located in Londonderry, New Hampshire, LPT’s line of laser projection and measurement systems are used throughout manufacturing environments around the globe to maximize productivity and efficiency. “The acquisition of LPT enhances FARO’s robust portfolio of 3D measurement solutions,” stated Dr. Simon Raab, FARO’s President and CEO. “In addition to LPT’s leading laser projection solutions, we believe LPT’s proprietary imaging laser

MACHINE TOOLS WORLD OCTOBER 2016

SNIPPETS

photogrammetry and imaging laser radar technologies have tremendous potential to disrupt the market by establishing a new class of high-speed laser measurement with advanced 3D imaging capabilities and we will focus our integration efforts on rapidly leveraging this potential. This technology is thousands of times faster than currently available Lidar products and has proprietary imaging features, which provide extraordinary qualitative and quantitative inspection capabilities in every area of manufacturing. In addition, this promising technology incorporates a

well-developed laser projection capability to guide assembly, making it a fully robotic, highspeed collaborative tool for manual or automated assembly and verification. In this case, ‘seeing’ is truly measuring.” FARO develops and markets computer-aided measurement and imaging devices and software. Technology from FARO permits high-precision 3D measurement, imaging and comparison of parts and complex structures within production and quality assurance processes. The devices are used for inspecting components and assemblies, rapid prototyping, documenting large volume spaces or structures in 3D, surveying and construction, as well as for investigation and reconstruction of accident sites or crime scenes.

13%

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

$35 bn

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

58%

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

32%

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

75%

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

BUSINESS NEWS

Hypertherm introduces Kennametal takes a new SilverPlus giant step forward with technology DUO-LOCK

Hypertherm is introducing a loweramp SilverPlus electrode. This new electrode, for its HyPerformance family of plasma cutting systems, is designed for cutting at 80 amps. Like all SilverPlus electrodes, the new 80 amp electrode is proven in Hypertherm laboratory testing to last more than twice as long as a standard copper electrode. Instead of replacing the electrode at a pit depth of 0.040 of an inch as recommended with standard electrodes, SilverPlus electrodes are designed to last to a pit depth of 0.080 of an inch. In addition, the electrode delivers a very consistent range 4 and 5 cut quality throughout its life, allowing owners to lower their operating cost, with no impact on cut quality or speed. The electrodes, protected by patent, are created by fusing a completely solid silver tip on to a copper electrode base. A hafnium pin is then inserted into the tip. This serves to dramatically slow the wear rate for both the electrode and nozzle as silver disperses heat better than copper. Hypertherm’s electrodes are further differentiated from competitive and after-market consumables by a superior bond

MACHINE TOOLS WORLD OCTOBER 2016

between the copper and silver. This results in more consistent wear rates, deeper pit depths, and more robustness to ramp down errors and hard failures. “The proven performance of SilverPlus makes these electrodes a popular and costeffective choice since it allows HyPerformance Plasma owners to cut their electrode and nozzle costs in half,” says Martin Geheran, a consumables product manager at Hypertherm. “These electrodes are a perfect example of Hypertherm’s commitment to lowering the cost of cutting for people who own our products.” In addition to the new 80 amp electrode introduced, Hypertherm also offers 130, 200, 260, and 400 amp versions with similar performance. Hypertherm designs and manufactures advanced cutting products for use in a variety of industries such as shipbuilding, manufacturing, and automotive repair. Its product line includes plasma, laser and waterjet cutting systems, in addition to CNC motion and height controls, CAM nesting software, robotic software and consumables.

Back in 2014, Kennametal announced a technology partnership with Haimer for the development of a modular cutting tooling system. Since that time, the company has been busy developing, testing, and building inventory of DUO-LOCK, which promised even then to be “the most rigid and most precise interface in the marketplace.” Today it’s even better. According to Thilo Mueller, manager of solid carbide end milling at Kennametal, DUO-LOCK is the only modular endmill solution able to compete at solid carbide levels, and outperforms its nearest modular competitor by more than two to one. That means full-width slotting at depths up to 1 x cutter diameter, and side milling up to 50 percent radial engagement at 1.5 x the diameter deep, even in stainless steel, titanium, and other high-temp aerospace alloys. Mueller says he’s excited about the tool’s robust machining qualities, but is equally enthusiastic about its broad initial product offering. “We have over 400 line items coming in the first wave, with many more coming early next year,” he says. “These include the most popular size end mills in both inch and metric, as well as a broad array of adapters, integral shank holders, and extensions.”

Many of those extensions are equipped with HAIMER’s Safe-Lock™ technology, a secure clamping mechanism that eliminates concerns over tool pullout and creep in highperformance milling applications. HSK, CAT, BT, and comparable spindle tapers are also available. One of the things that makes DUO-LOCK unique is its intelligent thread design. Using FEA-based design tools, Kennametal has optimized the connection to eliminate any possibility of tool failure even at elevated loads. The result, says Mueller, is that DUOLOCK handles 25 percent more torque than its closest competitor, permitting higher feedrates and axial depths of cut, especially in long reach conditions. The cutting geometry is likewise unique, and uses an upgraded HARVI front end with an asymmetrical flute design. This breaks up cutting harmonics, reduces chatter, and provides 20 percent or greater chip load per tooth compared to the solid carbide versions.

BUSINESS NEWS

Robotic revolution: Indian company gets Japanese patent Japan straddles the forefront of industrial robotics and boasts the highest concentration of such robots being manufactured, used and exported. Besides this, the Japanese patent office is one of the toughest to break through as it is flooded with robotic patent applications. When the Punebased Plazma Technology Pvt. Ltd. filed its patent application for enhancing the reach of a robot used in a diverse range of applications in cutting and welding, the application was challenged with many prior Japanese patents. Plazma had to refute each one by clarifying the uniqueness of their submission. This was for a combination of hardware and versatile software that enhances the reach of a robot.Technical excellence finally won the Japanese robotic-patent awarded to a home grown Indian company.

Boston Consulting Report The significance of this patent is better understood in the context of the current global, industrialrobotic space accurately described in the Boston Consulting Group’s noteworthy report titled: “The Robotic Revolution –the Next Great Leap of Manufacturing.” Excerpts: “The real robotics revolution is ready to begin. Many industries are reaching an inflection point at which, for the first time, an attractive return on investment is possible by replacing manual labor with machines on a wider scale. In some industries, robots will do more than 40 per cent of the manufacturing tasks. This development will power

MACHINE TOOLS WORLD OCTOBER 2016

Obsessed with Plasma: Hughen with his revolutionary RoboPlazma systems

positive gains in productivity in many industries around the world and catalyze defined shifts in competitiveness among manufacturing economies that have already reaped significant benefits. “A confluence of forces will power the ‘robotics takeoff’. For one, the prices of hardware and their enabling software are projected to drop by more than 20 percent over the next decade. At the same time, the performance of robotics systems will improve by around 5 percent each year. As robots become more affordable and easier to program, a greater number of small manufacturers will be able to deploy them and integrate them into industrial supply chains. “Advances in vision sensors, gripping systems, and information technology, are in the meanwhile, making robots smarter, highly networked, and immensely more useful for a wider range of applications. All of these trends are occurring at a time when developed and developing nations alike, are under mounting pressure to improve productivity in the face of rising labor costs and aging workforces.” From the Boston Consulting

Japan.This Indian company caters to present and future requirements for the metalworking industry worldwide. For three decades, Plazma has designed, developed and manufactured machinery for steel fabrication and plate processing related industries. It has already catered to over 1,000 customers comprising Multinationals, Giant Indian Corporates, large Public Sector Units and Small & Medium Enterprises across India, Africa, Kuwait, Mauritius, Sri Lanka, South Africa and other countries.

ROBOPLAZMA Systems

The Japanese patent won by Plazma Technologies, India

report, it is clear that industrial robotics is all set to experience a significant boom as it is already on the way to boosting more efficient production all over the world. Therefore, it is exceptional that this Indian company is at the forefront of robotic innovation and certified by a Japanese patent – ‘the holy grail of robotics. ‘

Innovator Throughout Founded in 1991, Plazma Technologies is not just another company supplying robotic solutions in India and to the world. Its unique DNA is proven by 15 Patents granted by the U.S.A, Middle East, South Africa and

Plazma’s dedicated team is imbued with a mission to transform fabrication by boosting robotic efficacies. This ingenious ‘Smarter Fabrication with Robotics’ mantra rewrites the very rules of any production line.The RoboPlazma range of robotic systems has the capability to cut all types of 3D jobs like dish end, pressure vessels, nozzle opening on boilers, Auger blade, Autocomponents fabricated assemblies, etc. RoboPlazma structural steel processing system can cut all profiles like i-beams, channels angles, square tubes , pipes and plates thus replacing 7 different machines. The Plazma in-house software powering these systems is called RoboSwift™: an artificial intelligence based proprietary software with intelligent shape recognition capabilities: This eliminates the need for human intervention or any requirement of skilled operators.The company’s patented software and Hardware turnkey solution enables a new 3D or 2D job to be cut every

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

G-Series

Horizontal 5 axis machining centers

Precision at the highest level

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

GROB_Indien_Anzeige_Magazin_die_and_mould_April_2016_DINA4.indd 1

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

www.grobgroup.com

02.05.2016 08:11:57

BUSINESS NEWS time. Complicated weld edge preparation, circular contour bevelling, single or double ‘V’ with root are all processed automatically.

with quality as part of Plazma’s unwavering commitment.

Capital- efficient business model innovations

• Roboplazma Rented systems for a project or on a yearly basis. • Expert cutting services Jobshop equipped with CNC 2D RoboPlazma system for 2D & 3D cutting for its customers to outsource cutting work.

For Robotics to truly succeed, ‘RoboPlazma solutions’ has to have a guaranteed Return on Investment. With this in mind, the Plazma team has created businessmodel innovations to make their Robotic solutions affordable for every budget. In addition to a range of models catering to varying price ranges, Plazma provides ‘Expert System Operation Services’. These include trained operators and seasoned experts to advise new customers. This enables new customers to bridge the initial learning curve and run RoboPlazma at optimum efficiency to meet project deadlines. For ‘out of spec’ special 2D or 3D cutting project requirements, Plazma’s experts develop software and hardware solutions ‘on the go‘ thus doing its utmost to ensure RoboPlazma delivers productivity

Plazma technologies provides a variety of Capital-efficient solutions like:

Technology Center for Training and Development Plazma has set up a state-ofthe-art Technology Center in Pune & Dubai. This Tech Center

The Japanese patent enables resolving a complex pipe problem

Plazma’s Technology Center in Pune: Managing Director Arundhati is actively engaged in training and extending benefits to b-schools and engineering institutes.

MACHINE TOOLS WORLD OCTOBER 2016

has over 35 different projects under development specifically to answer customers’ needs for new applications; dedicated software/ hardware engineers work two shifts a day. They are engaged in Research and Development of ‘state- of- the - art’ robotic solutions. Plazma is also addressing the gap between educational institutes and the industry by linking theoretical education with practical application training. This is to create a strong talent pool for industry. Plazma’s managing director Arundhati is actively involved with Business Schools and engineering institutes to structure

training courses on practical aspects such as Innovation Engineering, Social Engineering, and Leadership Training.

Inspired Team In his PUNE INSPIRE address (you tube: Hughen Pune Inspire), Plazma’s founder Hughen talks about his operating philosophy: ‘Technology through Flow’. It is difficult to believe that this ingenious Technocrat is a college dropout. His obsession with plasma goes back to his school days. His award winning and patented plazma torch technology inspired him to integrate the ionized power of ‘plasma’ with high performance, robotic-system innovations. Numerous Patents already granted and still being filed in many countries are a testimony to the constant technology upgradation by Plazma technologies Pvt. Ltd. To quote Hughen: “The case for robotics in India is not easy or straightforward. For the fabrication industry, Robotic solutions have to be technologically superior and economically viable. It is not feasible to offer any unaffordable technology. This necessitates ‘technological and business model innovations’ to make Roboplazma an attractive option. There is also the socio-economic impact of robotics on the perceived displacement of the labour force. We at Plazma educate the workforce through ‘training service packages’ thus ensuring that robotics enhances their quality of life.” Indeed, Hughen, Arundhati and their inspired team at Plazma constantly reinvent the technological, economic and social aspects of Robotics for their customers. - P.K. Balasubbramaniian

INTERFACE

How lightweight design gives greater flexibility in

automotive manufacturing

The vehicle bodies of tomorrow will not only need to be lighter, but above all will also require a highly flexible design. In the foreseeable future, additive manufacturing will be able to offer entirely new conceivable approaches

Dr.-Ing. Martin Hillebrecht, Head of Competence Center for Lightweight Design, Materials and Technologies, EDAG Engineering GmbH, Wiesbaden (Germany)

Mr. Sergio Raso, Head of Strategic Marketing - Laser Products, BLM Group, Cantù (Italy)

n a joint project, EDAG Engineering GmbH (Wiesbaden, Germany), Laser Zentrum Nord GmbH (Hamburg, Germany), Concept Laser GmbH (Lichtenfels, Germany) and the BLM Group (Cantù, Italy) presented the bionically optimized spaceframe produced by hybrid manufacturing to highlight a new way in which a bodywork concept that is adaptable and can be manufactured flexibly can be produced in order to make the increasing range of different vehicles manageable thanks to the large number of different drives and load stages. Additively manufactured bodywork nodes and intelligently processed profiles are combined. Thanks to additive manufacturing, the nodes can be configured to be highly flexible and multifunctional so that, for example, different versions of a vehicle can be produced “on demand” without any additional tooling, equipment and start-up costs. Steel profiles are used as connecting elements. They too can easily be adapted on an individual basis to the specified load levels by providing them with different wall thicknesses and geometries. The NextGen spaceframe is part of the EDAG “Light Cocoon” concept car, a compact sports car with a bionically configured and additively manufactured vehicle structure, covered with an outer skin made from a weatherproof textile material. We spoke to all of the partners involved in the project about the new approach of a lightweight frame optimized for manufacturing.

Q. Is it becoming more difficult in the automotive sector to achieve the sustainability targets? If it is, what contribution is the hybrid NextGen spaceframe design from EDAG making?

Prof. Dr.-Ing. Claus Emmelmann, CEO, Laser Zentrum Nord GmbH, Hamburg (Germany) 34

MACHINE TOOLS WORLD OCTOBER 2016

Mr. Frank Herzog, President & CEO, Concept Laser GmbH, Lichtenfels (Germany)

Martin Hillebrecht: Automotive manufacturers are under great pressure to develop vehicles which are due to go into production between 2015 and 2020. The new bodywork structures should weigh less, have high stiffness to ensure

For a new era of manufacturing

Renishaw’s new metal powder bed fusion additive manufacturing system for industrial production, RenAM 500M, features increased emphasis on automation and reduced operator interaction. The system is the first to be designed and manufactured in-house by Renishaw, applying over 40 years of cross-sector engineering excellence that spans electrical, mechanical and optical technologies. Highlights include: • Renishaw designed and engineered optical system with 500 W laser • Automated powder sieving and recirculation • Patented dual SafeChange™ filter system • Renishaw RESOLUTE™ linear encoder on Z-axis for precision and accuracy

Find out more at www.renishaw.com/additive

Renishaw India G K Archade, 3 floor, No 125/1-18 T Mariyappa Road, 1st block, Jayanagar Bangalore 560011 T +91(0)80 66236000 E india@renishaw.com

www.renishaw.com

INTERFACE outstanding performance and satisfy demanding load scenarios in the event of a crash. In spite of all the ambitious targets for weight reduction, greater demands from customers, thinking of alternative drives, comfort, functionality and networking, as well as new safety requirements from international legislators are sales criteria that do not favor lightweight construction. From my perspective, the core concept of a visionary and bionic spaceframe would be among other things only to use materials where they are really needed to deliver a function, safety or rigidity. So a reduced approach based on the motto “less is more”. Thanks to toolless additive manufacturing and the profiling method with minimal use of tools, it may even be possible in future to design all bodywork versions to suit the level of loading and manufacture them “on demand”. Whatever happens, there is definitely potential here. Sergio Raso: Sustainability is the overriding aim for the automotive industry. Various core technologies for the future of automotive production have so far been looked at. The frame structure of the EDAG Light Cocoon combines many of these technologies in one approach. For example, there is a lightweight hybrid design to achieve weight reduction and fuel efficiency, use of additive methods for a bionically optimized design and use of tubing and profiles to ensure that the vehicle frame can be manufactured in a highly flexible way.

Q. As the example of electric vehicles in Europe demonstrates, it takes a long period of time to progress from initial innovators such as the pioneers Hayek (original Smart) or Tesla Motors (USA) to get to adapted innovations. Is the automotive industry really ready to look at its products in completely new ways? Martin Hillebrecht: Experience shows that one possible way to embark on new manufacturing strategies such as lightweight design is often to produce

MACHINE TOOLS WORLD OCTOBER 2016

small numbers of vehicles in the luxury car and supercar segment. This clientele identifies with lightweight design, e-mobility and technical innovations much more than the mass market. These “innovators” are willing to accept much higher manufacturing costs as a price worth paying for better driving dynamics, comfort, safety and for ecological reasons. If the technology displays suitable potential and as its development advances to allow mass automotive production, the processes can then be scaled up from a niche product to enable larger volumes to be produced. But this definitely requires a degree of patience, long-term investments in the future of the companies involved and a great deal of technical expertise. I don’t accept that “a long period of time” is required, but it definitely takes some time to adapt new technologies.

should be roughly 100 kg lighter than their predecessors, depending on the segment of the market. A further weight saving of from 10 to 20% can be achieved in the bodywork and add-on parts. Many manufacturers have already succeeded in reversing the spiraling trend for increased weight. But what is also true is that in spite of all the ambitious targets for weight reduction, the greater demand from customers for alternative drives, comfort, functionality and networking as well as new safety requirements from international legislators are sales criteria that do not favor lightweight construction. It is a balancing act that we are trying to achieve.

Sergio Raso: In the automotive industry, the number of jobs depends to a large degree on the manufacturing methods and strategy employed. They have a crucial bearing on the cost structures, the achievable margins and the level of success. These factors shape the way we look at mobility and not least also the prosperity of many national economies. In order to maintain the level of automotive mobility that has been achieved, the automotive industry has continuously invested in making technological advancements to its automobiles and the production processes behind them. Investments in research and development are essential, and we at the BLM Group are also on this path of innovation and ongoing development.

action by governments, with their political targets, laws and definitely also the incentives that they provide. This focus, if we just look at the US state of California, is an increasingly prevalent fact that we must come to terms with. Automotive manufacturers are accepting these demands and also view political targets as an engine for driving innovation. So politicians and manufacturers share a common interest. Along with the known solutions for energy management, such as developing electric storage units and drives, and also vehicles equipped with fuel cells, the manufacturing processes can also be heavily geared to reflect the visions of “green technology”. The manufacturing design with allelectric bending machines, laser cutting machines with a high level of efficiency or laser melting are examples of how the BLM Group is committed to a “greener” future. The path toward intelligent conservation of resources and sustainability is an irreversible mega trend. All of the stakeholders in the automotive industry are conscious of this.

Q. Conservation of resources and “green technology” are key aspects. How does the automotive manufacturer view this? Martin Hillebrecht: Thanks to smart lightweight design, particularly with composite construction, the vehicles

Sergio Raso: Solutions for “green technologies” and intelligent energy management are heavily dependent on

TECH UPDATE

A Tale of Two

Cutting Tools â&#x20AC;&#x201C;

Rotary vs Indexable Based on material, operation and user requirements, both round tools and indexable tools have their distinct advantages. Read this article to understand which cutting tool fits your requirements in a better way

n the early industrial days of cutting tool development, metalworking was very limited. It was a slow task until the nineteenth century when the industrial age brought the availability of machine power from the steam engine and, later, electricity. Machine tools developed considerably in response and with the introduction of High Speed Steel (HSS) in the twentieth century, the modern metal cutting era began. Today, there are two types of cutting tools, rotary and indexable. Rotary, also known as solid round tools, forms one entire piece made up of the cutting edge and shank. It is typically associated with drilling, threading and milling applications. Indexable tools are predominantly made of inserts or tips, where the cutting edge is a replaceable shaped piece which is welded or clamped on to a tool body. These are generally used for turning, milling and hole-making operations. Fabio Sala is product manager for round tools and Lukas Pavlis, product manager for indexables, at global manufacturer Dormer Pramet. Both discuss the key elements which make up the differences between the two types of cutting tools, including the material, performance and versatility. Material â&#x20AC;&#x201C; Indexable At the beginning of the twentieth century, cutting tool material was sometimes only slightly harder than the material being cut. Therefore tool-life was poor and cutting speeds had to be kept very low. As cutting tool materials developed, they allowed for increased machining parameters and the ability to withstand higher temperatures while maintaining hardness. The harder the tool substrate the more wear resistant the cutting tool, resulting in longer tool life. The compromise here is that harder tool substrates are more brittle and more likely to fracture or break under adverse operating conditions.

MACHINE TOOLS WORLD OCTOBER 2016

TECH UPDATE www.mtwmag.com

Softer tool substrates mean the tool will be tougher, allowing successful machining even under adverse conditions. Although, tougher substrates are less likely to fracture or break, they operate at lower performance parameters and so tool life is not as long. An ideal cutting tool material should resist flank and point wear, as well as deformation, be tough to resist breakage, does not chemically interact with the work piece material, resist oxidation and diffusion and have good resistance to sudden thermal changes. Inserts are made from tungsten carbide, which is the most commonly used material for indexables. Other available material used for inserts includes cermet (CT), ceramics (CC), cubic boron nitride (CBN) or polycrystalline diamond (PCD). CT has good flank and crater wear resistance and is not prone to built-up-edge. Because of this, the cutting edge maintains its sharpness over a longer time. CC has a wide application area in cutting hard materials (45-55 HRc) and has high resistance to abrasive and thermal conditions. CBN is an excellent cutting tool material and offers extremely hard high thermal resistance. CBN is utilized in materials such as hardened steels and cast iron. PCD exists in two types (natural diamond or industrial diamond) and is utilized for nonferrous materials, such as high silicon aluminum due to its high resistance to wear. As PCD is extremely hard and brittle, it is not a good choice for high hardness or impact applications. Material – Rotary Round tools are traditionally made from High Speed Steel (HSS), High Speed Cobalt (HSCo or HSS-E) or Solid Carbide. Carbon, Chromium, Tungsten, Molybdenum, Vanadium and Cobalt all make up the main alloy elements used within high speed steel cutting tools. HSS is a medium alloy that has good machinability and performance. It offers toughness and is a cost-effective option for a wide variety of large scale drilling and threading applications in multiple materials. However, it is not very wear resistant and so not suited to demanding, difficult conditions. Cobalt high speed steel offers a good combination of toughness and hardness, providing good machinability and wear resistance. This makes the material suitable for drills, taps, milling cutters and reamers. Solid Carbide is the most widely used and wear resistant cutting tool material today and is suitable for both round tool and indexable applications. Performance & versatility – Indexable From a cost perspective, indexable inserts and tool holders represent a significant investment, however, they have the potential to last for longer periods of time. Also, when a replacement is needed, this is more time and cost efficient because of the need to only rotate or change the insert. To support the long-term investment of indexable inserts, they are also

interchangeable and versatile. Machinists have the ability to keep the cutter (or tool holder) in place while easily switching the inserts with varying alternative grades more suited to machining different work-piece materials. Indexable cutting tools offer greater versatility in terms of performance than rotary tools, providing stable results even in adverse conditions and are able to perform multiple operations. For example, the operational versatility for milling inserts includes plunging, helical interpolation, profiling and enlarging a hole. Indexable cutting tools can also offer much larger diameter capability than round tools. Performance & versatility – Rotary Although round tools generally involve a large initial investment compared to inserts, this investment can be spread over the long-term with the added possibility of regrinding. This is not an option with inserts. The geometry, substrate and coating of a round tool determine performance. Application specific tools have the potential to produce greater accuracy than general purpose tools. Also, the overall design allows the machine operator to achieve much smaller diameters. The four-facet Split Point geometry, for example, used on rotary drills, was originally developed for deep oil holes in automotive crankshafts. Today, it is used on many drill designs for a wide variety of hard and soft materials. It can be applied to a variety of drill point angles, the most common being 135°. This highlights the evolution of round tools where key features, developed for specialist and unique applications have, in time, expanded for use in a wide number of applications and materials. A key benefit of the split point is easier and more precise self-centering and to prevent the tool from “walking” before penetrating the work-piece. The web thinning or split point greatly reduces thrust and adds a positive rake cutting edge that extends to the center of the drill. In many materials the point will also act as a chip breaker to produce small chips which can be ejected more efficiently through the flutes. This is a distinct advantage in most applications, but especially when portable drilling or in a drill press where bushings cannot be used. Summary Both round tools and indexable tools have their own distinct advantages based on material, operation and user requirements. Each one continues to see on-going developments and improvements, including new geometries, coatings, substrates and manufacturing processes, such as edge preparations, surface finishing and other treatments. As cutting tools, they present a collective offer to end-users by providing an overlap in diameters and applications, so that tooling engineers can assess and advise where and when it is appropriate to apply each.

OCTOBER 2016

MACHINE TOOLS WORLD

COVER STORY

ANCA : Leadership with Flexibility &

Precision

Jeffrey Foregard

General Manager - Asia Executive Director ANCA Pty. Ltd.

MACHINE TOOLS WORLD OCTOBER 2016

COVER STORY www.mtwmag.com

Q1. ANCA has gained substantial market share in Indian machine tool industry, please elucidate the success story of the company? ANCA started our business in India through a local dealer and it soon became apparent that this was not the right strategy given the requirements of our customers and the market. We then took a decision to set up our own company with direct local employees throughout India, and this together with the superior technology offered with the ANCA products proved to be a successful move and saw us capitalize on the market and increase our market share. Our highly skilled engineering and marketing teams constantly strive to create superior products resulting in ANCA continuing to maintain its position as world leader in our segment of the market. New innovative technologies such as Linear Motors and Non Contact Laser measuring systems along with our production monitoring software differentiates us from our competitors. The flexibility and step-changing technology that we offer is what customers are seeing as the key advantage. We have faster cycle times along with superior surface finishes on tools along with the ability to run the factory unmanned for 24/7 production. This I believe is the future, and we have it today.

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? With 98% of our sales out of Australia,

ANCA is truly a global company with our Corporate HQ in Melbourne along with our core manufacturing facility. We have a second manufacturing facility in Rayong, Thailand and an electronics manufacturing site in Taichung, Taiwan. Our sales and marketing offices are headquartered in three locations, namely Shanghai China which takes care of the Asian markets, Michigan USA which covers the Americas (North & South) and Weinheim Germany which covers all of Europe. Satellite offices are also set-up in key locations around the world. All these offices are supported by local staff members.

Q3. What are the market prospects for the ANCA products in India and How do you plan to position these products? Our prospects in the Indian market looks to be good and this has been proven by our success to date. The growth in the automotive sector along with the global alliances of Indian companies with some of our International customers has had a positive impact on our business. In terms of servicing the sector, our Thailand manufacturing facility has the capability to provide a total quality product at an acceptable price level for the Indian market and this has helped us to increase our share in this lucrative market. This coupled with our local footprint have positioned us for growth. Today, the volumes are satisfactory, however, the future looks promising and I am anticipating to see tremendous growth in our segment over the next five years.

Q4. Can you brief us about the marketing strategies that were applied in order to stand out in the competition of machine tool industry? At ANCA, we understand that a strong brand is key to your success and enable you to stand out from your competition as well as attract the best people to work with you. We are also fortunate that the company has a proud history of reinvesting in developing new products and technology which means our machines capabilities can speak for themselves. Our marketing strategies include attending the key major machine tool exhibitions along with talking to our customers about their individual needs and then ensuring we are able to meet them. I believe that the value of building close relationships with your customers and taking the time to really understand their needs is core to any marketing strategy. In this industry marketing should keep the industry up-to- date on your latest product or service as technology is constantly evolving. The ANCA machine is also highly flexible so we want our customers to intimately understand its capabilities and how they can get best out of their machine. We do this via regular web seminars, monthly e-mail marketing campaigns and regular updates to our robust social community. Finally, we have an extensive advertising budget that enables us to reach our customers in high numbers. But it should never end at the sale. One of our key strategies to keep the customer happy is to provide the

OCTOBER 2016

MACHINE TOOLS WORLD

COVER STORY best possible after sales and service. This included moving to larger premises to support our initiative to stock a range of spare parts in our Bangalore facility along with demonstration machines.

Q5. Please elucidate in brief about the companyâ&#x20AC;&#x2122;s infrastructure & What are the measure that are being taken from the product manufacturing to distribution? The ANCA products are built in two of our manufacturing locations, namely, Melbourne in Australia and Rayong in Thailand. Both of these factories adopt exactly the same total quality principles ensuring our products reach our customers on time and to specification. We adopt lean manufacturing principles along with 5S throughout our organization. Keys factors include reducing our inventories worldwide whilst still maintaining a delivery schedule that meets our customers needs. Our global quality team constantly review processes and procedures to ensure we are delivering a premium service from the sale through to delivery to after sales and this is driven right through our organization from the top down.

Q6. Brief us about the R&D and Quality policy for your business? ANCA invests heavily in R&D in various parts of the world. We have dedicated software and engineering teams located in Melbourne, Bangalore, Rayong and Taiwan supporting our global R&D initiatives and this has proved a huge success for us. Our substantial dollar investment in R&D allows us to continue to create new solutions for our customers that a year ago seemed impossible. For example, our new LaserPlus product has revolutionised the market, using a laser beam to measure the tools dimensions and then automatically compensate to maintain required tolerances achieving much higher efficiencies and accuracy. The fundamental promise of our product is that it provides reliable precision grinding and if our quality standards are not right we have not met our promise. Our quality policy is simple,

MACHINE TOOLS WORLD OCTOBER 2016

if it does not meet our strict quality control standards, we will not ship the product.

Q10. What are the key technological trends that are driving machine tool industry?

Q7. Please comment on the current machine tool scenario in India?

In our segment, customers are looking to produce cutting tools in both mass production and small batch runs. In order for our machines to meet these two very different needs we need to have the best possible technologies built into our products to enable total flexibility for our customers. Life span of the machine along with high accuracy is also critical from our customers point of view.

I believe the current situation for the machine tool business in India is very healthy. As growth in other markets appears to be returning back to normal levels, I see India continuing to develop and could potentially be the next major market for ANCA in years to come. This is the reason we decided to expand our operations in Bangalore to ensure we are capable of meeting increasing demand. The larger facility along with substantial investment in a software R&D team based in Bangalore allows us the ability to respond to our customers needs immediately.

Q8. Could you brief us on Indian & Global perspective of machine tool industry? What are the distinguishing factors? The industry we are in is cyclical. Fortunately, all machine tool builders have enjoyed tremendous growth over the last four to five years on the back of the huge demand of smart phones. This has been a major driving factor in machine tool growth and whilst this trend continues we can see a positive outcome for the machine tool industry. However, we cannot be complacent and we are also targeting other segments such as automotive, aerospace and medical to name a few to ensure we have the ability to diversify so when one segment is down we are actively strong in some of the other segments.

Q9. In your opinion how can the Indian machine tool industry become globally competitive? Maintain a total quality philosophy and ensure this is achieved. This along with keeping up with the available moving technologies will go a long way to help the local machine tool industry in India.

Q11. How far the factors like government norms, excise duty, taxation, exim policies are affecting your business? Whilst the duties and import tariffs have reduced dramatically over the past ten years or so, they are still on the high side and this along with difficult import/ export terms does continues to be a challenge for companies importing and on some cases re-exporting machine tools into and out of India.

Q12. What are the best possible remedies you can advise in order to maintain the high profitability in the shrinking margins market of India? This is a difficult question to answer. There are a number of scenarios which include differentiating your products from your competitors, offering something special from a technology point of view are some of the methods we use to ensure we are capable of achieving our profit targets. However, with the standard machines it does prove difficult so I believe it comes down to delivering a quality product to our customers along with providing the best possible after sales support. This will ensure customers do return to us to do business.

Q13. What is your vision for your company? To be an agile world class leader in supplying innovative technology. To be a leading designer and manufacturer of high quality and innovative products and solutions.

CASE STUDY

Making the entrepreneurial dream possible How a Haas UMC-750 universal machining centre has helped in establishing OMC as a serious maker of cycling componentry

t’s rare to meet an Italian who isn’t passionate about some sort of wheeled transport – cars, motorcycles, scooters, etc. – and Ivan Cavallaro is no exception. Like so many of his compatriots, he’s a cycling nut – in particular, road cycling. His days as a “serious” racer may be behind him, but

MACHINE TOOLS WORLD OCTOBER 2016

performance bicycles remain so much in his blood that he invested in a Haas UMC-750 universal machining centre to make some of the lightest, strongest highperformance components available. The origin Around ten years ago, Ivan and his brother, Walter, also a cyclist and CNC

machine operator, went into business “to work for us and do something mechanical,” as Ivan recalls. They machined small parts for local businesses until around 2008/9, when they came up with an idea to design, make, and sell their own-design cycling componentry, under the brand name

CASE STUDY OMC-Italia. It may not have wheels, but signore Cavallaro is as passionate about his Haas as he is about his bikes. In fact, one of OMC’s most successful products – the one that really established the company as a serious maker of cycling componentry – is named in homage to Haas. The machine tool cognoscenti know very well that the nomenclature of the company’s vertical machining centres originated with the VF-1: the Very First One, back in the late 1980s. The OMC single-piece combined, double chain ring and spider, with hollow pedal cranks, that Ivan machines on his UMC 750, is designated the V-Strong One. “In 2012, we upgraded our CAD/CAM to TopSolid, and redesigned the part to make it even lighter and stronger,” says Ivan. “Walter and I invested the last of our money to bring the product to market during a very difficult time for the Italian economy. We took a big risk, but we knew we had a great component.” Improved productivity

Traditionally, the two front chain rings are machined separately, and then bolted together on a central spider, to which the pedal cranks are also attached. On the OMC unit, the spider and the chain rings are all one part, machined from a 2-kilogram solid billet, and ending up at

MACHINE TOOLS WORLD OCTOBER 2016

just 160 gram. The two separate pedal cranks are hollow, which saves a lot of weight, and are also machined from solid. “We start with over 7 kilograms of aluminium, and we end up with a complete unit – a very strong assembly of front rings and cranks – weighing around 540 grams,” says Ivan. “Saving weight and building-in strength are our two most important goals. Professional cyclists put huge amounts of power through the front chain rings and pedal cranks, so we test our products on a rig to make sure we get the very maximum strength-to-weight ratio. From a productivity point-of-view, the Haas UMC-750 has allowed us to reduce machining of the front chain rings from 10 ops to just a single setup. It’s proven to be a great investment. Tolerances are around 4 microns, which the Haas machine has no difficulty with, whatsoever.” Sadly, Ivan’s brother and business partner, Walter, lost his life in a tragic motorcycle accident in the summer of 2015. In the intervening year, Ivan has continued to build OMC’s name as an innovator for ultra-lightweight bicycle parts. Walter would undoubtedly be proud. Like his brother, he was a cycling nut, and all cycling nuts are obsessed with the ride: going faster, traveling further, and having as much fun as possible.

In 2012, we upgraded our CAD/CAM to TopSolid, and redesigned the part to make it even lighter and stronger - Ivan Cavallaro, Founder, OMC

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CASE STUDY

KMTC promotes quality standards of Chinese 5-axis

CNC machine tools KMTC has developed a variety of ‘China’s first’ high performance machine tools, leading the development of machinery and the machine tool industry in China

s a market leader in metrology, Renishaw has provided KMTC with advanced solutions in machine calibration and performance evaluation, including XL-80 laser interferometer, QC20-W telescoping ballbar system, XR20-W rotary axis calibrator and AxiSet Check-Up.

Advanced solutions in machine calibration

KMTC has a very strict quality control where each machine has to be calibrated twice: in manufacture and at the client site before it goes into production. Some large machine tools need to be dismantled after first calibration in manufacture, and calibrated again after re-assembly on site. Yang, supervisor of KMTC Metrology Centre, says “We used to adopt laser interferometers from another supplier before we started the partnership with Renishaw. Although the other supplier’s system performance was good, it was a problem when travelling to customer sites as we had to carry the full system kit in 3 large cases. We found many advantages when we switched to Renishaw’s first generation ML10 laser interferometer system which was compact and portable. We now widely use Renishaw’s latest XL-80 laser interferometer system in our production and benefit from its extended functionality.” KMTC has purchased 18 laser interferometer systems. In KMTC’s current machine tool models, the accuracy and resolutions

MACHINE TOOLS WORLD OCTOBER 2016

are up to 3 µm/m and down to 1 µm/m respectively. KMTC engineers are now able to finish the calibration on an axis of 2 to 3 metres travel distance in 30 minutes. Axis length can be up to 60 metres on some models. Renishaw’s XL-80 laser interferometer offers accuracy of ±0.5 µm/m at normal environmental temperature. It can provide a resolution of 1 nm at a speed of 4 m/s as well as measuring distance up to 80 metres, which is long enough to satisfy most of the machine tools manufactured. Transforming rotary axis calibration

Rotary axes are becoming more popular in use with the growth in 5-axis machine tools. Conventional rotary axis assessment is not only time consuming but also requires skilled operators. Yang said “We used to adopt a multitooth indexing table working with a quasi laser tube or a 24 face prism with auto-collimator to measure positioning accuracy of rotary axes. During the measurement, the upper half of the multi-tooth indexing table is lifted off manually and turned to a defined measuring angle. Then, we counter rotate the rotary table by the same angle to re-align with the laser tube. As a result, the errors can be measured. The accuracy of this approach is quite high, up to ±0.2 arc seconds but the tradeoff is time consumed; even an experienced technician has to spend one day to complete the measurement. The 24 face prism projects images on its reflective surface via the light tube.

However the limitation is the measuring angle interval must be a multiple of 15 degrees. The Renishaw XR20-W rotary axis calibrator has transformed the way we calibrate rotary axes on machine tools. The XR20-W works with the XL-80 laser, allowing the measurement to be completed within 2 hours, reducing labour costs. The operation is quite simple, available with a software user interface in Chinese language, where operators with basic computer knowledge are able to get started quickly.” The Renishaw XR20-W rotary axis calibrator employs wireless operation where data capture is synchronized to axis movement, with accuracy up to ±1 arc second, allowing automated measurement at any defined angle interval. All calibrators are factory calibrated and delivered with traceable certification. The XR20-W also supports off-axis measurement, allowing measurement even when the calibrator

CASE STUDY www.mtwmag.com

is not directly installed on the rotary axis pivot point. It is one of the frequently used functions by KMTC. “The XR20-W features many improvements over its RX10 predecessor, including Bluetooth wireless technology which makes the data capture process more reliable. Renishaw has a strong reputation in metrology so some of our customers specifically request that we use Renishaw’s calibration products for commissioning, despite us explaining that traditional methods, such as multitooth indexing table, are able to offer comparable accuracy too”, concluded Mr. Yang. Apart from laser interferometers, KMTC has also started to incorporate use of the Renishaw QC20-W ballbar system into its production. With a simple and quick ballbar test a user can identify the overall performance of their machine tool, as well as diagnosing problems. This enables customers to measure

automatically update parameters and compensations for rotary axis pivot point position errors. This has greatly improved the precision performance of 5-axis machine tools. Benefiting from Renishaw’s technical expertise

conventional 3-axis machine tools in accordance with ISO 230-4. Renishaw has launched Ballbar Trace software, which it offers to existing ballbar users for free. This provides verification for 4 and 5-axis machine tools in accordance with ISO 10791-6 using XCal-View data analysis software. KMTC also uses Renishaw’s AxiSet Check-Up to perform a fast and accurate health check of rotary axis pivot points on multi-axis machine tools, and

Manufacturers encountering technical issues during machine tool measurement need support and guidance to help them achieve optimum measurement results. “KMTC has been collaborating with Renishaw for more than 10 years. Renishaw sales engineers are always very helpful and provide invaluable technical knowledge and support. They always respond to us quickly and provide useful suggestions. They are happy to share information about updates and notify us of new products, which is one of the key reasons why KMTC and Renishaw maintain such a long term partnership,” Yang said.

OCTOBER 2016

MACHINE TOOLS WORLD

CASE STUDY

Accusharp shows why it is special When compared to tool development and bench mark performance, Accusharp shows why it is way above its competitors

or one of its customers, Accusharp designed a Tungsten Carbide Special Drill. This special drill is used for final operations on a component of large batch sizes having component dimensions between 125 mm & 330 mm. The component requires to have multiple hole in a range of 36 to 70, in a single work piece. Special requirements

Precision of drill sizes requires dimensional consistency less than 0.005 mm. If any drill, while in operation, breaks into the component, the costly component is directly rejected. Therefore, the prime requirement of the tool performance is that, the tool should not break, while in operation. Any inaccuracy or variation in the drilled hole-size results in component rejection. From the drilling operational cost point of view, tool Life performance is also important. The same tool is required for drilling holes on the work piece at different locations having different hardness between 48 & 60 HRC. And therefore, the same tool needs to perform equally at different working conditions. For work piece components, in material EN 36C, as a part of product being exported to end customers. Cost of the finished work piece component is between 1,50,000 & 5,00,000 INR. Issues with competitor’s tool

The customer was facing issues,

MACHINE TOOLS WORLD OCTOBER 2016

with the competitor’s tool, like size inconsistencies, poor surface finish, poor tool life, frequent tool breakage, and ontime’delivery of tools. Because of the above problematic issues from the competitor’s tool, the customer’s productivity was much lower than his estimated norms. The process rejection was high. This caused high rejection cost beyond acceptance by the management. The delivery performance to end customers was getting affected. Frustrated with the issues, the customer invited Accusharp to assist and provide a better solution. An Accusharp cutting tools specialist was invited by the above customer to assist him, and to resolve the issues of the competitor, by developing tools with appropriate design and solution, to meet customer’s requirements. Accusharp’s field engineer appeared at the customer’s work place and studied the application details, and process parameters. The case study data, compiled by Accusharp’s field engineer was shared with the design department. Analysis of the data was done by our development team, consisting of Field Engineering, Design, Development,

Production, and Commercial cells, to arrive at a solution to resolve customer’s issues and meet the requirements. Proposal drawing was prepared for customer’s approval. After the customer’s approval, a few samples of tools were manufactured and supplied to the customer. Accusharp’s field engineer conducted trials with the sample tools, at the customer’s end. The following test result are self-explanatory. It goes without saying, that Accusharp, today, is the preferred supplier to the customer, for these tools.

Benefit of Accusharp’s tool

TECH TRENDS

Made in India, Made for India

ince the foundation, Sparkonix has had an unwavering focus on developing an ecosystem of technology and services focused on the specific needs of Indian customers. From material selection to the features in controllers, Electric Discharge Machines (EDMs) from Sparkonix are not just made in India, but made for India. While there are many aspects that define the unique needs of the Indian customers, three in particular are important for EDMs. Price matters! The Indian customers are highly price sensitivity and are known for their affinity to ‘value for money’. Sparkonix has been sensitive to this need of Indian customers. With over 20+ standard models in EDMs, Sparkonix is able to provide the best value for money for its customers. Sparkonix also has the distinction of serving the widest range of customers. Starting from a one man shop focused on removing drill bits to the largest enterprise in The country - the Indian Railways, Sparkonix’s EDMs are used by every segment in the industry. Installations in over 100+ industrial clusters in India, is a testimony to Sparkonix’s ability to match the expectations of every customer segment in the Indian market. Service Counts... Another aspect, that is very close to Indian customers is the assurance for good service. “Over our four decade long experience, we have proved that supporting our customers to get the best out of their EDMs, is integral to the value of our products”, says, Shailesh Patwardhan of Sparkonix. Service has three dimensions, time to respond, trace-ability and time to solve the problem. Sparkonix uses highly

MACHINE TOOLS WORLD OCTOBER 2016

advanced mobile based ticketing system that provides complete transparency to customers on Service engineer availability, resolution and next actions. It’s a one of a kind system and definitely a benchmark in service delivery in the Indian machine tool industry. Make your own EDM India and customisation are synonymous and EDMs are not an exception to this.Sparkonix has the distinction of developing more than 100 types of fully customised EDMs for a wide variety of applications across industries.. From four head EDM Drills to machining of large sized jobs that won’t fit in any conventional EDM, Sparkonix has provided a variety of solutions to serve the unique needs of Indian customers. “We work closely with customers to help them practically make and build their own EDM”, adds Shailesh. While the basic EDM technology remains same, the entire architecture of machine is built to suit the application of the customer.

As the largest Indian manufacturer of EDMs, Sparkonix is a unique example of solutions and value can be built around a specific set of expectations. That also happens to be the secret of success for Sparkonix.

For more information, Website: www.sparkonix.com

Every chip tells a story

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

Marposs India pvt ltd 147 Sector 7, IMT Manesar - Phone: +91 124 4735700 sales@in.marposs.com

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TECH TRENDS

Igus launches lubrication free

linear guide

Heavy-duty version of the drylin T linear guide from igus, now comes with adjustable clearance

he drylin T guide as a heavyduty version with adjustable clearance provides users with more precision during linear movement, even in very rough environments. The HD version with stainless-steel cover is also suitable for heavy loads in dirty surroundings and is insensitive to impacts. Dirt, adhesive residue or mud are all factors that can influence the running of a linear guide system. In order to counter this, igus GmbH from Cologne has developed a heavy-duty version of the drylin T linear guide. This is also available with adjustable clearance in order to achieve greater adjusting precision even in difficult environments. The heavy-duty guide carriages TW12-20 can be adjusted seamlessly in the bearing clearance. This is very easy to do with an allen key.

MACHINE TOOLS WORLD OCTOBER 2016

As the plastic sliding elements made of the self lubricated material iglidur J are integrated into the carriage in such a way that they cannot be lost, they can be easily removed from the rail and pushed back on for assembly purposes. The complete linear guide causes little friction and is wear-resistant. Particles cannot stick to the carriage and impair running as no lubricant of any kind is necessary. Both the rail made of hardanodised aluminium as well as the carriage made of anodised aluminium with a stainless-steel cover are corrosion resistant. Interesting alternative to roller guides In addition, this carriage simultaneously ensures easy and robust linear guidance. It is insensitive to impacts and can tolerate high loads of up to 740 kilograms and is therefore ideal for difficult

extreme applications. The low weight and the compactness of the system allow easy and uncomplicated assembly. The range of floating bearing versions offered reduces assembly and alignment times drastically. Due to the qualities of the system, namely its load bearing capacity, the absence of lubricants and its resistance to the influence of surroundings, the drylin T HD is an attractive product for many different branches of industry. Uses in the wood industry, for welding equipment or for equipment construction are just some examples. The possibility of manual clearance adjustment, however, offers great potential for a wide range of applications. As the drylin T HD was deliberately designed to have the same dimensions as classical roller guides, the retrofitting of existing installations is possible without difficulty.

TECH TRENDS

Laser calibration at the speed of light High speed data capture technique cuts calibration time 85-95 percent, minimising downtime on key assets

he word “laser” implies “light speed” for the casual listener, but witnessing a bi-directional laser calibration run on just one linear axis of a CNC mill conjures up a completely different image – that of something less than the speed of light. A short 1 m axis can typically take 30 to 60 minutes as the machine axis moves in 10 mm increments and stops to pause and settle before the laser interferometer takes a reading. That pause can be as long as 23 seconds during some tests. The downtime it causes for calibration of a large, high value asset can make a machine shop owner bite through nails. Depending on machine crashes and the quality system the shop adheres to, a machine may be out of action for several days each year to perform a laser calibration, so shop owners are always focused on this issue. New technique reduces settling time significantly However, a technique that takes advantage of a feature in Renishaw’s XL-80 laser interferometer reduces settling time to just 250 milliseconds after each incremental axis move, cutting calibration times by 85-95 percent. In addition to reducing downtime on critical production assets, this methodology better reflects axis positioning accuracy under actual cutting conditions, where moves are fast and there is virtually no settling time before tool engagement with the work. Quality Tech Services in Byron, Georgia, USA, has used the technique and instructed new laser buyers on it as well. “As a new calibration service, the

MACHINE TOOLS WORLD OCTOBER 2016

first concern we hear when we walk in the door is downtime on a machine,” said Mike Schraufnagel, company owner. “Customers will do anything to cut downtime on a critical asset, and our customers who own lasers love this capability. For us, the technique has been a boon to our efficiency. What normally would take 30 minutes now takes just three. In one afternoon we were able to complete six laser set ups and three ballbar set ups on a machine in two hours. This would normally have taken at least a day.” M-Code and an open contact relay is all that is required To use the high speed calibration technique, a machine’s CNC could use an available M-code which, if not available, is usually a purchasable option to close a “normally open” set of relay contacts for between 10 and 20 milliseconds. Closure of the relay contacts, via an auxiliary I/O cable, will provide a trigger for the laser to record the difference between the laser reading and the target position. M-codes are typically used in CNC for probing cycles, to control coolant and capabilities other than axis positioning moves, so this option is available as standard on many CNC. In others M-Code may be an option

that simply needs to be purchased or turned on by the OEM. “We identified spare relays that can be controlled via M-Codes on a Haas CNC machine in our lab. This got us started in thinking of the many ways users could reduce overall machine down time by triggering the laser interferometer via a part program. This type of signalling will more accurately record the moment the machine achieves its commanded position” said Michael Wilm, Calibration Business Manager, Renishaw Inc. “Because mechanical relay contacts can bounce for the first few milliseconds, we have added a bounce rejection feature programmed into the electronics of the laser. The laser simply needs to see the relay close for as little as a microsecond; any chatter within 20 milliseconds gets ignored, the laser takes a reading, and the axis moves to the next measuring position.” High speed data capture can be used to calibrate positioning stages and other equipment where no CNC is involved. “It may take some customising of the machine control with an auxiliary board to trigger the laser, but these boards are readily available and well known by people in the controls business,” Wilm concluded.

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TECH TRENDS

FARO introduces new class of LIDAR with HSI technology The firm has disrupted in-process guided assembly and verification with the introduction of a new class of LIDAR with High Speed Imaging (HSI) technology

ARO has announced the launch of the FARO VectorRI Imaging Laser Radar, an ultra-high speed, large-volume, non-contact 3D measurement solution with highresolution 3D imaging and projection guidance for manual and automated manufacturing processes. “This product introduces a new class of LIDAR with High Speed Imaging (HSI) technology. HSI combines ultrahigh speed 3D scanning and ranging with high-resolution 3D imaging and projection. The solution is a groundbreaking advancement in largevolume, non-contact metrology and guidance – and promises to provide industrial manufacturers with significant inspection cycle time reduction and exceptional throughput,” stated Dr. Simon Raab, FARO’s President and CEO. “The FARO VectorRI is the world’s first and only LIDAR with HSI technology delivering performance improvements over traditional LIDAR solutions, with high speed distance measurement, high speed beam steering, image-contrast functionality and projection guidance capabilities. ”

VectorRI has proprietary 3D imaging capabilities to provide qualitative and quantitative inspection data. This largevolume, high-definition 3D imaging and recognition functionality allows the FARO VectorRI to detect features within the scan, improving the ability to measure and inspect corners, fasteners, tooling balls and hole centers as well as fitting 3D shapes over very large areas. Additionally, high-resolution scanning, capable of composing an image of 400 million pixels, provides high-resolution zoom capabilities on critical features. Dr.Raab added, “The advanced 3D imaging capabilities of the FARO VectorRI are unrivaled in the market today. Extreme resolution and very dense point spacing allow the system to scan massive areas without sacrificing fine details that would be missed by any other device. Moreover, the FARO VectorRI is equipped with image-contrasting functionality that allows the system to easily define features and edges, and is even powerful enough to detect the angle of each layer or ply of carbon fiber during the layup process for composite part manufacturing.”

Fast and accurate LIDAR HSI technology The FARO VectorRI utilizes this fast and accurate LIDAR HSI technology to deliver a continuous stream of highresolution surface data with scanning speed that is thousands of times faster than any currently-available technology. This industry-leading speed is enabled by the use of advanced galvo-mirror beam steering as opposed to the conventional gimbal arrangement deployed by other solutions. Not only does the solution provide unmatched speed, the FARO

Automated measurement routines Engineered to streamline measurement workflows, the FARO VectorRI has built-in functionality that allows users to easily program fully-robotic, automated measurement routines that can run without any operator interaction. Until now, this degree of automation was impossible without the use of large, costly and complex robot integration. Users can further eliminate the need for robots by installing multiple FARO VectorRI systems in a SurroundScan configuration, to be controlled from a

MACHINE TOOLS WORLD OCTOBER 2016

single workstation in a shared coordinate system, creating a very large-scale, metrology-enabled area for unparalleled ability to measure parts and assemblies throughout the entire facility. Additionally, the FARO VectorRI has full-featured 3D laser projection and In-Process Verification (IPV) capabilities, providing the ability to accurately project a laser outline of parts, artifacts or areas of interest onto any surface or object. A 3D CAD model is used to provide a virtual template which operators and assemblers use to quickly and accurately position components with absolute confidence. Step-by-step assembly and guidance instructions are projected directly onto the work surface. Then, using IPV technology, the FARO VectorRI scans any placed components to ensure complete conformance and precise placement. For enhanced operator efficiency, patented topographical (TOPO) software creates a visualization of errors in the form of a topographical projection onto the part or assembly being inspected for quick and easy decision-making. This robust functionality completely eliminates the need for physical templates or hard tooling and streamlines the production and quality control processes. The FARO VectorRI Imaging Laser Radar is a game-changing solution for large-volume surface inspection and measurement of parts, assemblies and tools, in-process guidance and verification, fully-automated in-line inspection or any application requiring high-resolution scan data.

Absolute Rotary Encoders with Integrated Diagnostics

The HEIDENHAIN rotary encoders ECN/EQN 1300 with optical scanning have become the industrial standard in feedback systems for incorporation in servo motors. The integrated diagnostics and sturdy components ensure very high signal quality and availability, which are necessary prerequisites for use in safety-related applications. Also, they provide all information necessary for commissioning, monitoring and diagnostics. The result: guaranteed system availability from start to finish.

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Angle Encoders

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Contouring Controls

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Position Displays

Length Gauges

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Rotary Encoders

TECH TRENDS

Hypertherm launches new generation of computer

numeric controls Hypertherm, manufacturer of plasma, laser, and waterjet cutting systems, is shipping a new CNC platform called EDGE Connect

he next generation CNC from Hypertherm contains a number of enhancements for operator ease of use, reliability, and customizable performance “Our customers wanted greater functionality integrated into their cutting machines coupled with our embedded expertise. EDGE Connect delivers that through our new software applications running on this new hardware platform,” said Nathan Pascarella, CNC Product Marketing Manager for Hypertherm. “In addition, EDGE Connect offers greater flexibility for machine operators with ProNest CNC, a feature that allows SureCut outcomes to be programmed quickly and efficiently from the touchscreen interface. It is a great complement to our offline CAM software, providing a solution when offline CAM programming might not be available.”

MACHINE TOOLS WORLD OCTOBER 2016

Cutting machine customization is further enhanced by quick and easy set up through an EtherCAT communication platform and custom software configuration that allows for up to 12 axes through an online configurator. The hardware platform is the foundation and software selections enable any EDGE Connect to be set for various cutting applications. Furthermore, cutting machine manufacturers can develop their own operator consoles and auxiliary programs using the Soft Op Con API and PLC Connect. Hypertherm designs and manufactures advanced cutting products for use in a variety of industries such as shipbuilding, manufacturing, and automotive repair. Its product line includes plasma, laser and waterjet cutting systems, in addition to CNC motion and height controls, CAM nesting software, robotic software and

consumables. Hypertherm systems are trusted for performance and reliability that result in increased productivity and profitability for hundreds of thousands of businesses. The New Hampshire based company’s reputation for cutting innovation dates back nearly 50 years to 1968, with Hypertherm’s invention of water injection plasma cutting. The 100 percent associate owned company, consistently named a best place to work, has more than 1,400 associates along with operations and partner representation worldwide.

New features include: • The newest version of Hypertherm’s Phoenix software coupled with SureCut technology for unsurpassed ease of use and consistent performance for cutting applications. • A software based operator’s console and embedded PLC feature called PLC Connect™ that allows for greater customization of a cutting machine with reduced costs. • Enhanced CNC based nesting for convenient operator programming with SureCut outcomes via ProNest CNC. • Three new modern hardware options that improve performance, reduce weight, and increase reliability.

Make Every Second Count New Gleason P90iC and P90CD Hobbing Machines with parallel or sequential chamfering/deburring are your solutions for high-volume production of precision gears and shafts. Available with integrated automation â&#x20AC;&#x201C; all from one source. www.gleason.com/everysecond

TECH TRENDS

Empowering Women – The Ador Welding Way

oday women have equal participation in every sphere of industrial activity. Why should Welding be an exception? In fact more and more women are making their career in Welding, more so since inverter technology and digitalization have made welding less arduous and more a pleasure. Technological innovations and automation have made welding more sophisticated and scientific where women can prove to be more productive. In fact the trend has already started in various sectors of the industry where welding is a process for production or maintenance. The Integral Coach Factory of the Indian Railways at Perambur, for instance, is employing a good number of women welders. One company that is in the forefront of welding education and women empowerment is Ador Welding Ltd., popularly known as ‘Welders to the Nation’. The Ador Welding Academy has churned out over 1,00,000 welding professionals in a span of four decades. The company , in the vanguard of welding education and skill development, has a special drive for making welding suitable for all genders. There are certain processes of welding in which women are doing exceptionally well. The company has trained girls in aviation welding sector for special equipment fabrication. “We are working with some companies who share our vision of empowering women. For instance, we have partnered with Mahindra & Mahindra for training and providing women welders & professionals for their plant at Chakan,” says Ador Welding managing director, Satish Bhat. The company has teamed with NSDC (National Skill Development Corporation) to train more than 14,000 people in welding. This would include a large number of women welders, welding supervisors and engineers. This

MACHINE TOOLS WORLD OCTOBER 2016

is significant in the wake of the widening gap between demand and supply of welding professionals being faced by the country which is on a growth trajectory especially in the wake of the ‘Make in India’ mission. The Ador Welding Academy in Pune is engaged in skill training. It develops innovative tools to support welding skill development & education. Under PreService Training, the Academy provides employment linked finishing courses for Welders, Supervisors, Engineers & Inspectors. It is working in tandem with regional & national agencies with proposals for competency and assessment standards, complementary training modules and other initiatives that will strengthen the nation’s skill mission. It also co-develops concurrent certificate modules in welding production with diploma and degree colleges to improve the employability of pass-outs. Under ‘InService Training’, it enhances skill sets and on-the-job performance to meet industry requirements for best manufacturing practices. Under ‘Technical Training’, it covers a wide range of topics starting from arc physics & controls, to weld defects & remedies, types of welds, materials & microstructures, chemical & mechanical attributes of weld joints, codes & specifications, welder performance qualification, structuring quality plans & policies including occupational health and safety. And under ‘Graduate Programs’, the Academy works with BE and Engineering Diploma Colleges to provide students with opportunities to improve their employability in welding and manufacturing careers. In addition to its training centers in Pune and Raipur, the Academy has added four new locations of training in association with partners at Killari, Dist. Latur, Maharashtra; Chandrapur,

Maharashta; Hosur, near Bangalore as well as Chennai. The Academy has the distinction of having contributed to building National Occupation Standards (NOS) and Qualification Pack (QP) for various Sector Skill Councils, and has conducted training for trainers under Automotive Skills Development Council (ASDC)’s sector skill council. The Academy’s association with Dr. Babasaheb Ambedkar Research & Training Institute (BARTI) is an on-going and symbiotic one. The programs under BARTI are also being implemented in Chandrapur and Killari, along with Pune Center. Ador Welding Ltd. (formerly known as Advani-Oerlikon Ltd.), has been synonymous with welding in India for over 64 years. Regarded as a pioneer and leader in welding industry, Ador has progressively extended its knowledge and expertise to cater to a sophisticated range of user needs in India, the Middle East, Africa and South-East Asia. Ador provides a comprehensive range of welding consumables, equipment, services and Automation solutions to ensure excellence in welding and fabrication in every key sector. With four manufacturing plants, two technology development centers, eleven sales offices, international office in UAE and more than a hundred distributors across India, Ador partakes effectively in nation-building. Ador is putting up an impressive show of its capabilities and commitments in Welding at the India Essen Welding & Cutting Fair 2016 being held at the Bombay Exhibition Centre, during 5-7 Oct. – P.K. Balasubbramaniian

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

WIDIA’s new product offers modular flexibility WIDIA’s Top Ream platform covers the majority of hole finishing needs, with diameters up to 42 mm (1.65 in.) and a range of edge preps and geometries available

he three keys to hole quality are diametral accuracy, form and position, and surface finish. Boring tools are the undisputed king in all of these areas, but they’re also one of the slowest methods of hole finishing, and in most cases are limited to 10:1 depth to diameter ratios or less. Conventional carbide-tipped reamers produce good hole quality, are substantially faster than boring and able to reach much deeper, but they also have an Achilles heel. The steel shank to which the carbide flutes are brazed has a thermal coefficient three times that of carbide, and is subject to growth during machining operations. Worse, sharpening of these tools often leads to less than desirable results. The mixture of carbide and steel wreaks havoc on grinding wheels, providing a reground edge that is rarely as good as the original tool. Also, PVD and especially CVD coating of reground tools is problematic, because the temperature inside most coating vessels reaches upwards of 530 degrees C (986 F), leading to micromovement of the brazed carbide flutes. Addressing conventional problems WIDIA Products Group has addressed these problems and more with its new Top Ream carbide reaming solution. Instead of four to eight (or more) individually brazed carbide tips, Top Ream uses a single carbide disc and brazed joint, providing a strong connection that is virtually immune to thermal effects during machining operations. WIDIA manufacturing engineer Tom

MACHINE TOOLS WORLD OCTOBER 2016

Bobos notes another important advantage of Top Ream’s all-carbide tip. “Steelbodied reamers tend to get banged up on the ends. The center can get nicked or distorted, preventing an accurate regrind. With carbide, you always have a good center to locate on.” The result is a minimum of four “like new” regrinds vs. an average of three questionable ones. However, there’s more to Top Ream than its ability to hold an accurate edge. “Overall it’s just a better design,” Bobos says. “A single piece of carbide is inherently more stable and resistant to vibration. The through-hole style has an 18-degree left hand spiral that does a great job of pushing the chip forward. It’s really best in class.” The Top Ream platform offers best in class carbide as well. WIDIA’s WU05PR advanced reaming grade was developed specifically for the demanding tool wear and surface finish requirements encountered in most hole reaming operations. For example, tests performed over a total cut distance 100 feet (30 m) in

length showed an ability to consistently maintain surface finishes of 32 μin Ra (0.8 μm) in 4140 steel alloy and 64 μin Ra (1.6 μm) in gray cast iron, three times that of TiAlN-coated tools. Jerry Hanna, WIDIA Director of Sales Operations, says the Top Ream covers hole diameters up to 42 mm (1.65 in.), with the TRF shank-style starting at 14 mm (0.551 in.), and the TRM modular tool from 20 mm (0.787 in.) and up. “This size range covers the lion’s share of requests from our customers,” he says. “We also offer a wide variety of custom geometries, diameters, and edge preps, all available in three weeks or less.” If you’re worried about custom cutting tools, don’t be. “With reaming, 98 percent of the tools are custom,” Bobos points out. “We encourage our customers to try standard sizes, but they should also ask us for advice. We have the ability to optimize solutions specifically for any application—if you’re machining titanium, there are specific geometries and coatings for that. Same with 316 stainless, or Inconel. A slight tweak to the hone, or modifying the leading edge a little bit can make a huge difference in productivity and hole quality.” TRM series’ mounting mechanism One of the best features of the Top Ream is the TRM series’ mounting mechanism, which makes simultaneous contact on the cutting head’s face and taper. Twist the locking screw and the reamer head pops out, with no need for head to body orientation. This provides a strong, vibration-free, and—most importantly— extremely precise reamer interface.

TECH TRENDS

How KM4X is improving bottomline for job shops The KM system from Kennametal Corp., Latrobe, PA has been a top performer in the Quick change modular tooling area for over three decades, and is known throughout the industry for its high clamping strength and consistent accuracy in both spindle-mounted and static tooling applications

uick-change modular tooling is a clear way to increase productivity, shorten setup time, and generally improve the bottom line for job shops and large manufacturers alike. The bending moment of KM4X is substantially higher than any tooling interface available on the market today, superior even to Kennametal’s own KM design So when aerospace giant Boeing came to Kennametal with a request for a heavy-duty spindle connection capable of outperforming traditional CAT and BT-style adapters, tooling engineers turned to this robust and well-established

MACHINE TOOLS WORLD OCTOBER 2016

platform as a starting point. The result was a 100 mm spindle connection with four ball tracks instead of two and up to 40 percent greater clamping force than comparably-sized KM tooling. That was 15 years ago. KM continues to thrive, and was adopted in 2008 by the International Organization for Standardization (ISO) as ISO standard 26622. The original Boeing-inspired design has been renamed as well, and marketed for the past several years as KM4X100™, a spindle platform popular with machine builders such as Fives Group, Mitsui Seiki, Stama, and others, as well as those machine shops looking

for superior rigidity in demanding machining conditions. KM4X tooling family gains a new sibling That popularity is about to grow. Kennametal has announced the KM4X tooling family has gained a 63 mm sibling, one aimed at a broader machine tool platform and therefore greater availability to the machining community. “Just as we did with Boeing, we challenged ourselves to make a great solution even better,” says Bill Redman, Kennametal Global Product Manager, Tooling Systems. “The clamping

TECH TRENDS

strength, bending stiffness, and RPM capabilities of the KM4X63™ are dramatically higher than virtually any other connection out there.” Redman and others on the product management and engineering team aren’t done. They recently approached a number of machine builders to ask for opinions on the initial KM4X product offering. Based on that feedback, Kennametal continues to expand the portfolio—the KM4X lineup now includes shrink fit toolholders, HydroForce™ hydraulic chucks, TG and ER collet chucks, and a variety of other spindle tooling, clamping units, and modular adapters, with more on the way. “By the end of 2016, we’re going to add roughly 30 new line items, most of which will be extensions in the 80 to 200 mm range, and centerline turning tools to support mill-turn applications,” says Redman. “We’ve found that, because of KM4X’s extreme rigidity, we can greatly increase gage lengths. This means our customers can reach much farther without having to buy a

MACHINE TOOLS WORLD OCTOBER 2016

special tool, something that’s especially important with 5-axis machining—they can basically add on whatever extension length is needed and off they go, in both static or rotating applications. We’re pretty excited about that.” Faster and more efficient One example of this is a 674 mm gage length (26.54 in.) KM4X boring bar that will be displayed on an Integrex i-400 in the Mazak booth at this year’s IMTS. “KM4X63 has a maximum bending moment of 2,100 Nm (1548 ft. lb.) and, depending on the machine, clamping force of 36 to 58 Kn (8093 to 13038 lb.),” he says. “It’s the strongest connection available in this size range, period.” It’s also faster. Redman says KM4X63 comes “out of the box” capable to 38,000 rpm, which is higher than HSK-A and “dramatically” faster than competing brands of spindle tooling. For those shops on the fence about spindle tooling and quick-change, Redman offers the following advice. “There’s nothing worse than going into a shop that just bought a $500,000

machining center or lathe and then discovers they should have opted for a different tooling platform. We as tooling providers have an obligation to educate customers, and get them thinking about what they’re trying to accomplish— whether they need high spindle speeds for an aluminum or die-mold application, or greater low-end torque for titanium and HRSA machining. The majority of tooling systems out there can accommodate one of these things, but not both. We feel KM4X provides a competitive advantage no matter what you’re cutting.” Works effortlessly on stationary applications KM and KM4X work on stationary applications as well, as in this centerline turning tool holder for multi-tasking machines and mill-turn lathes. Due to its inherently balanced design, KM4X63 achieves “out of the box” spindle speeds 30% greater than HSK, and nearly twice that of comparably-sized polygon-style toolholders.

TECH TRENDS

The leader of innovation in machine tool construction offers ideal ways of achieving digital transformation with its DMG MORI Software Solutions

A glimpse into the future of

machine tool construction The leader of innovation in machine tool construction offers ideal ways of achieving digital transformation with its DMG MORI Software Solutions

raditionally DMG MORI showcases a cross-section of the most innovative technologies when the AMB opens its doors to trade visitors from all over the world. With around 30 exhibits from the fields of turning, milling and advanced technologies on an exhibition area of over 2,000 m² the machine tool producer gave visitors a glimpse into the future of production from 13th to 17th September 2016. The innovations on show during the trade fair included the Robo2Go automation solution – this can be used on

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several machines without any knowledge of robots. A key building block in DMG MORI’s customer-oriented digitalisation strategy is the app-based CELOS® system, that the machine tool manufacturer first presented around three years ago and which it has consistently continued to develop in a targeted manner ever since. Using this uniform user interface for machine and office PC, employees in shop floor and job scheduling can manage, document and visualise all job order, process and machine data.

Open Architecture Thanks to its open architecture, CELOS® allows the exchange of information with higher–level structures in addition to the impact it has in the shop floor area. So CELOS® offers customers complete integration of their machines in the company organisation while simultaneously creating today the interface of metal cutting production in the cyber-physical production system of the future. The benefits in day-to-day operation are convincing: a 30 percent time saving in tooling times and 50

TECH TRENDS percent less time and effort for the calculation of technology values or the search for important information are just a few of the effects that can be achieved with CELOS. Customers also profit from the continuous further development of the CELOS system, because with every new release DMG MORI implements 50 enhancements. In addition, DMG MORI will be presenting ten new CELOS APPs at the AMB. These will include the new CELOS DEVELOPER APP, with which partners will be able to develop their own APP for the very first time. Workshop-oriented programming is still of great importance, especially in single item production and the production of small and medium-sized quantities – and it will remain just as important for a long time to come. Working with cycles is state of the art in this respect and the reason why standard cycles in turning, milling and drilling have long been part of the scope of performance of modern controls. Based on its decades of application experience DMG MORI has gone far beyond the standard and currently has 24 exclusive DMG MORI technology cycles for the fields of turning / turning-milling or rather milling / milling-turning in its portfolio. These enable operators in the workshop to programme even complex machining tasks themselves directly on the machine via a dialog using parameterised context

MACHINE TOOLS WORLD OCTOBER 2016

menus up to 60% faster. Outstanding examples here include the machining of free-form surfaces using 5-axis interpolation or various cycles for gear cutting or gearwheel production. Other cycle highlights include the MPC (Machine Protection Control) for the protection of machines, workpiece and tool, the 3D quickSET® toolkit for checking and correcting the kinematic accuracy of 4 and 5-axis machines or the Application Tuning Cycle for the processoriented tuning of feed drives in relation to the table load at the push of a button. Heavy-duty machining at an attractive package price 5-axis machining of the highest level

is also the trademark of the fourth generation of the successful duoBLOCK series. Outstanding features here include the highly stable design of the universal machines, long-term accuracy and highest precision with up to 4 μm positioning accuracy even in the standard version. With its DMU 90 P duoBLOCK® DMG MORI now presents a machining centre that will continue the triumphal march of the series. This latest model is designed as a package machine with a 430-Nm and 52kW motor spindle, space for 60 SK50 tools plus an IKZ coolant unit and guarantees an economical entry into heavy-duty machining. Applications in tool and mould making as well as in general mechanical engineering call for investment in reliable, high-performance production equipment. DMG MORI has included the attractively priced DMU 90 P duoBLOCK in its range with universal machining in mind. With an X-axis travel path of 900 mm and a workpiece weight of 1,800 kg, it outperforms the smaller DMU 80 P duoBLOCK. Where its technical equipment is concerned, DMG MORI has concentrated on heavy-duty machining and offers the DMU 90 P duoBLOCK® as an appropriately equipped package machine.

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TECH TRENDS

In order to bring all four grinding spindles and the measuring probe into contact, a Direct drive swivels the grinding spindle turret with high repeatability and precision.

Why the S141 is a trend-setting cylindrical

grinding machine No matter whether its a flange component that is required or spindles up to 1300 mm, the S141 CNC Universal internal cylindrical grinding machine can meet any challenge 74

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ith the S141 STUDER introduced another trend-setting cylindrical grinding machine to the market in 2014. Its technical features and true STUDER precision are extremely impressive. No matter whether its a flange component that is required or spindles up to 1300 mm, the S141 CNC Universal internal cylindrical grinding machine can meet any challenge. The machine’s ergonomic design and user friendliness are evident at first glance. Two gener-ously-sized sliding doors provide the best accessibility not only to the workpiece but also when changing the grinding wheel. Short changeover times and fast reprogramming of the controls help keep downtime to a minimum. This makes the machine very interesting for the production of single pieces, small and large series.The S141 is available in a variety of model lengths for workpieces up to maximum lengths of 300, 700 and 1300 mm (11.8”, 27.5” and 51.1”).In all models, the swing diameter over the table is Ø 400 mm (15.7”) and the maximum grinding length is 250 mm (9.8”) for internal and 150 mm (5.9”) for external grinding. The S141 is the ideal machine for grinding spindle shafts, spindle casings, rotor shafts, axes or flange parts. What sets S141 apart The Granitan machine bed provides excellent cushioning behavior. The revolutionary StuderGuide guideway system with linear motors offers the highest levels of geometric path and guide accuracy. The grinding spindle turret with integrated swivel axis enables the use of up to four grinding spindles and a universal measuring probe. The workhead is adjustably mounted on a swiveling table. The automatic swivel axis has a swiveling range of -10° to +20° (length of model 1300 mm (51.1”), +15°). The robust steady-rest specially designed for internal grinding enables simple setup and uni-versal use. The machine can be equipped with up to

TECH TRENDS www.mtwmag.com

With its short changeover times, the S141 has the potential for mass production and the nec-essary flexibility to finish single pieces economically. two pivoting dressing units with fixed or rotating dressing tools. This enables the engagement of optimized grinding tools throughout the machining process, fulfilling a key prerequisite for maximum precision with dimensional stability, contour accuracy and surface quality of the workpieces. Thanks to the 15” Fauc control series 31B touch screen operating terminal with integrated computer, which is positioned to the right of the generously sized double sliding door, the grinder has a perfect overview of the entire work area while operating the machine.

Two different intuitive operating systems can be put to use: The StuderWINand StuderSIM. The S141 is being launched on the market as a fully developed new product. Over many months, several S141 were in use in the production areas at Fritz Studer AG and at a cus-tomer site. The production of qualitatively challenging workpieces has already been put to a hard daily stress test: the S141 has proven itself to be extremely reliable. Advancing work on the S141 STUDER is now advancing work on

the S141, which has been successfully launched on the market, to produce its S131 and S151 machines and thus introduce an entire series. The S131 is much smaller and more compact than the S141 - with a swing diameter over the table of Ø 250 mm (9.8”) and a maximum grinding length of 175 mm (6.9”) for internal and 125 mm (4.9”) for external grinding. It is available for workpieces with a maximum length of 300 mm (11.8”). The S151 is a somewhat larger than the S141 - it has a swing diameter over the table of Ø 550 (21.6”) mm and a maximum grinding length of 400 mm (15.7”)for internal and 150 mm(5.9”) for external grinding.It is available for workpieces with a maximum length of 700 mm (27.5”). Naturally, the S131 and S151 machines are designed using the same fully developed technology as the S141.In the design of the S141 particular focus was placed on ergonomics.

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TECH TRENDS

How Haas is playing a role in Motorsports

In its inaugural season competing in the Formula One World Championship, Haas F1 Team continues to score points. Is this beginnerâ&#x20AC;&#x2122;s luck or a result of applying the same pragmatic, common sense approach to motor racing that team owner Gene Haas instilled at Haas Automation since founding the CNC machine tool manufacturer in 1983? 76

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ll eyes were on Haas F1 Team when it entered the FIA Formula One World Championship in 2016, becoming the first American-led Formula One team in 30 years. After all, history has shown that newcomers tend to struggle in the worldâ&#x20AC;&#x2122;s most sophisticated form of motorsports.

TECH TRENDS www.mtwmag.com

Exceeding expectations Inside the Formula One paddock, Haas F1 Team has exceeded expectations. But for Gene Haas, founder of Haas Automation and owner of Haas F1 Team, obtaining results is always the expectation. Since Haas Automation’s inception in 1983, the company has risen to become one of the largest machine tool builders in the world by total unit volume. The Oxnard, California-based factory employs approximately 1,300 people and exports 60 percent of its annual production to more than 60 countries. There are close to 185,000 Haas CNC machine tools installed around the world, supported by a network of 170 Haas Factory Outlets (HFOs) and nearly 3,000 Haas Technical Education Centres (HTECs). Seven new HTECs have opened in Europe alone since the start of 2016.

However, Haas F1 Team has bucked that trend by collecting enough points that midway through its debut season, its neck-and-neck with established Formula One teams that have been around for decades. With still half the season remaining, Haas F1 Team has already scored 28 points, the most of any firstyear team in this millennium.

Funding community causes Augmenting this infrastructure is the non-profit Gene Haas Foundation, which funds community causes as an official commitment to corporate and social responsibility. Since its creation in 1999, the Gene Haas Foundation has awarded in excess of $22 million to nearly 1,000 organizations, many of which are schools and colleges where because to the foundation’s efforts, students receive financial assistance with tuition, books, work clothing, small tools and manufacturing study trips. The steep ascent of Haas Automation has been mirrored by Haas’ endeavors at the racetrack. In 2002, he formed a NASCAR team that is known today as Stewart-Haas Racing. It is now a powerhouse, four-car team in NASCAR’s premiere series with two championships and more than 30 victories. The methodologies used to make StewartHaas Racing successful are currently being employed at Haas F1 Team, and the industry has noticed. Haas F1 Team’s headquarters is located on the same Kannapolis, North

Carolina, campus as Stewart-Haas Racing, but Haas F1 Team also has a European base in Banbury, England. And just like at Stewart-Haas Racing and at Haas F1 Team’s Kannapolis home, the Banbury location has Haas CNC machine tools prominently featured. In fact, this is a common sight inside the facilities of many other racing teams and its supply chain of subcontractors around the world, all of which rely on Haas CNC machines to make components accurately and cost-effectively. The dedication to quality and the endless search for efficiency is what made Haas Automation the largest machine tool builder in North America. Those same values form the foundation of Haas F1 Team – an organization that serves as a catalyst in making Haas Automation a premium, global brand.

Haas – an influential name Paddock magazine listed Haas as one of the top-100 most influential people in Formula One. Appearing on the list for the first time at number 30, Paddock said: “Gene Haas – new to F1 in 2016, but an experienced hand in motorsport having been involved in NASCAR for many years. Gene made a smart move this year with his Ferrari partnership allowing his team to punch above their weight in their inaugural year.” Haas was also recently named on Time Inc.’s “The Drive” top-10 list of the most influential car persons.

OCTOBER 2016

MACHINE TOOLS WORLD

TECH TRENDS

The Diversity of Tactile Measurements The four HEIDENHAIN length gauge product ranges: From online device monitoring and 0.1 µm accuracy to almost zero Newton gauging force

The number of metrology applications is almost infinite—automated testing, multipoint measuring stations and individual test stations are just a few of the variants, and each application demands specific properties of the encoders and evaluation electronics used. HEIDENHAIN provides a wide spectrum of solutions for such purposes which, thanks to photoelectric scanning, benefit from high accuracy across the complete measuring range.

he diversity of uses for HEIDENHAIN length gauges is hardly less than the number of applications. For measuring rooms, the monitoring of measuring equipment or for manually operated measuring stations, the CERTO and METRO series are ideal, with accuracy of better than 1 µm. ACANTO and SPECTO length gauges, on the other hand, are suitable for automated test equipment and multipoint measuring stations because of their specific construction designs. High accuracy over the complete measuring range means that several different components of various sizes can be measured with identical accuracy levels by all length gauge models. The result is that supplementary devices are not needed. All variants also feature special characteristics targeted at the wide diversity of applications. Together with suitable evaluation electronics, HEIDENHAIN solutions meet the highly specific demands of metrological tasks.

MACHINE TOOLS WORLD OCTOBER 2016

HEIDENHAIN ACANTO: Absolute length gauge with online device monitoring In dynamic measuring tasks such as on test stands, counting errors can occur in the subsequent electronics when using incremental encoders. These are often caused by excessive speeds or vibrations. The absolute length gauges from the HEIDENHAIN ACANTO series avoid such counting errors by continuously determining the absolute position value for each request without needing a reference run, thus immediately providing a measured value. Measuring errors caused by excessive plunger speeds (e.g. from bounce) belong to the past. HEIDENHAIN ACANTO length gauges also supply analyzable data about the measurements, providing information

about the specific rating with each machining step or quality testing step. This is made possible with the bidirectional EnDat 2.2 interface, which in addition to the position value provides further information about the length gauge: • Valuation numbers supply data about the current state of the encoder. Continuous monitoring of the functional quality of scanning is therefore possible. • Warnings and alarms allow conclusions to be drawn about components affected by failure, e.g. the light unit. • Upon switch-on, the electronic ID plate immediately displays all technical parameters for the encoder. This avoids erroneous configuring of the evaluation electronics.

TECH TRENDS www.mtwmag.com

An important aspect of the Industry 4.0 topic is supporting people via technology, for example with self-configuration and self-diagnosis. The subsequent electronics can independently configure the signal period or measuring step with the transmitted information. Also, the EnDat 2.2 interface enables information to be written back to the length gauge. Two different corporate divisions directly benefit from this added value: • Quality Assurance can determine the quality of measurements with the diagnostics information. • Machine maintenance can avoid unnecessary idle times during production via advance inspections thanks to the valuation numbers. The valuation numbers are dynamically generated in a similar way to the maintenance intervals for modern automobiles according to their driving conditions, with the encoder detecting whether a light source is aging, for example, or the scanning equipment is contaminated. The measuring range of ACANTO length gauges is 12 mm or 30 mm according to specific version, with IP67 protection. The compact station width of 15 mm means they are also especially suitable for multipoint measuring stations. Multipoint measuring equipment is gaining in popularity Multipoint measuring stations are becoming ever more important in the field of industrial measuring technology. Electronics control the simultaneous measurement of several measured values on a test component in such applications, and often as part of a predetermined testing procedure with complex measuring tasks. The SPECTO series features a station width of just 13 mm for such applications, enabling several length gauges to be positioned in tight spaces. To keep space requirements in the system low, cables can be either axially or radially connected. HEIDENHAIN SPECTO length gauges are also ideal for in-process measurements thanks to protection classes to IP67. Accuracy of ±1 µm is ensured over measuring strokes of 12 mm or 30 mm. The short-range accuracy (measurement error in a measuring range of 200 µm) is typically less than 0.3 µm, and

Online device monitoring for all machining steps and quality inspection steps providing information for quality assurance and machine maintenance

OCTOBER 2016

MACHINE TOOLS WORLD

TECH TRENDS repeatability has the same low value. These values are possible among other factors due to the highly precise ball guide, designed for a life of more than 60 million measuring cycles. To ensure that data from multipoint measuring stations is reliably and quickly evaluated, HEIDENHAIN offers the MSE 1000 modular subsequent electronics, enabling the simultaneous measurement of up to 250 measurement channels over a wide variety of interfaces. When designing the MSE 1000, HEIDENHAIN placed an emphasis on simplicity for installation of the modules and connection to the encoder. Modules can be mounted to DIN rails to achieve tidy and compact measuring stations. The selected system configuration of the modules is detected automatically and unnoticed by the user, who only needs to define and set the specific channels. The MSE 1000 also of course allows EnDat encoders to be connected in their entire functionality, enabling all the benefits provided by the ACANTO length gauges to be used for example. Valuation numbers, warnings, alarms and the ID plate can be displayed and queried via the unit. In addition to support for the EnDat HEIDENHAIN protocol for absolute encoders, all common incremental encoders, further connection options for analog sensors and LVDT and HBT displacement sensors from well-known producers are also supported. Modules with switching inputs and outputs enable interaction with other actuators in the encoder. A Compressed air switching module for direct control of e.g. pneumatically actuated length gauges is also available. Data transmission is via standard Ethernet. The scope of supply of the MSE 1000 includes, in addition to a system configuration program, a DLL library that allows users to develop their own testing programs. With testing processes requiring further actions (depending on the measuring results), complex sequences can thus be stored. The ND 2100G GAGE-CHEK evaluation electronics are ideal for up to eight measurement channels, displaying the

MACHINE TOOLS WORLD OCTOBER 2016

values of the single channels or directly evaluating these. The ND 2100G GAGECHEK can also carry out complex calculations via equations and comparisons, with the software and hardware enabling the saving of processes and responses and the controlling of switching inputs and outputs. In this way, PLC functionality can be integrated into the evaluation electronics. HEIDENHAIN METRO and HEIDENHAIN CERTO: Measuring below 1 µm With an accuracy of ±0.1 µm and repeatability of 0.03 µm, the HEIDENHAIN CERTO length gauge gives you the most exact tactile measurement over a range of up to 60 mm that the market has to offer. HEIDENHEIN measures repeatability with five measurements across the complete measuring range near to the lower plunger stop. Repeatability specifies the difference between the initial measurement and the settled condition of the encoder after five measurements. The advantages of photoelectric sampling are exploited to the full, with the finest lines being sampled without contact and therefore without wear, thus enabling such outstanding technical parameters. The calibration chart also indicates a value for linear error compensation. In combination with an ND 287 evaluation unit, the achievable accuracy improves to ±0.03 µm. Using the recommended CS 200 gauge stand even results in a thermally invariable measuring loop. Since the gauge stand and the HEIDENHAIN CERTO mechanism both consist of Invar (expansion 1 ppm/K) and the scale with 2 µm signal period is manufactured from ZERODUR (expansion 0.1 ppm/K), small variations in temperature, which generally cannot be avoided, do not affect the accuracy. Length gauge accuracy is specified in the range of 19 °C to 21 °C for this reason. For high-accuracy measurements, such as stations where the finished dimensions are checked, the optional analog module of the ND 287 can be used to compensate for deviations in the temperature of the workpiece or the entire system. The electrical motor of the

length gauge offers three gauging forces and a constant probing force over the entire measuring range. A further series in the accuracy grade below 1 µm is the METRO product range, and just like CERTO length gauges, these feature a precision graduation with a 2 µm signal period. This ensures system accuracy of ±0.2 µm over the entire measuring range of 12 mm or 25 mm. The interplay of ball bearing guides and highprecision photoelectric scanning achieves repeatability below 0.03 µm, and shortrange accuracy with a measuring range of 12 mm is typically less than 0.03 µm. Tactile length gauge with a measuring force of almost zero Newton Continued progress in the field of materials technology is leading to increased use of flexible materials such as elastomers in industry. The desire to produce ever more compactly also presents new challenges for the measuring of delicate workpieces. The undesired deformation of elastic parts caused by the encoder may distort measurement results, and workpieces made of highly sensitive materials can also damage or destroy the encoder. The MT 1281 MW length gauge from HEIDENHAIN’s METRO range now enables a test object to be measured tactilely with minimum risk from deformation or damage. This is due to the unusually low measuring force of between 0.01 N and 0.07 N manifested by the length gauge over its complete 12 mm measuring path. The ND 287 evaluation unit is suitable as a subsequent electronics unit for standalone measuring stations. When combined with the METRO series, a measuring step of 1 nm is possible. It also offers many possibilities for capturing and classifying measurement series as well as creating histograms. The ND 287 thus makes it easier to evaluate the manufacturing process. Contributed by

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VARVEL production lines

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

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

agency.com

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

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

Indiaï¿½s Premier Exhibition of Metal Cutting, Metal Forming,Automation, Forging & Foundry Industry

SEC SUNITA ENGINEERING CORPORATION

India's premier exhibition on machine tools & automation [Gold Participants]

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CNC Machine Tools

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+91-9879566567 | rajesh@imtos.com | www.kdclglobal.com

PROJECTS

Airport Airport Authority of India (AAI)

Airport Automobile Aviation

PROJECT

Engineering Ports & Shipping Power Railways

UPDATE

Transport

MACHINE TOOLS WORLD OCTOBER 2016

The survey works in the Pettah and Muttathara villages have commenced for the expansion of Thiruvananthapuram International Airport. The district administration is undertaking the survey works to acquire 8 hectare of land for further airport development. Airports Authority of India had been insisting on the state government for providing 32.8 hectare to set up a new domestic terminal and ancillary facilities.

Place: Kerala Contact: P.C. Mahavar, First floor, Technical Block, AAI, Trivandrum International Airport, Thiruvananthapuram- 695008, Karela. T: 0471-2501464, 2702600, Extn-2303, E: dgm_tvm@aai.aero, Airport Authority of India (AAI) Tiruchirapalli International Airport expansion is planned. Around 370 acre of the 510 acre of land required is already acquired. AAI is scouting for a consultant to handle the expansion project. Tenders have already been floated. The work is expected to commence before March 2017.

Place: Tamil Nadu

Contact: K Gunasekaran, Airport Director, Tiruchirapalli Airport, Tiruchirapalli-620007, Tamil Nadu. T: 0431-2341810, 2341547, M: 7373774163, F: 0431-2341812, E: apdtrichy@aai.aero Airports Authority of India AAI is undertaking the construction of new integrated Terminal Building at VSI Airport Port Blair. Bids are currently invited for the balance work. The completion is targeted in 42 months.

Place: Andaman and Nicobar Contact: R K Nirwal, General Manager (Engg-C), Directorate Of Engineering, Rajiv Gandhi Bhawan, Safdarjung Airport, New Delhi-110003, Delhi. T: 011-24655718, M: 8527569995â&#x20AC;? Airport Authority of India (AAI) The development of Jharsuguda airport is being carried out through joint funding from AAI and Odisha Government. The agreement was signed in July, 2014 to develop the airstrip. The state government has handed over 106.23 acre of land out of which 51.8 acre is government land. The contracts are awarded for the construction of passenger terminal building, pavement, service block, staff quarters and ATC tower. The completion is envisaged by

PROJECTS www.mtwmag.com

June 2018.

Place: Odisha Contact: P.Battacharya, Deputy General Manager (CNS), Jharsuguda Airport, Jharsuguda, Odisha. T: 06645-284112, F: 284112, M: 9433893219, E: cnsic_vejh@aai.aero

Automobile KIA Motors A part of Seoul-based automobile manufacturer Hyundai Motors plans to set up manufacturing unit in Tamil Nadu. The state government has offered about 400 acre of land for the same.

Block, Rajeev Gandhi Bhavan, New Delhi-110003, Delhi. T: 011-24643246, E: arun.kumar63@nic.in

Ministry of Civil Aviation The aviation ministry has signed an MoU with Maharashtra Government to facilitate regional air connectivity by making it affordable by enacting different concessions offered by the Union government. The work on Shirdi airport is on and commercial operations are likely by November 2016. The other airports that will be ready include the ones at Sholapur, Jalgaon, Gondia, Nanded, Akola & Kolhapur.

Place: Maharashtra Place: Tamil Nadu Contact: Han-Woo Park, CEO & President, 231, Yangjae- dong, Seocho-gu, Seoul, 137-938, South Korea. T: +82 2 3464 1114, F: +82 2 3464 6845, W: www.kia.co.kr.

Aviation Ministry of Civil Aviation Plans to set up 50 regional airports over the next three years to enhance air transportation. Ten of these airports would be ready by the end of this year. The cost of each of these airports would be about Rs. 50-100 crore.

Place: Nationwide Contact: Arun Kumar, Joint Secretary (AK), MCA, B

Contact: Arun Kumar, Joint Secretary (AK), MCA, B Block, Rajeev Gandhi Bhavan, New Delhi-110003, Delhi. T: 011-24643246, E: arun.kumar63@nic.in

Engineering Tube Investments of India (TII) Ltd Murugappa Group company plans investment to expand its tube manufacturing capacity.

Place: Tamil Nadu Contact: Sandanand, Senior General Manager, (Project), Dare House, 2, (Old No. 234), N S C Bose Road, Chennai-600001. T: 044-42177770-6, F: 42110404, M: 9840708581

Ports & Shipping Mumbai Port Trust (MbPT) Plans to revamp port trust land on the eastern coast of Mumbai. Consultant services is sought to prepare a master plan to develop the port land comprising marina, a tourist village, passenger terminal, etc.

Place: Maharashtra Contact: Shekar Lagwankar, Superintendent Engineer, Port Bhavan, Surjiwallabdas Marg, Ballard Estate, Mumbai-400001, Maharashtra. T: 022-66564040 IL&FS Engineering and Construction Company Ltd Plans to set up a captive port in Cuddalore district in Tamil Nadu. The port will be developed and run by Adani Port. The proposed port will handle 15-25 million tonnes per annum (MTPA) of imported coal for the power plant and it will have two coal berths of 600 metre length with breakwaters.

Place: Tamil Nadu Contact: Tarun Kumar Udwala, Sr Manager (Corp Comm), Door No. 8-2120/113/3, 4th Floor, Sanali Info Park, Road No. 2, Banjara Hills, Hyderabad-500033, Telangana. T: 040-40409333, F: 40409444, E: info@ilfsengg.com,

V.O. Chidam- baranar Port Trust The port trust plans to undertake development of shallow draught berth for handling general cargo, north cargo berth- III for handling coal, north cargo berth- IV for handling containers and clean cargo. Apart from this the port aims to construct truck parking terminal, upgradation of coal jetty-I and coal jetty-II, installation of 5 MW solar power plant and other related works.

Place: Tamil Nadu Contact: Balamurali, Assistant Executive Engineer, Tuticorin-628004, Tamil Nadu, T: 0461-2352252, 2352290, 2352500, M: 9677456479, E: balavocport@gmail.com,

Power IL&FS Engineering and Construction Company Ltd Bagged a PGCIL order along with Unitech Power Transmission for the turnkey works of 765 KV transmission line works for BhujBanaskanta Transmission Line (Part-V) in Gujarat. The completion period is targeted in 23 months from the date of issue of the LOA.

Place: Gujarat Contact: Tarun Kumar Udwala,Sr Manager (Corp Comm), Door No. 8-2120/113/3, 4th Floor, Sanali

OCTOBER 2016

MACHINE TOOLS WORLD

PROJECTS

Info Park, Road No. 2, Banjara Hills, Hyderabad-500033, Telangana. T: 040-40409333, F: 40409444, E; info@ilfsengg.com, tarun_udwala@ilfsengg.com,

Bihar State Power Transmission Company Ltd The company is laying of 132 kV LILO line of both circuit of 132 kV BTPS- Purnea transmission line to new GSS near Korha (Katihar).

Place: Bihar Contact: P.K Govil, 4th Floor, Vidyut Bhawan, Bailey Road, Patna-1, Bihar. T: 0612-2504442, F: 0612-2504305, M: 7763817701, E: ce.trans664@gmail.com Maharashtra State Electricity Transmisson Company Ltd The company is implementing the laying of 400kV DCQ line from 400 kV Koradi-II substation to 765 kV Koradi-III substation. The completion is targeted by December, 2016.

substation at Julurupada (Bommanapalli) in Khammam district.

Place: Telangana Contact: Latha Vinod, Chief Engineer (Projects), Vidyut Soudha, Khairatabad, Hyderabad-500082, Telangana. T: 040-23393453, M: 9440907399, E: ce_proj1_transco@ telangana.gov.in,

Railways Indian Railways Plans to construct 168.289 KM broad gauge railway line from Hubli to Ankola in Uttara Kannada District. The Supreme Court-appointed Central Empowered Committee (CEC) had disapproved this project in 2015 citing irreparable damage likely to be caused to the ecology. The National Green Tribunal gave its nod to Railways in February, 2016 and had recommended to take this further with the state government and can apply for converting forest land into non-forest land.

Place: Maharashtra Place: Karnataka Contact: Rahul Nandurkar, Deputy Executive Engineer, Construction Division I, Vidyut Bhavan, Katol Road, Nagpur-440013, Maharashtra. M: 8554993570, E: ee4610@mahatransco.in

Transmission Corporation of Telangana Ltd Setting up of 400/200 kV

MACHINE TOOLS WORLD OCTOBER 2016

Contact: Anil Saxena, Additional Director General (PR), Room No. 310, Rail Bhavan, Raisina Road, New Delhi-110001, Delhi. T: 011-23381332, 23303665, M: 9810046241, 9868679525, F: 23385215, E: dpr@rb.railnet.gov.in

Indian Railway Station Development Corporation (IRSDC) IRSDC along with China Railway Construction Engineering Group are likely to take up development of Baiyappanahalli station in Bengaluru, Karnataka under the proposed Foreign Rail Technology Cooperation Scheme (FRTCS).

Place: Karnataka Contact: Parag Verma, Chief Operating Officer, 4th, Floor, Palika Bhawan, Sector XIII, R.K.Puram, New Delhi-110066, Delhi. T: 011- 24672718, 24672719, 24672723, F: 24672720, E: parag.verma@irsdc.com, ceo@irsdc.com, Indian Railway Station Development Corporation (IRSDC) â&#x20AC;&#x153;Redevelopment of Habibganj railway station in Bhopal district is planned over 40.91 ha of land. The land would be used for development of existing station and proposed railway colony. The project is being implemented by a consortium of Bansal Construction Works and Prakash Asphalting and Toll Highways through SPV - Bansal Pathways Habibganj Pvt Ltd. The project comprises provision of modern amenities like escalators, lifts, parking lot, landscaping, concourse, walkway, travelators, parcel corridor, subways, food plaza, clinic, office complex, etc as part of the

redevelopment of the station. Habibganj Railway station, is the first station to be redeveloped through Public Private Partnership (PPP) route under the station redevelopment program of Indian Railways

Place: Madhya Pradesh Contact: Parag Verma, Chief Operating Officer, 4th, Floor, Palika Bhawan, Sector XIII, R.K.Puram, New Delhi-110066, Delhi. T: 011-24672718, 24672719, 24672723, F: 24672720, E: parag.verma@irsdc.com

Transport Amaravati Metrorail Corporation Ltd (AMRC) Vijayawada metro project completion is targeted by December 2018. The phase-I project is proposed to have a 11-km corridor being divided into two parts, 5 km and 6 km. Around 75 acre of land would be required as per initial estimates for building metro depot and the stations. Centre has so far allocated only Rs 100 crore for the project in the last Budget.

Place: Andhra Pradesh Contact: N.P. Ramakrishna Reddy, MD, 1st Floor, Jawaharlal Nehru Building Canal Road, Vijayawada Municipal Corporation, Vijayawada, Srikakulam-520001, Andhra Pradesh. E: nprkreddy@yahoo.co.in

PRODUCTS www.mtwmag.com

PRODUCT SHOWCASE Shrink Fit Holder Technology & Advantages Shrink Fit tool holder can provide tremendous holding strength and TIR for critical high speed or high precision cutting applications, which is not possible with most tool holders.

How it works: Each Shrink fit tool holder is manufactured with an inside diameter slightly smaller than the shank diameter of the cutting tool. A heat induction unit is used to quickly heat the holder end of the Shrink fit, expanding this inside diameter. At this point, the tool shank slips easily into the holder. As the holder cools, the resulting thermal contraction exerts a tremendous, uniform pressure around the entire surface of the tool shank leaving total concentric gripping strength. Removing the tool is just as simple — you simply reverse the process! Tool changes can be accomplished in seconds, dramatically increasing machining productivity by reducing tool change downtime. Shrink fit technology and design provides; Best possible TIR (Total Indicator Reading) • Best possible balance • Best available gripping power • Increased tool and spindle life • Thin profile holders for machining hard-to-reach places • Design and build custom holders for any application • Short gauge lengths available for increased rigidity • Ability to preset for required tool length • Ideal for end milling, drilling, reaming, boring and all other critical rotary tool applications regardless of cutting tool material • Eliminates wrenches, collets, set screws and other accessories • Reduces costs associated with tool changes, holder maintenance & machine downtime

For Product Enquiry Contact Birla Precision Technologies 206 Dalamal House, 1st Floor, Jamnalal Bajaj Marg, Nariman Point, Mumbai - 400 021 Web: www.birlaprecision.org Email: itmth@indiantool.com.

Conclusion - The Shrink fit tool holding System is by far the most economical system in the world today. The increased productivity and increased tool life can be measured. Additionally, reduced tool change down time will contribute to the considerable reduction in costs. Birla Precision offers wide range in Shrink Fit adaptors on BT/DV/CAT & HSK tapers. Extra long gauge lengths are available to approach machining deep areas. Bore size ranging from 6 mm to 32 mm & ¼”to 11/4” In Inch sizes.

OCTOBER 2016

MACHINE TOOLS WORLD

PRODUCTS

Missile Lube® 1, 1XL, 1XXL, 1XXXL Straight Cutting Oil for HONING FEATURES • • • • • •

Chlorine-Free Original Synthetic and Vegetable EP Technology Non-Staining Easy to Recycle and Waste Treat Can be used on all materials Low Misting

Missile Lube 1 XL is Approved by Boeing Aircraft, and Lockheed Martin

GENERAL DESCRIPTION Hangsterfer’s Missile Lube 1 series includes high quality’ high performance’ chlorine and sulfur free oils. The combination of synthetic and vegetable based Extreme Pressure additives increase tool life and improve surface finishes for a variety of metalworking operations. Composed of highly refined raw materials’ the Missile Lube 1 series helps keep the machine clean and minimizes operator exposure to mist and smoke. Offering superior lubrication for the machine tool as well as the tool-work piece interface’ the Missile Lube 1 series provides benefits in productivity and equipment life. The non-toxic and non-corrosive blend is designed for easy waste disposal and operator safety. Missile Lube 1- The highest viscosity of the Missile Lube range is suitable for abroad range of applications. Due to its viscosity it provides the maximum lubricity of the tool workpiece interface especially on demanding metal cutting and metal forming applications. Missile Lube 1 XL - The combination of low viscosity mineral oils and EP additives make it ideal for grinding carbide and high-speed steel. The wheels stay clean and last longer, while surface finishes improve. It is excellent for high speed machining of aerospace aluminums and other exotic materials. Missile Lube 1 XXL - With 100% more synthetic EP additives then the 1 XL, the 1 XXL has a much lower viscosity. It can be used for the same applications as 1 XL, but is more suitable for very small work, as 1 XXL is easier to deliver to the tool-workpiece interface.

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

MACHINE TOOLS WORLD OCTOBER 2016

Missile Lube 1 XXL and 1 XXXL are well suited for honing of ferrous and non-ferrous materials where chlorine additives are restricted. They are non-staining and leave little residue while providing rust protection. The extreme pressure additives in Missile Lube provide flushing and pickup protection for the abrasive while allowing fee cutting for superior finishes. Honing is a cutting operation with very small chips. Missile Lube 1 XXL and 1 XXXL are suited for use with solid and expanding hones in all type honing machines. Suitable for use on hone materials but not limited to; diamond’ supper abrasives’ ceramic and silicone carbide.

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.

Latch clamps with safety locking mechanism ELESA+GANTER, manufacturers of standard machine elements has enlarged its latch clamp product range with “Latch clamps with locking mechanism”. Every design features a locking mechanism which prevents the inadvertent or vibration-induced opening of the latch clamp. Naturally, the latch clamps are also designed for operation with one hand. The handles have a red and oil-resistant plastic cap. All movable parts are lubricated with special grease. The GN 853 latch clamps are ultimately made of burnished, case- hardened C 10 steel. Their tie rods are made of burnished steel grade St 32.

Ganter supplies the following design versions:

For Product Enquiry Contact Elesa and Ganter India Pvt. Ltd. A-54, Sector-83, Noida-201305 (U.P.), INDIA Phone: 0120-4726666 E-mail: info@elesaganter-india.com, marketing@elesaganter-india.com Web: www.elesa-ganter.com

• Coding 1: without tie rod and latch bracket • Coding 2: with tie rod and latch bracket Next to the steel design, there is also a stainless steel variant where all sheet metal parts and the tie rod are made of rust-resistant stainless steel. For very high retaining forces, Ganter’s range includes the GN 852.1 latch clamps with locking mechanism. They are made of forged steel and chemically blackened precision-cast metal. The bearing bolts are made of hardened and polished steel. The latch brackets are included in the delivery.

OCTOBER 2016

MACHINE TOOLS WORLD

PRODUCTS

LEGEX Series LEGEX – Ultra High Accuracy 3D CNC Coordinate Measuring Machine

For Product Enquiry Contact Mitutoyo South Asia Pvt. Ltd. C-122, Okhla Industrial Area, Phase-I, New Delhi-110 020 Phone: (91-11)-26372090, 40578485 E-mail: delhi@mitutoyoindia.com, Web: www.mitutoyoindia.com

LEGEX is the culmination of 80 years of Mitutoyo technology. Recognized as the world’s ultimate high accuracy 3D CNC CMM, LEGEX offers an accuracy of (E0, MPE = 0.28 + L/1000)µm. Mitutoyo Research & Development team is constantly engaged into development of new technologies. High-precision machining, drive mechanism & encoder / sensor techniques play a very important role in making our CMMs very robust & long lasting. The highest accuracy in LEGEX series has been achieved because of our focus on superior design, materials & manufacturing techniques followed at state-of-the-art facility in Japan. For an unmatched performance, LEGEX uses a fixed bridge structure with integrated Y axis guide rails, central drive and precision air bearings running on rigid guide ways ensuring superior stability of motion and ultra-high measuring accuracy. LEGEX is equipped with ‘air-damped spring isolators’ having auto-leveling feature to completely isolate the measurement from any possible floor vibrations. A newly developed ultra-high accuracy crystallized-glass scale with an ultra-low expansion coefficient of 0.01x10-6/K is used on each axis. This ultra- high accuracy 3D CNC CMM has been made possible through rigorous analysis of all possible error-producing factors and elimination or minimization of their effects. A variety of optional probe systems are available, including touch-trigger probe; scanning probe, laser probe, surface roughness probe, vision and other special probes like UMAP & MPP. Mitutoyo’s MPP-310Q is ideal for low measuring force and ultrahigh accuracy, while the MPP10 is the only probe in the world dedicated for effective thread-depth measurement. Machines in this series are suitable for complex, small- to medium-sized workpieces such as gears, bearings, lenses, dies and scroll rotors and master gauges which must be inspected to exceptionally high dimensional accuracy. This superior structure is powered by the industry leading MCOSMOS family of softwares by Mitutoyo featuring simple geometric measurement, profile scanning, digitizing, online/offline part program creation as well as additional applications such as gears and air-foil inspection.

Welding Fume Extractor, King Extractor-II-MU 3

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 OCTOBER 2016

Welding Fume Extractor, King Extractor-II-MU 3 is a mobile mechanical high efficiency self-cleaning filter designed for workplaces. The filter cleans ir from different kinds of dry dust, welding aerosols and other dry contaminants from most industrial processes. The filter cartridge is cleaned automatically without interrupting the filtration process. The cleaning extends the cartridge service periods and minimizes maintenance. The Filter is designed for continuous indoor operation under the following climatic conditions: • Air temperature from +10 deg. C to +45 deg. C. • Relative humidity : 80% at 25 deg. C • The compact construction integrates the filter, extraction arm and fan • The filter can be used at workplaces unreachable to other ventilating equipment, and • The filter requires connection to a general compressed air supply. The standard delivery set includes Built-in fan, Control console, Filtering cartridge of respective type, Spark arrester, Oil separator with reduction box for compressed air system, and Electrical grounded cable L= 5 m with plug.

ADVERTISERS INDEX COMPANY NAME

PG. NO.

COMPANY NAME

PG. NO.

ACCUSHARP CUTTING TOOLS PVT. LTD.

ACE MANUFACTURING SYSTEMS LTD.

BACK PAGE

ADOR WELDING LIMITED

GLEASON WORKS (INDIA) PRIVATE LIMITED

GROB MACHINE TOOLS INDIA PVT. LTD.

H ANCA MACHINE TOOLS PRIVATE LTD APEX PRECISION MECHATRONIX PVT. LTD.

BHOOMI REALTORS AND CONSTRUCTIONS

47 83

IMTEX - 2017

IMTOS 2017

PLAZMA TECHNOLOGIES PVT. LTD.

R RAJKOT MACHINE TOOLS SHOW - 2016

RENISHAW INDIA (PUNE)

S SANJAY TOOLS & ADHESIVES

SPARKONIX (INDIA) PVT LTD

JYOTI CNC AUTOMATION LTD.

CAPITAL FIRST

CNC SOFTWARE, INC.

T TECHNO INDUSTRIES

J BIRLA PRECISION TECHNOLOGIES LIMITED

PG. NO.

B BHARAT FRITZ WERNER LTD.

HEIDENHAIN OPTICS & ELECTRONICS INDIA PRAIVATE LIMITED

COMPANY NAME

U UCAM PRIVATE LIMITED

MACHAUTO EXPO - 2017

UNITED GRINDING GMBH

MAPAL INDIA PRIVATE LIMITED

UNITY CONTROLS PVT. LTD.

MARPOSS INDIA PVT. LTD.

U-TECH ASSOCIATES

MGM-VARVEL POWER TRANSMISSION PVT. LTD.

D DOWEL ENGINEERING WORKS

E ELECTROTHERM (INDIA) LTD.

EMAG INDIA PVT. LTD.

ENGIMACH - 2017

ERWIN JUNKER MASCHINENFABRIK GMBH

WIN INDIA - 2016 MITUTOYO SOUTH ASIA PVT. LTD.

INSIDE BACK COVER

MMC HARDMETAL INDIA PVT. LTD.

INSIDE FRONT COVER

P F FATTY TUNA INDIA PVT. LTD.

PHILLIPS MACHINE TOOLS INDIA PVT. LTD.

Y YAMAZAKI MAZAK INDIA

18-19

YASKAWA INDIA PVT. LTD.

YG CUTTING TOOLS CORPORATION PVT. LTD.

FRONT GATEFOLD

OCTOBER 2016

MACHINE TOOLS WORLD

Mr.

Jeffrey

Inside Story

Foregard

General Manager - Asia Executive Director, ANCA Pty. Ltd.

My Lifeâ&#x20AC;&#x2122;s Goals

Aim & Ambition: My aim and ambition in life is to have a successful career along with a good balanced life between work and family time. To effectively manage my team ensuring their success at all times and to maintain a professional work ethic. Vision: To provide strong leadership skills to my team & ensure succession planning is always planned and prepared for thereby guaranteeing the future success of our business. Install a culture within my team to ensure a positive outcome at all times, even when the going gets tough. Social Goal: Ensure we consider the environment whenever possible and to give back to the local communities. Business Goal: To give my 100% and work hard and make the difference. Effect positive change through structure and experience and mentoring others. Make a positive impression and deliver whenever possible and most importantly to never avoid the challenges and difficult aspects of the job at hand, either externally or internally and to provide a stable and effective management style to my team.

My Leisure Choices Favourite Tourist Spot: London and Mauritius. Music I like : All of it Sports I Love : English premier league soccer. I am a huge fan of Crystal Palace whom I have supported for the last 45 years.

Ask my Taste Buds Favorite food: Indian and a good English Roast. Favorite Drink: A glass of red wine from the Penfolds estate.

In Awe of I Admire: Mother Theresa for all the great work she has undertaken. I also admire people who continue to give back to other people. The gift of giving to those who are in need of it is something I really respect and admire in others who do this.

MACHINE TOOLS WORLD OCTOBER 2016

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