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

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Contents

www.mtwmag.com

Vol 2 Issue 06 | NOVEMBER 2016

Executive Publisher Shirish D.

COMPANY PROFILE

CEO

Shekhar D.

Editor

80 years of Blaser Swisslube: A Perspective

Shilpa Dongre

Marketing Team

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

Electrotherm (India) E&P Division: .......

Designer & Layout

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

Dynaspede thrives in Mechatronics

Online Division Ganesh M., Pradeep M. Pillalamarri

Circulation Executive Satish Kadam, Amol Ranshur

Shavo Technologies offers high-tech ....

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

COVER STORY

TECH TRENDS

United Grinding : Precision with perfection Mr. Sudheendra C. R., President - India Operations, United Grinding GmbH

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

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

BUSINESS NEWS

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 NOVEMBER 2016

ZAcode: Benefits for users and manufacturers

10 Multi Cutting Edge fine boring of interrupted bores with the EA-system

INTERFACE

Open & flexible CNC architecture with TwinCAT 3

Robotics in machine tending

CASE STUDY

Haas: The machines that changed the world of........

Kingâ&#x20AC;&#x2122;s College Hospital installs neuroinspire surgical...

BFW brings manufacturing industry together .....

Seco increases selection of Disc Mill Cutters with introductions and expansions

Sparkonix - shaping mould making in India since four.....

22 26

MICO Generators from eldec

A winner of the Greater Hartford 2016 top...

Accusharp Gun-Drills

ANCA launches a stepchange in the robot teaching..

22 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.

TECH PROFILE

58 Ador impresses visitors at India Essen

PROJECTS

PRODUCTS

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

TECH PROFILE

Multi Cutting Edge

fine boring of interrupted bores with the EA-system

pen or extremely interrupted bores such as those found, for example, in the cast housings of gear pumps, are a challenge for fine machining. Until now the desired results, for example with regard to the parallel alignment of the bores, could generally only be reliably achieved using single cutting edge tools. Spindle tools or pad-guided tools were used for this. These methods are effective, but very time-consuming. In order to allow such bores to be machined faster and hence more costeffectiveness, MAPAL has developed a multi cutting edged fine boring tool with guide pads. With the development of Mapal Multi cutting edge fine boring tool the cycle time is significantly reduced compared with single cutting edged tools. At the same time, the guide pads ensure maximum accuracy. The tool diameter can be adjusted. When the feed rate for the machining is known, a single axial fine adjustment is necessary. This provides a uniform distribution of the material removal at the inserts. This leads to long tool lives

MACHINE TOOLS WORLD NOVEMBER 2016

The new multi cutting edge tool from MAPAL for fine boring can be fitted with HX or TEC indexable inserts, depending on the application and a very good surface quality. The tool can be fitted with HX or TEC indexable inserts, depending on the application. The HX indexable inserts with six cutting edges are suitable for through holes. Blind holes and shoulders can be finely machined using TEC indexable inserts with four cutting edges. The EasyAdjust-System from MAPAL is used for clamping the indexable inserts. The heart of the system is an innovative cassette that stably holds

Bores with extreme interrupted cuts can be reliably fine bored using the new tool from MAPAL

the indexable insert with its six or four cutting edges without any play. The back taper of the minor cutting edge is already integrated into this cassette. The setting effort for the back taper is thus completely eliminated. Due to the exact guidance of the cassette on a precision guide pin, the back taper remains unchanged even during diameter adjustments. The new fine adjustable tool with the number of indexable inserts and guide pads adapted to the diameter impresses in particular with the high accuracy of the results and the high costeffectiveness. Initial tests in practice have shown very good results: In particular the tool achieves a parallel alignment of the bores of less than 1 Îźm. For more information, you are requested to contact National Sales Manager â&#x20AC;&#x201C; Mr Rajesh Kumar.K.G Phone: +91 9741499824 Email:rajeshkumar@in.mapal.com, info@in.mapal.com Website.: www.mapal.com

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

You

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Editorial Board

Editorial Index A Accusharp Ador Welding

62 58, 102

ANCA Machine Tools

Beckhoff

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

66, 68

Renishaw Metrology Systems Ltd.

Jyoti CNC Automation LTD

36, 84 72

Birla Precision

Mastercam

Blaser Swisslube

Mitutoyo South Asia

Bonfiglioli

10 18, 20 101

NUM

DMG MORI

Dormer Pramet

Phillips Machine Tools

30 36

Ratnaparkhi Electronics 102 Renishaw

Effica Automation

Effica Automation Ltd.

Kennametal

MAPAL India

Mr. MIHIR Baxi President – Global Sales

Systems

Ms.Samina Khalid Marketing Manager

Bharat Fritz Werner

Dynaspede Integrated

Mr. Arjun Prakash Managing Director

KOMET GROUP

Mr. A.P. Jayanthram Managing Director

Heidenhain India Hypertherm

Electrotherm

Seco Tools India

26, 56

EMAG INDIA

Shavo Technologies

52, 74

ESPRIT

Shell Lubricants

Solitaire Machine Tools

Sparkonix

FARO Technologies

Gleason Corporation

United Grinding Unity Controls

Haas Automation Hangsterfer

86 100

Ziehl-Abegg

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.

MACHINE TOOLS WORLD NOVEMBER 2016

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

38 100

CHINA/South Korea/Taiwan Mepax - Konaxis Shanghai Julien PENARD Tel : (+86) 21 6252 2731/ china@mepax.com

BE DYNAMIC!

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

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

BUSINESS NEWS

ANCA launches a step-change in the robot teaching process with its new RoboTeach solution ANCA’s new RoboTeach solution enables greater efficiency and accuracy when setting up robot automation on their CNC grinding machines. By automating the teaching of the RoboMate Fanuc 200iD robot, the new product significantly decreases downtime achieving greater productivity and reduces the need for specialised operator skills. Simon Richardson, ANCA MX Machine Platform Product Manager said, “Until now, teaching of the Fanuc Robot (200iD) on RoboMate could be labour intensive and require a unique set of operator skills. Furthermore, accuracy could vary depending on the user conducting the teaching. To solve this problem, ANCA has released RoboTeach, a product that automates the teaching of the RoboMate Fanuc 200iD robots on

teach the Robot positions and coordinates.

RoboTeach Key Benefits

our MX and TX machine platforms.” RoboTeach is a machine run program that uses the high accuracy of the grinding machine to measure the robot position and automatically teach and calibrate the robot. The robot position is taught using an electrical contact touch probe held in the robot gripper and a mandrel that locates the position of the machine collet adaptor and tool storage pallets. A series of instructions on the

operator screen guide the user on how to teach the Fanuc robot using ANCA Loadermate software. The easy to follow instructions ensure the operator can quickly and easily

• Reduction of manual intervention during the teaching process. • Reduction of time taken to teach the Robot from several hours to under 30 minutes. • Reduction of set up time achieving cost savings. • Consistent teaching of the robot to improve grinding accuracy. • Increases productivity and reduces downtime. • Significant improvements of the end to end process for teaching the Robot. The RoboTeach product has a software option and teach tooling kit. The teach tooling kit is supplied in a compact carry case with relevant teaching materials.

Mastercam announces new post processor for sinumerik controllers CNC Software, Inc., producers of Mastercam CAD/CAM software announced a 3-axis milling post processor that will unleash the highest productivity on Sinumerik-controlled machine tools. The new post processor was developed utilizing the technical expertise of Siemens CNC engineers. This post processor includes support for Sinumerik 840D sl and 828D CNCs from Siemens and features: • CYCLE 832 support for high-speed settings • Drill cycles (CYCLES 82, 83, 84, 85, 86, 840) • WORKPIECE output for graphical simulation • Tool call as tool name or tool number • TOFFR option • Siemens 3-axis application guide “We’ve been collaborating with Siemens in this development for the release of Mastercam

MACHINE TOOLS WORLD NOVEMBER 2016

2017, and are proud to announce the 3-axis milling post processor as the initial launch of strengthening our relationship for future posts that will benefit mutual customers,” says Pedro Sanchez, Jr., Post Department Manager of CNC Software, Inc. It is cooperation like this that provides Mastercam users the opportunity to truly complement their CAM investment and give their shops the best chance at a more efficient

manufacturing solution, from design to part. Chris Pollack, east coast dealer and importer regional account manager, commented, “By educating Mastercam on the key advanced functions of the Sinumerik control, Mastercam has been able to create a post-processor that provides the most value to our mutual customers.” Pollack continued, “Siemens looks forward to continuing to help Mastercam create more advanced post-processors in the future.”

BUSINESS NEWS

A winner of the Greater Hartford 2016 top workplaces award CNC Software, has been awarded a 2016 Top Workplaces honor by The Hartford Courant. The Top Workplaces lists are based solely on the results of an employee feedback survey administered by WorkplaceDynamics, LLC, a leading research firm that specializes in organizational health and workplace improvement. Several aspects of workplace culture were measured, including Alignment, Execution, and Connection, just to name a few. “The Top Workplaces award is not a popularity contest. And oftentimes, people assume it’s all about fancy perks and benefits.” says Doug Claffey, CEO of WorkplaceDynamics. “But to be a Top Workplace, organizations must meet our strict standards for organizational health. And who better to ask about work life than the people who live the culture every day—the employees. Time and time again, our research has proven that what’s most important to them is a strong belief in where the organization is headed, how it’s going to get there, and the feeling that everyone is in it together. Claffey adds, “Without this sense of connection, an organization doesn’t have a shot at being named a Top Workplace.” Brian Summers, Vice President of CNC Software, Inc.,

says, “We are honored to be one of the top workplaces in Connecticut again! This award is important to us and an indicator that we continue to operate successfully as a company. We actively strive to engage our employees in numerous ways, from fun group activities to companywide brain-storming sessions to include everyone in a continuous cycle of inspecting and adapting to our ever changing environment. By clarifying our company direction and continually looking for this improvement, it is an empowering process for the employee to have their input heard and to let them feel in control of their destiny. While we maintain our industry leader status in the CAD/ CAM industry, we continue to believe that a pleasant and nurturing workplace is vital for our employees and the continued success of CNC. We also believe that by keeping our company light on our feet with our agile mindset, we can adapt quickly to changing market requirements. We will continue to look for new ways to align our company as it matures and are thankful to receive this award.”

FARO launches PointSense 17.5 with new tools FARO® (NASDAQ:FARO), the world’s most trusted source for 3D measurement and imaging solutions for factory metrology, product design, construction BIM-CIM, public safety forensics and 3D solutions and services applications, announces the release of PointSense 17.5, providing powerful new tools for extracting and aligning building and plant features from point cloud data inside Revit® and AutoCAD®. PointSense 17.5 for AutoCAD® provides more customized tools for the extraction of building components, such as walls, windows and doors. After extracting the building components, architects benefit from new alignment tools that

MACHINE TOOLS WORLD NOVEMBER 2016

dramatically speed up the process of delivering 2D plans from 3D point clouds. In addition to these new features for architects, industrial facility designers also benefit from new functions for creating 3D plant models. One of the several new features is an automated cylinder extraction tool, which reduces time and simplifies 3D modeling of piping from point clouds. Besides new tools in PointSense for AutoCAD®, PointSense 17.5 for Revit® also speeds

up workflows with a new toolset for pipe modeling and a new visualization tool that shows the user only the relevant parts of the scan project that they are interested in. “With the new pipe modeling and visualization tools in PointSense for Revit® and the advanced functionality for architects in PointSense for AutoCAD®, customers will see a dramatic increase in their daily efficiency,“ stated Joe Arezone, FARO’s Chief Commercial Officer. “MEP engineers can work directly inside Revit®, without having to use third party software tools for pipe documentation, and architects will benefit from faster alignment workflows.”

SNIPPETS

Analyst predicts the global metal forming machine tools market to grow moderately at a CAGR of 4% during the forecast period.

3.44% Analysts forecast the machine tools market in the US to grow at a CAGR of 3.44% during 2014-2019.

5.10% Analysts predict the machine tools market in Germany to grow at a CAGR of close to 5.10% until 2019.

88%

The metal cutting segment accounted for 88% of the market share during 2015 & expected to see the fastest growth during the forecast period.

32%

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

BUSINESS NEWS

ZAcode: Benefits for users and manufacturers “All our products have the same genetic code”, says Peter Fenkl, CEO of Ziehl-Abegg at the Chillventa. Anyone who can operate one device can easily cope with any other device from the Künzelsau-based fan manufacturer. “Many visitors were interested in this unique logic that our expectations for the show were clearly exceeded”, said Fenkl. We have obviously touched on a key topic here.” The company has been able to achieve this because the in-house development, programming and manufacture of motors and control devices has been the strength of the technology leader from Künzelsau for decades. Service technicians and facility managers often work under time constraints: ventilation systems have to readjusted, customised control units adapted accordingly, or a system needs to be expanded. Even if an element has to be replaced, a continuous operating and communication concept helps to save time. Uniform concepts in all Ziehl-Abegg products provide the

essential basis both for internal and external communication. “Anyone connecting one of our EC fans also automatically knows how to connect a Ziehl-Abegg frequency inverter”, says the CEO, explaining the ZAcode. From the moment Ziehl-Abegg products are installed the systems designer doesn’t need to bother him/herself with different electronic systems. Ziehl-Abegg is the only manufacturer in the market that can connect, control and regulate all systems and products with a single logic. “This has enabled us to reduce the complexity and eliminate error sources” emphasises Fenkl. The integrated operating concept extends across the wide performance range from a small 1 kW to approximately 30 kW output. It includes axial fans and centrifugal fans. In addition, the company offers solutions both with the energysaving EC technology as well as the conventional AC technology. The uniform handling is particularly important with applications in which EC fans and frequency converters are used to

equal extent. So all Ziehl-Abegg’s products have standardised connections and can also be expanded on a modular basis. The basic structure, the so-called “basic design”, is the same for all products and offers the option of analogue control at any time. Up to now this has been the preferred application in the systems. With the help of an add-on module, a bus interface can be fitted to a basic design at any time so it can be integrated into modern system concepts. This product design reduces inventories as there is no need to hold multiple versions in stock. At the same time, the user retains the flexibility to expand a simple and inexpensive product at any time – “Buy only what you need”. Ziehl-Abegg offers various pluggable, add-on modules for integration into the desired bus systems on the customer side: CAN-open, Lon, Modbus, PROFIBUS; PROFINET or EtherCAT are currently available. Add-on modules for other systems are developed and supplied as required.

BFW brings manufacturing industry together on a single platform Bangalore based Bharat Fritz Werner (BFW), one of Kothari Group’s flagship companies, a leading manufacturer of machine tools announcedthat the first edition of Manufacturing Daywhich concluded successfully had some high profile speakers including Shishir Joshipura, Managing Director, SKF;Kamal Bali, Managing Director, Volvo; Kishore Jayaraman, President, Rolls Royce India & South Asia. They spoke about topics ranging from Make in India & how to get the best out of it, Opportunities in Indian Manufacturing – Auto sector & Aerospace and Future Manufacturing. There were 220 participants from over 100 manufacturing companies attending the Maiden Edition of

MACHINE TOOLS WORLD NOVEMBER 2016

Manufacturing Day. Speakers from Industry Leaders like Godrej Aerospace, Toyota Engine Industry, TVS Motors, Volvo EicherCommerical Vehicles, Sigma Electric Corporation, UNO Minda, TAL Manufacturing Solutions, Thermax, Eaton India, Walchandnagar Industries, Ador Welding Academy were part of the Panel discussions on Future Factories: Productive Shop Floor, Innovation Led Manufacturing and Talent & Skill Development for Manufacturing. Although, manufacturing is the backbone of any economy globally, it has always played an understated role.Acknowledging the contribution of manufacturing industry to Indian economy and

to bring the large manufacturing fraternity together, this first edition of Manufacturing Day is BFW’s bid to put Indian Manufacturers on the global map. Speaking at the event, Ravi Raghavan, Managing Director & CEO, BFW said, “We are inching towards exciting yet challenging times. We have to make collaborative efforts in order to respond to the challenges faced by the industry, simultaneously, avail of the opportunities collectively. There are issues such as acquiring and retaining talent faced by the industry that need to be addressed. There is greater efforts required for us to come together and share our industry learnings, initiatives and perspectives.” With the advancement in

economy, manufacturing industry has evolved too. There is a greater requirement than before for technological enhancement, innovation, customisation, flexibility and speed. Manufacturing is ubiquitous and an integral part of our lives. Everything we see in our lives be it cell phones, buildings or laptops is linked with manufacturing industry in some way. The advancements in different fields such as IT or healthcare is associated with manufacturing. Technology coupled with Manufacturing will be twin growth drivers of the country.

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

COMPACT

BUSINESS NEWS

Bharat Fritz Werner (BFW) announces launch of the first edition of manufacturing day One of Kothari Group’s flagship companies, Bharat Fritz Werner (BFW), a leading manufacturer of machine tools with 55 years of presence, announced the first edition of Manufacturing Day which was held on October 19, 2016 in Pune. Although, manufacturing is the backbone of any economy globally, it has always played an understated role. Acknowledging the contribution of manufacturing industry to Indian economy and to bring the large

manufacturing fraternity together, this first edition of Manufacturing Day is BFW’s bid to put Indian Manufacturers on the global map. Speaking to media in Pune, Ravi Raghavan, Managing Director & CEO, BFW said, “We are inching towards exciting yet challenging times. We have to make collaborative efforts in order to respond to the challenges faced by the industry, simultaneously, avail of the opportunities collectively. There are issues such as acquiring and retaining talent

faced by the industry that need to be addressed. There is greater efforts required for us to come together and share our industry learnings, initiatives and perspectives.” With the advancement in economy, manufacturing industry has evolved too. There is a greater requirement than before for technological enhancement, innovation, customisation, flexibility and speed. Manufacturing is ubitiquous and an integral part of our lives. Everything we see in our lives be it cell phones,

buildings or laptops is linked with manufacturing industry in some way. The advancements in different fields such as IT or healthcare is associated with manufacturing. Technology coupled with Manufacturing will be twin growth drivers of the country. He further added that, “PM’s visionary initiative such as ‘Make in India’ should trickle down the industry so that everyone benefits from it. The first edition of Manufacturing Day is being held in Pune. We plan to celebrate this day every year.”

Shell Lubricants bags award second time in a row Shell Lubricants, the global market share leader in finished lubricants, bagged the ‘Lubricant company of the year’ award second time in a row at the recently concluded 3rd edition of India Wind Energy Forum Excellence Awards; held in Goa. This year’s edition focused on the various factors which will lead to a resurgence in the Indian wind energy sector, making it one of the most favorable wind energy sector globally. Mr. Akhil Jha, Vice President Technical, Shell Lubricants India chaired the session on “Technology for Tomorrow: New Trends” and Mr. Siva Kasturi, Regional OEM Manager – Shell Lubricants India & South East Asia addressed the audience on “Emerging Trends in Turbine Lubrication Challenges in Power Sector”. Elated on the occasion, Mr. Akhil Jha, Vice President - Technical, Shell Lubricants India said, “Customers and technology are at the heart of everything we do at Shell Lubricants. This consecutive industry recognition from The India Wind Energy Forum is a testimony of our continued commitment towards the Indian market. At Shell Lubricants India, our journey has been marked with an approach that is spread across the full spectrum of our value chain. We are dedicated towards catering to the varied maintenance requirements of the wind sector through a host of technologically advanced products and services. We assure our OEMs and

MACHINE TOOLS WORLD NOVEMBER 2016

customers that we will continue to add more value to their business as a valuable partner.” India is the fourth largest wind energy producer in the world with 21.2 GW generation in 2016. The government of India has aimed to take it up to 60 GW by 2022. Wind energy is the cleanest form of energy source in terms of carbon footprint intensity and also the fastest growing energy source amongst the energy basket in India. Considering the fast growth of this sector, the key requirements of wind turbines are higher reliability and equipment protection to ensure lower maintenance and asset management cost. Keeping this in mind, Shell Lubricants offers the complete portfolio of products and services for Wind turbines. Shell has responded to the

modern challenges in wind turbine lubrication by developing the next generation fully synthetic gear oil - GTL based Shell Omala S5 Wind for the main gear box and greases Shell Gadus S5 V460 KP and Shell Gadus S5 V110 KP for main, yaw and pitch bearings. These products are designed to exceed the modern day challenges in wind turbine lubrication and offer very high level of reliability and lower cost of ownership to the sector. Commenting on the role of Shell Lubricants India at the conference, Mr. Vijay Kumar, MD, Firstview Group and Wind Insider said, “We are delighted to have a leading lubricants manufacturer like Shell Lubricants as part of the forum to help promote the role of lubricants in the wind energy sector. The objective of this two- day event was to provide the speakers and delegates an opportunity to interact and connect with policymakers, key stakeholders and other industry experts. This forum focused on government policy and the role of renewable energy community in supporting an expedited growth of the wind energy sector in India.” Represented by CEOs and other senior officials, the event also witnessed participation from reputed firms like Regen Powertech, Mytrah Energy, Grant Thornton India LLP, Tata Power, GE Renewable Energy, Gamesa Renewables Pvt Ltd and Panama Wind Energy, among others.

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

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GROB_Indien_Anzeige_Magazin_die_and_mould_April_2016_DINA4.indd 1

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BUSINESS NEWS

Seco increases selection of Disc Mill Cutters with introductions and expansions Seco has further expanded the industry’s widest selection of disc milling inserts and cutter bodies. In response to customer demands, Seco has introduced the 335.14 small-diameter exchangeable head system, 335.16 cutter for T-slot operations and cassette versions of the 335.25 cutter that incorporate round inserts. Incorporating small-diameter exchangeable carbide heads, the 335.14 offers a versatile, precise cutting profile that easily tackles any type of material. These cutters are ideal for groove milling, circlip grooves, full radius profiles and chamfering. Reliable exchangeable head systems control machining costs. The 335.14 product line comes in a wide variety of cylindrical and integrated collet chuck shanks in diameters from 9.7 mm to 34.7 mm that cut widths from 0.7 mm to 5.15 mm. The highly stable 335.16 cutters incorporate 4-edged inserts to economically perform

demanding T-slot operations. Modern insert geometries reduce machining forces and noise for optimum tool life. Centralised cooling channels

effectively remove chips and provide excellent surface finishes and finished part quality. Cutters come in diameters from 25 mm to 50 mm based on standardised T-slot dimensions. The wide selection of insert geometries and grades cut many materials in widths ranging from 11 mm to 21 mm. The expanded line of 335.25 disc mill cutters now includes new cassettes for 16-mm and 20mm round insert diameters. These cutters perform well in various full side, face or half side and face operations for applications involving corner radii. The exchangeable cassettes ensure long, reliable cutter performance. The large choice of insert geometries and grades provide freer cutting operations and increase cost-efficiency in any type of material. Regular and extra-large cassette sizes accept 16-mm and 20-mm round insert diameters. Cutter diameters range from 100 mm to 315 mm.

Hypertherm introduces mild steel consumables for Kjellberg PerCut 221M & PerCut 451M torches Hypertherm’s Centricut brand is shipping new consumables designed for use with all Kjellberg PerCut 221M and PerCut 451M torches found on Kjellberg HiFocus neo plasma cutting systems. The new Centricut brand consumables for mild steel cutting deliver the same benefits found when using Kjellberg neo consumables, at a lower cost. In addition, the Centricut brand consumables are designed with keyless nozzles for use in all Kjellberg torch models available today. Testing by Hypertherm confirms consumable life, cut speed, and cut quality are all comparable or better when using the Centricut brand. In addition, the Centricut brand consumables offer process repeatability. “Hypertherm’s engineering

MACHINE TOOLS WORLD NOVEMBER 2016

and manufacturing excellence ensures users get high quality consumables that provide consistent, reliable performance of their cutting system,” explains Cynthia von Recklinghausen, the product manager for Hypertherm’s Centricut brand. “At the same time, customers can lower their overall cost of cutting since Centricut brand consumables cost less.” Centricut brand products, like all Hypertherm products, are designed with critical-to-function tolerances

and are precision manufactured by advanced machinists to deliver the best quality product every time. Businesses interested in a free trial of any Centricut brand product or a technical consultation about improving their cutting process can contact Hypertherm at 800-7527623 or their authorized Hypertherm distributor. 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.

BUSINESS NEWS

Bonfiglioli to expand operations in India and Bologna Bonfiglioli Transmissions Pvt Ltd, the India-based subsidiary of Bonfiglioli Riduttori S.p.A. has announced an expansion of operations in India and also in the company headquarters in Bologna, Italy. Expansion plans in India include improvements to existing facilities in Chennai and construction of a new facility in Pune (Chakan area), for a total investment of 85 Cr INR (11.3 million euro). The current plants in Chennai, located at the SIDCO Industrial Area, Thirumudivakkam, covers an area of 180,000 sq.ft. and the Mannur plant located close to Sriperumbudur covers an area of 100,000 sq.ft. These plants are highly integrated facilities that manufacture gearboxes and gearmotors for mobile machinery, wind turbines and industrial processes. The facilities also house an R&D Centre, which develops products tailor-made for the Indian market. • A new facility of 140,000 sq.ft will be built, adjacent to the current plant at Thirumudivakkam. It will house modern assembly lines, R&D Centre and test labs, all built with the highest standards of quality and safety, consistent with Bonfiglioli locations worldwide. The expected capacity is 75,000 units per year and will enable Bonfiglioli to serve existing and new markets and customers in off-highway, construction, mining, agriculture and material handling applications. • A completely new facility will be built in Pune (Chakan area, western India) and is

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expected to be ready in March 2017. This new facility will be approximately 45,000 sq.ft., including 3,000 sq.ft. of office space and will contain 11 assembly centres and 2,000 warehouse locations, all built to the highest standards of quality and safety, consistent with Bonfiglioli locations worldwide. The expected capacity is 150,000 units per year to serve customers in food, packaging, cement, steel, pharmaceutical, textile, material handling, sugar, power generation, paper and water treatment sectors. In Bologna, Italy, the company will break ground on a new SMART factory based on Industry 4.0 technologies and innovations. The new production plant, an investment of 450 Cr. INR (60 million euro), will cover an area of 1.6 million sq.ft and produce 800,000 units per year in an eco-friendly and people-friendly environment. With over 32,000 sq.ft. of rooftop gardens, nearly 500 trees, and a photovoltaic installation of 3MWp the building will be nearly zero-energy while using the same energy requirements as today. The building will also have noise, emissions

and soil impact control to lessen the environmental impact. Construction is expected to begin in early 2017. Sonia Bonfiglioli, Chairman of Bonfiglioli Group, stated “Bonfiglioli is celebrating its 60th anniversary this year, but we are not looking at the past. We are looking toward the future and how Bonfiglioli can become a model for industrial development, and how we can better serve our customers in high growth countries like India. The new plant in Bologna will be an industry benchmark, with smart and efficient systems required for Industry 4.0 operations, while the expansions in India will enable Bonfiglioli to increase the production capacity in India to drastically reduce lead times to customers in India and nearby countries – all with the goal to help sustain Bonfiglioli through the next 60 years and beyond.” In addition to the expansions, Bonfiglioli has also announced plans to build a second home for abandoned and disadvantaged children in Chennai, India. The first home, CheerFutureLand Home for Boys, was built in 2009 near the Chennai plant of Bonfiglioli to give disadvantaged boys the chance to have a better life and a

future to look forward to. Since it opened, dozens of boys have lived at CheerFutureLand where they received a loving home environment and a solid education. One young man has grown up in the home and now works at the Bonfiglioli Chennai plant as a technician. Now, the company wants to give the same opportunities to young girls and a second home will be built near the current boys home. The new home in Govindavadi Village (Kancheepuram District) will include accommodations, dining facilities, gardens, a playground and areas for recreation and extra-curricular activities like drawing, dancing, sports, music, gardening and more. Vocational training in disciplines such as tailoring and computer skills, in addition to education in a core subjects (mathematics, science, English language, etc.) will be part of the daily routine as well. For safety and security, CCTV cameras will be installed, along with the presence of security personnel and women wardens. The puja for the girls’ home will be on Wednesday, 19 October. “My father had a passion for helping children, especially in educating them and giving them a chance for a better future,” said Ms. Bonfiglioli. We built the boys home in Chennai because, while the Bonfiglioli plant in Chennai was having great success, we could not ignore the children in that area who needed help. We hope to continue this trend in order to give back to the communities where our plants are located around the world.” All media are invited to attend the puja.

BUSINESS NEWS

Precision wood machining centre uses 28-axis CNC system from NUM Krüsi Maschinenbau has launched a precision wood machining centre that is based on a 28-axis CNC system from NUM. The new MC15 provides very high quality wood machining capabilities and can be equipped with up to 28 axes and a maximum of 6 machining heads, each of which can be fitted with 4 machine tools. Wooden bars with dimensions from 650 cm wide and 300 cm high, and with a variable length of up to 1200 cm and a weight of up to 1.5 tons, can be machined easily and quickly from all sides. Krüsi Maschinenbau AG has a 50-year history of precision high quality wood working machines. It would not have been possible to build visionary wooden structures such as Metz’ Centre Pompidou in France, the Tamedia building in Zurich or the Nine Bridges golf club in South Korea without Krüsi CNC machines. Such structures consist of several hundreds of individual parts where it is rare occurrence that any one piece is like another. The precision systems from Krüsi process all

wooden elements, regardless of how complex or delicate the construction. Krüsi Maschinenbau employs a workforce of about 20 and, like NUM, is an internationally operating Swiss company with its registered office in Schönengrund in the Appenzeller region – just a few kilometers away from NUM’s company headquarters. Apart from high-tech systems for free-form beams, the company’s range of products includes longitudinal circular saws, chalet construction machinery and trimming machines. The initial cooperation between NUM AG and Krüsi Maschinenbau AG took place in the middle of the 80’s. At that time, the first fully automatic CNC-controlled trimming machine in the world was successfully brought to market. The now completely newly designed MC15 CNC wood machining centre has been developed jointly as the result of close cooperation between Krüsi and NUM. The highly modern CNC wood machining centre enables

workpieces of all kinds to be sawn, milled, planed, chamfered, beaded, drilled and grooved from all sides. The MC15 is suitable for all work pertaining to modern and conventional wood construction engineering, which demands stringent quality and precision. The MC15 is modular in design, i.e. the number of machining heads and even the dimensions of the loading and unloading station can be adapted as required. The current MC15 is itself built on a gigantic scale in order to machine the aforementioned wooden bars at the maximum dimensions of 30 x 60 x 1200 cm. With a length of 28 m, a width of 3 m, and a height of 3 m above the ground and 1 m depth below the floor, the modern CNC wood machining centre cannot be overlooked. In order to move the heavy wooden bars weighing up to 1.5 tons, the X-axis has four motors, two on each side of the balk. These are controlled independently. However, in most cases they are used synchronously. The 6 machining heads are each moved laterally on the

Y-axis, each having its own motor. They are mounted on two portals, one above and one below the workpiece. The portals are positioned at the height of two Z axes with 2 motors each. The 6 machining heads, each of which is provided with a spindle, can be fitted with up to 4 tools per head. Alternately, 2 machining heads can continuously machine the wooden bar, one from below and the other from above. The 28 axes are controlled with the help of a NUM Flexium+ CNC controller. Apart from the integrated safety controller, the CNC wood machining centre has NUMDrive X drives to control the axes and SHX single cable motors to drive the axes, as well as an FS192LS touch-sensitive screen to control the machine. All these components come from NUM, since this is the only way that proper and precise working of the machine can be ensured for a machining operation from beginning to end. This newly designed CNC wood-machining centre has already awakened the interest of a number of customers and orders for several machines have already been received. At the industrial Trade Fair for wood in Basel, Holz in 2016, the MC15 will be showcased for the first time to a wide audience. A larger machine on which wider wooden bars can be machined is already in the planning phase. This is always done in order to give customers a competitive edge in an increasingly tough market. For more information, Website: www.num.com

MACHINE TOOLS WORLD NOVEMBER 2016

Creating Tool Performance

A member of the UNITED GRINDING Group

HELICHECK PRECISION / ADVANCED Optical CNC measuring machines for non-contact tool measurement

Fully automated measuring machines HELICHECK PRECISION / ADVANCED for rotation-symmetrical tools. For tool diameters from 2 to 320 mm, tool lengths up to 420 mm. Tool weight up to 25 kg. www.walter-machines.com

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 · madabhavi@grinding.ch · www.grinding.ch

Creating Tool Performance

BUSINESS NEWS

Delivering security when you need it

Dormer Pramet has expanded its existing range of forming taps for standard thread forms MF, UNC and UNF, as well as adding taps with oil grooves and through coolant. The Dormer forming taps are a dependable option when creating threads, offering both dynamic strength and high dimensional accuracy. The comprehensive program now includes designs and thread forms for the majority of applications and materials across all major industry segments. The five new lines of forming taps, added as part of the company’s November 2016 launch, offer greater accuracy and produce a stronger thread than standard cutting taps with increased load bearing capabilities. Manufactured from High Speed Cobalt (HSS-E), the taps provide lower surface roughness and a highly stable design, reducing the risk of breakage for added operational reliability. Available with Titanium Nitride (TiN) or Titanium Carbon Nitride (TiCN) coatings, the taps thread profile generates low torque, reducing friction and ensuring a smooth surface finish. The chamfer geometry provides a better run-in and even wear, with options for blind and through-hole machining.

MACHINE TOOLS WORLD NOVEMBER 2016

Meanwhile, Dormer Pramet has launched a comprehensive program of solid carbide taps for machining hardened steels and other difficult to machine materials. The use of hardened materials in industrial processes is becoming increasingly common, creating a greater need for cutting tools that can operate in extreme conditions. To support this, Dormer Pramet has developed five new lines for threading depths up to 3xD under its Dormer brand. The new carbide taps – identified by the T2xx designation - form part of the company’s second product launch of 2016. Offering a high level of performance and productivity, the taps are recommended for machining hardened materials up to 63 HRC, providing high wear resistance and long tool life even at high speeds. The T2xx range can support cutting speeds three times greater than HSS-E taps and, with a highly stable tool design, offers less risk of breakage. The taps are available in a choice of straight flute and spiral flute geometries with either a Titanium Carbon Nitride (TiCN) or Super-B (TiAlN + WC/C) coating. Through coolant and forming tap options have also been added.

DMG MORI increases order intake by 12% in the third quarter

In the third quarter 2016, DMG MORI AKTIENGESELLSCHAFT saw a positive development with € 601.4 million or +12% in its order intake (previous year: € 538.7 million). We have thus exceeded the order intake for the last four quarters. The successful autumn trade fairs also contributed to this. Sales revenues amounted to € 536.6 million (previous year: € 558.6 million). EBITDA was € 52.1 million (previous year: € 57.0 million), the EBIT reached € 38.7 million (previous year: € 43.1 million) and EBT amounted to € 37.8 million (previous year: € 43.1 million). The drop in earnings was mainly attributable to the measures already initiated for realignment. The group recorded earnings after taxes of € 26.1 million for the third quarter 2016 (previous year: € 29.8 million). As at 30 September, order intake was € 1,759.6 million and thereby slightly above the previous year (€ 1,742.0 million). Sales revenues amounted to € 1,629.1 million (previous year: € 1,648.8 million). EBITDA reached € 146.3 million

(previous year: € 151.9 million), EBIT was € 104.0 million (previous year: € 111.5 million) and EBT € 99.0 million (previous year: € 108.8 million). As at 30 September 2016 the group recorded earnings after taxes of € 68.9 million (previous year: € 75.1 million). Sales revenues in the third quarter amounted to € 536.6 million (previous year: € 558.6 million). For the first nine months, sales revenues were € 1,629.1 million (previous year: € 1,648.8 million). International sales revenues were € 1,100.0 million (previous year: € 1,098.7 million). Domestic sales revenues were € 529.1 million (previous year: € 550.1 million). The export quota amounted to 68% (previous year: 67%). In the third quarter, order intake developed positively: At € 601.4 million or +12%, the company exceeded the figure for the last four quarters (previous year´s quarter: € 538.7 million). We achieved significant growth with our machine tools.

BUSINESS NEWS

DP Technology continuously forges partnerships with academia DP Technology joined the College of Electromechanical Engineering at Beijing Union University and the Beijing Intelligent Mechanical Innovative Design Engineering Research Center to host the ESPRIT CAM & Smart Manufacturing seminar in Beijing on September 22, 2016. The seminar brought into focus the most critical manufacturing topics in China in order to better support the ten-year national plan, Made in China 2025. The Made in China 2025 program promotes the transfer into smart manufacturing, improves applications in smart manufacturing and fosters the next generation in a wide array of manufacturing industries. The event was attended by more than 60 people from local manufacturing companies, universities and members of the press. The seminar was a joint speaking engagement for outstanding businessmen and technicians. It featured many topics to support attendees and ESPRIT users on their path to success, including Industry 4.0, smart manufacturing, manufacturing automation and the partnership between industry and academia. Guang Cheng, Dean of College of Electromechanical Engineering of Beijing Union University, addressed the current status and major trends in the future of smart manufacturing from historical, conceptual and practical aspects. Mr. Cheng stated that the College of Electromechanical Engineering is committed to developing high quality application engineers with an international point of view. He also stated that, “We would like to facilitate cooperation with DP Technology to further the development of smart manufacturing. The current research focus of Beijing Intelligent Mechanical Innovative Design Engineering Research Center covers a wide range of smart manufacturing technologies, including prototype design and manufacturing, human-machine inter-

MACHINE TOOLS WORLD NOVEMBER 2016

action and usability testing, & smart manufacturing & service.” “With more than thirty years’ experience, ESPRIT CAM is the only software which is capable of supporting B-axis multi-tasking, 2-5 axis milling, 2-22 axis turning and 2-22 axis, Wire EDM and offers a platform which gives users customized solutions through any object-oriented programming language. With customers across the world, ESPRIT CAM has been applied in a wide range of industries, including aeronautics and astronautics, automotive, industrial machinery, education, medical machinery, energy and so on. In order to provide better service to customers, DP Technology operates sales and technical support centers in multiple locations: Beijing, Tianjin and Guangzhou in order to provide high performance professional and efficient services. DP Technology also adds value to education in China as a part of their ongoing commitment to support the ‘Made in China 2025’ plan. For many years DP Technology has partnered with higher education institutions, technical middle schools, technical high schools, and technical colleges. DP Technology works hand in hand with local schools and colleges to create certification and training centers and to help build the education revolution in China. DP Technology will be an official and major sponsor of the 7th National Vocational Students Skills CompetitionCNC machining contest and will also provide technical support at the event. To sponsor the biggest machining contest in China, DP Technology is taking a proactive approach in engaging with the stakeholders in these industries, but also shows the capability and determination to support the Made in China 2025 plan “, said Mike Lauer, General Manager at DP Asia-Pacific. In the seminar, David Zhang, vice General Manager in DP China, and Cliff Ji, sales engineer

in DP North China also shared the most up to date CNC technology in ESPRIT CAM. “With a continuing thirst for new technology in the modern industry, CNC manufacturing has become popular in many areas. ESPRIT CAM is able to provide a complete package for customer’s manufacturing solutions in many different industries. In addition, ESPRIT CAM is compliant with IoT and the Industry 4.0 initiative. In this way, ESPRIT CAM not only provides users a new concept of automatic machining but also reduces the programming time with easy operations for high quality parts. As a global CAD/CAM company, DP Technology believes that through the cooperation with educational institutions, they have the power to improve manufacturing in China. DP Technology has always been committed to being the world’s leading CAD/CAM technology to college educators and students, specifically when multi-tasking machining with high-speed cutting. Introducing CAD/CAM technologies also helps provide high-end technical personnel to the industry. While we have been in this game for a long time, we will never stop learning and improving upon our cooperation with academia.” said David Zhang.

Cliff Ji also shared several benefits of ESPRIT CAM in the seminar. • ESPRIT CAM offers customized solutions for any type of machine tool to cut parts with any shape of geometry • ESPRIT CAM provides edit-free post processors with accurate G-code • ESPRIT CAM’s full machine simulation prevents machines from collisions • ESPRIT CAM is a cloud-enabled CAM to simplify the selection of cutting tools and automatically obtain the recommended ones.

BUSINESS NEWS

Kennametal’s Mill 4 indexable milling cutters gains a new member The Mill 4-11 offers the free cutting action of a single-sided insert at the low cost per edge of a double-sided. The Mill 4-11 is also available in a variety of mounting options, with cutter diameters ranging from 16 mm (0.625 in.) to 80 mm (3.000 in.) The issue with many square shoulder indexable milling cutters is the stair-step effect they leave on workpiece walls. Two years ago, Kennametal introduced a doublesided 90º milling platform that eliminates this issue while providing manufacturers a cost-effective machining solution to boot. The Mill 4™ Series of indexable shoulder mills is now a proven performer, offering high metal removal rates,

excellent tool life, and surface finish that frequently eliminates semi-finishing operations—and in some cases, can even be used as a finishing cutter, reducing reliance on expensive solid carbide end mills. Kennametal is expanding its game-changing Mill 4 family with a new cutting tool, the Mill 4-11. Designed for smaller machining centers, the Mill 4-11 accommodates 40-taper CAT and BT, HSK50, and similarly-sized spindles. Due to its free-cutting capabilities, it is ideal for successful metal removal in less-than-rigid setups and on lightduty machine tools, multitaskers and live-tool lathes. Tim Marshall, Senior Global

Product Manager for Indexable Milling, says the Mill 4-11 enjoys the same strong insert design as its larger cousin, the Mill 4-15, but is 24 % shorter and 34% narrower. With an 11 mm (0.433 in.) maximum cut length, this addresses the needs of those job shops and manufacturers producing smaller parts and part features while still offering high metal removal rates and excellent tool life. “What’s unique about it is the step down,” says Marshall. “Because of the insert design and precision, there’s very little mismatch between passes— for example, using a 63 mm diameter tool (2.48 in.) and our

SGE geometry, we were able to achieve less than 8µm (0.00003 in.) deviation between successive 6 mm (0.236 in.) deep passes. One of our largest automotive customers completely eliminated a finishing operation on a steel alloy housing because of it, saving them many thousands of dollars annually.”

The popular HAAS CNC tech show ‘HaasTec’ is set for November & December’16 The popular HaasTEC shows are returning to India this year with two events arranged for different regions of the nation. Managed by the Haas Factory Outlet (HFO) in India (Phillips Machine Tools India Pvt. Ltd.), the first HaasTEC will take place from 16th-19th November at Ahmedabad in the western state of Gujarat and will be followed closely by HaasTEC Manesar from 07th to 10th December, in the industrial district of Gurgaon near New Delhi. In line with previous HaasTEC events, a number of innovative, affordable Haas CNC machine tools will be on view. Indeed, two machines will be on show for the first time in India, the Haas ST-15 & Haas DT-2. All of the Haas

MACHINE TOOLS WORLD NOVEMBER 2016

CNC machine tools on display will be powered and performing demonstrations, cutting metal. Haas specialists from the HFO will be available to guide visitors through the demonstrations and answer any questions about the machines. Show stopper HAAS UMC-750 five-axis vertical machining centre offers a capacity of 762 x 508 x 508 mm in the X, Y and Z-axis respectively. It features a two-axis inbuilt trunnion rotary table and a 40-taper, 22.4 kW, 12000 rpm direct drive spindle. Other features of this advanced machine include a 40+1 side mount tool changer, 25.4 m/ min rapids, co-ordinate rotation and scaling, rigid tapping, a wireless intuitive probing system and a 284 litre flood coolant system.

Other Haas CNC machine tool models scheduled to appear at both HaasTEC events include the ST-10Y turning center with Y-axis, VMC’s - VF-2 & VF-2SS & Mini Mill. Visitors are invited to bring along components or drawings for a full evaluation of optimized machining solutions. Indeed, the HaasTEC events will also feature a number of the company’s industrial partners, all able to offer complementary technologies and advice. Demonstrations, tours and a live Q&A counter will be among other event highlights. In fact, apart from Haas Caps / T-Shirts, visitors also stand a chance to win a trip for two to the 2017 Monaco Grand Prix to see Haas F1 Team live!

COVER STORY

United Grinding :

Precision with Perfection Mr. Sudheendra C. R. President - India Operations, United Grinding GmbH

Q. Please brief us about recent initiatives undertaken in machine tools space of United Grinding Group? Which are your focus areas? For the United Grinding Group, a big portion of our worldwide business comes from Automotive & suppliers, precision engineering, aerospace & suppliers, & Tooling. We see a similar trend in India & obviously are our focus markets. United Grinding Group consists of Swiss & German brands, which are known for their innovation, quality & precision in manufacturing technology.

MACHINE TOOLS WORLD NOVEMBER 2016

COVER STORY www.mtwmag.com

United Grinding Group invests a substantial amount of our sales on R & D every year to bring out innovative solutions for the future & further development of our products. Our company Studer introduced a new platform of machines for internal grinding applications in the automotive & suppliers, energy, medical, aerospace, tooling, machine manufacturers, die & mould, precision engineering and transport and heavy industry sectors. For Laser technology, our company Ewag is the technology leader. Laser Line Ultra & Laser Line Precision are the 2 machine types for ultra hard materials like CBN, PCD, CVD, MCD etc Our company Schaudt, market leader for Camshaft grinding machines has added Crankshaft Grinding machine to the product portfolio.

Q. What are the market opportunities for your products in India? How do you plan to position these products? We are the worldwide number 1 grinding machines manufacturing group & have the World’s strongest brands. We see a big potential from the Indian market. We opened our own Branch Office in Bangalore in 2007 & before that our brands have been present in India through our business partners for more than 30 years. Our brands have a strong & long connection to the Indian market. With the 8 brands of United Grinding Group, we offer our customers the broadest possible ranges of applications for grinding, eroding, laser finishing & combined finishing. We present our customers the biggest product portfolio of machines to suit requirements & the most complete array of services to support our customers.

Q. What is your marketing strategy for India? You will find us where our customers are. Our group has produced & delivered

more than 1500 machines to the Indian market. This is why we opened our branch office at Bangalore. In 2013, we established our technical center with demo machines to do test grinding of customer components, do training for customer machine operators both in handling of our machines as well as on the machine maintenance side, machine acceptances etc. Our motivation is to increase our customers’ competitiveness. We always strive to support the long term success of our customers by offering the best possible solution for the application & being a reliable partner that our customers can trust. We distinguish ourselves from competition by offering our customers innovative solutions for their applications & the best support to help their business succeed & become more profitable. Due to the above, we have seen a healthy growth on the order income & gain in market share for our brands in India.

Q. According you what are the factors affecting to your business? I would like to say challenges. The general perception - “Cheap is best”. Unfortunately this is not true. When something is manufactured cheap, it will obviously have compromises on material, quality etc. Whenever you hear about German & Swiss machines, the first thing that comes into anybody’s mind is precision, reliable and long lasting machines. There is a definite reason why our machines are long lasting, reliable & still retain precision & accuracy. We have been successful in educating & convincing our customers the benefits that they will derive in investing in high quality, high precision & reliable machines of United Grinding Group which will produce highly precise components in microns for many years &

hence guaranteeing profits for a long time. Our customers have realized that they have made a wise decision in investing on our machines & hence placed this trust on us. Import taxes in India is a challenge to any imported machine manufacturer & hopefully there will be a rationalization after the GST is rolled out..

Q. What are the key technological trends that are driving machine tools industry? We get many requests from customers for complete processing of their components in the same clamping without setup changes. Some of our solutions to satisfy our customers’ request are – Studer S 242 machine which can do both grinding & hard turning of components in the same clamping. Ewag Laser Line which is used for complete finishing of ultra hard material cutting tools from solid material including creating special geometries, negative chamfer, chip breakers & also for modifying surface characteristics to improve tool life. Blohm & Maegerle 5 axis grinding centers for complete machining of nozzle guide vanes & blades for the aircraft & energy generation sectors. For grinding process, we focus on reducing secondary process times to increase productivity for our customers, & as a result improve profitability. Smarter machine software that supports the operator with optimizing process parameters is a key focus area which is getting better by the day, thanks to our inhouse software development teams.

Q. What is your vision for your company? My vision for United Grinding India is to be No.1 in our market & strive hard to continuously improve market share.

NOVEMBER 2016

MACHINE TOOLS WORLD

COMPANY PROFILE

300GMSL Multi-Sensor Inspection Machine

leason Corporation introduces its latest innovation in gear inspection technology with the 300GMSL Multi-Sensor Inspection Machine; providing the capabilities of four instruments on one platform. Designed for manufacturers of automotive, aircraft and other likesized gears, the 300GMSL offers a single, compact, reliable and easy-to operate inspection solution to apply the most desirable gear measurement and analysis methods for both R&D and production applications. An extremely versatile platform, the 300GMSL is capable of performing tactile probing to support traditional gear feature data collection on spur and helical gears, spiral and straight bevel gears up to 300mm in diameter. In addition, the platform supports noncontact, laser, full form scanning for a wide range of workpieces to support gear development efforts where large amounts of data need to be collected faster than possible with conventional tactile probing. Optional features include surface finish measurement and Barkhausen Noise Analysis; to further improve throughput while reducing cost of ownership and floor space requirements. The integration of advanced technology such as laser scanning expands the functionality and application range of this platform. The advanced laser scanning probe

MACHINE TOOLS WORLD NOVEMBER 2016

delivers faster data collection speeds than conventional probing methods with comparable accuracy; making the 300GMSL a perfect solution for research and development applications such as rapid prototyping and reverse engineering. The 300GMSL is also well suited for normal production operations requiring high-speed topography inspection as well as increased non-gear inspection capabilities and the ability to inspect soft, compliant materials such as plastic gears. The optional Advanced Operator Interface puts a number of powerful tools right at the operator’s fingertips including video telephony, note pad and voice mail messaging capability along with QR/bar code reading. The user-friendly, fully Windows® compatible GAMA™ application software suite provides users a highly intuitive interface with simple input

screens for programming workpiece data. About Gleason:

Gleason is a leader in the development, manufacture and sale of gear production machinery and related equipment and automation solutions. The Company’s products are used by customers in automotive, truck, aircraft, agriculture, mining, energy, construction, power tool and marine industries and by a diverse set of customers serving various industrial equipment markets. Gleason has manufacturing operations in the United States, Brazil, Germany, Switzerland, India, China and Japan, and has sales and service offices throughout North and South America, Europe and in the Asia-Pacific region. For more information, Website: www.gleason.com

COMPANY PROFILE

80 years of Blaser Swisslube: A Perspective “Serving comes before earning” - This is the customer-focused corporate value under which the Swiss lubricant manufacturer Blaser Swisslube is celebrating its 80th company anniversary. It all started back in 1936 with “Blaha-Glanz” - a shoe polish. Since then, the company has grown from a small regional business into a global player. In the company’s own Technology Centre, the focus is on research and development. This focus has resulted in a breakthrough being achieved in a current civil aviation project.

he first successful product made by the former Blaser+Co. AG was Blaha-Glanz, a water- repellent shoe polish that was sold on the surrounding farms. Willy Blaser laid the foundation for today’s company group in the crisis year 1936. As a 20-year-old who had been unable to find work in the painting trade he had trained in, he founded a one-man company in his parent’s house in Hasle-Rüegsau where he produced

MACHINE TOOLS WORLD NOVEMBER 2016

lubricants and chemical-technical products especially for agriculture. Perseverance was the order of the day due to the shortage of raw materials during the war years. The real upturn in the company’s fortunes began after the war when the customer base expanded to include besides farmers, mechanical

workshops, the construction industry, the wood and metal processing industries and the first industrial factories. “With the same pioneering spirit that was present when the company was founded, tireless work was done to continue to expand the company, to increase and modernise the manufacturing facilities, as well as to increase the level of research and development,” explains the grandson and current Managing Director, Marc Blaser.

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

INDIAN ENTERPRISE

AMERICAN RIGIDITY

ITALIAN INNOVATION

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

COMPANY PROFILE Step-by-step towards becoming a global player

Fast forward to 1974 when Peter Blaser, (Chairman of the Board of Directors since 2010), picked up the baton to become the second generation of the Blaser family to manage the company. As a trained mechanical engineer, he introduced and added metal processing in the company’s repertoire as well as establishing and expanding the sales network in Europe and further afield. Owing to the international orientation and ambitions of the company, the corporate name was also changed to Blaser Swisslube during this time. In 1981, Blaser Swisslube Inc. was founded in Goshen, New York. In 1995 and 1996, subsidiaries in Germany, the Czech Republic and Japan followed. Today, Blaser has its own subsidiaries and agents close to its customers in around 60 countries across the globe and employs a total of 600 employees - 300 of whom are employed in Switzerland. From metalworking fluid to Liquid Tool

The company continued unabated to develop its expertise in all things to do with metalworking fluids. This involved expanding and refining its research and development facilities to what, today,

MACHINE TOOLS WORLD NOVEMBER 2016

“The partner and we at Blaser Swisslube are very satisfied with the results achieved. Although improvements with respect to reduced cycle times were not the focus of these tests - we are ready to work with the partner to optimise these too” - Marc Blaser, Managing Director, Blaser Swisslube are the largest of its kind in the industry. With a surface area of around 3,500 m2, 70 chemists, microbiologists and laboratory technicians work on designing and developing coolants of the highest quality and, adopting true continuous improvement principles, analyse metalworking fluid samples from customers around the world. In order to be able to offer customers an effective added value when it comes to machining, the company inaugurated its very own

Technology Centre in 2009. Marc Blaser: “Our Technology Centre is truly stateof-the-art and enables us to carry out stringent tests on new metalworking products and system solutions. It also ensures that we are able to work in partnership with customers helping them improve their productivity, economic efficiencies and machining quality by identifying and developing metalworking fluid solutions that are tailored exactly to their needs, which we call a Liquid Tool. “The ability to work collaboratively and consultatively with customers is a key strength of ours, and the continued investment in our research and development facilities provides us with distinct technical (and competitive) advantages.” Doubling of the tool life

In a recent project, Blaser experts in the Technology Centre impressively optimised the tool life. A renowned partner filled the role of international supplier and manufactured vehicle parts from a high-strength titanium alloy. In the ultra-modern Technology Centre in Hasle-Rüegsau, a range of tests were started with the goal of optimising the tool life during pocket machining. The specialists at Blaser reproduced the partner’s machining environment and employed the same machining parameters and data using a DMG Mori DMU 65 mono block machining centre, and began comprehensive tests employing trochoidal milling strategies. The tests compared machining performance (specifically tool wear) when using a conventional metalworking fluid against an optimal metalworking fluid specifically adapted to the partner’s needs. The series of width of wear tests were conducted up to 0.30 mm. The results were excellent. Using the optimally adapted coolant from Blaser Swisslube, 11 instead of just five pockets could be milled until the wear on the tool forced the processing to be stopped. The result achieved was confirmed in various series of tests, and corresponds to a doubling of the tool life.

A Masterpiece in Precision, Performance and Reliability SIGMA-7 SERVO DRIVE SERIES

SMALLER MOTORS - HIGHER EFFICIENCY

Power range from 50 W to 15 kW

100% compatible with Sigma-5, up to 20% more compact

Now 16 times higher resolution: 24-bit encoder

Less inherent heating

SAFE OPERATION IN SMALL HOUSING Reliable tuning-less operation, even if dynamic load changes

Integrated functional safety: SIL 3, PL-e, Category 3, Stop Category 0 (Safe Torque Off)

Speed regulator bandwidth: 3.1 kHz

Additional safety features: Stop Category 1and 2, Safely Limited Speed

Vibration-free operation thanks to new filtering functions at high-frequency vibrations

Integrated EtherCAT and Mechatrolink

Force ripple compensation for better tracking

YASKAWA India Pvt. Ltd.

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

COMPANY PROFILE

Electrotherm (India) - E&P Division:

A customer centric leader for Heat Treatment. Customer centricity

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

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

MACHINE TOOLS WORLD NOVEMBER 2016

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

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

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

Process monitoring without the bottlenecks

at: See us e ngalor 17, Ba 0 2 3 X 2 E 1 B IMT , stand Hall 3A

Reduce bottlenecks and scrap with quick and easy process monitoring using the Renishaw Equator™ Join hundreds of manufacturers worldwide who have increased flexibility and inspection capacity with the low cost Equator comparator. • Low cost increase of inspection capacity • Flexibility to inspect multiple parts • Insensitivity to workshop temperature change • Easy integration into automated cells • Low cost of ownership - no periodic calibration or maintenance Process Monitor software for the Renishaw Equator allows users to view an instant status monitor bar chart of last measured features, historical results for the feature selected, and three status displays allowing management of re-mastering. The limit for re-mastering can be set on the basis of temperature drift, time since last master, or by number of parts measured.

For more information visit www.renishaw.com/equator

Renishaw India [Pune] S.No.282, Hissa No.3, Raisoni Industrial Estate, Village Mann, Tal:Mulshi, Pune 411057 T +91 20 6674 6200 F +91 20 6674 6211 E india@renishaw.com

www.renishaw.com

Renishaw Equator PM ad India A4 1116.indd 1

02/11/2016 16:02:23

COMPANY PROFILE

Dynaspede thrives in

Mechatronics D

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 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 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.

Panel Building

Machine Building

Tool Room

MACHINE TOOLS WORLD NOVEMBER 2016

- P.K. Balasubbramaniian

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.

HEIDENHAIN OPTICS & ELECTRONICS INDIA PRIVATE LIMITED

Angle Encoders

Linear Encoders

Chennai 600031, India

Contouring Controls

phone +91 44 3023 4000

Position Displays

Length Gauges

www.heidenhain.in

Rotary Encoders

COMPANY PROFILE

Shavo Technologies offers

high-tech tailor made solutions

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

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

Applied gas delivery systems

MACHINE TOOLS WORLD NOVEMBER 2016

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

COMPANY PROFILE

High pressure regulators

Gas specializes in design and manufacture of air moving products including vacuum pumps, compressors, air motors, gear motors, vacuum generators and regenerative blowers. “As a matter of fact, our journey of working with high technology industries started with Gast which today remains one of the world leaders in air motors and fractional horse pumps,” reveals Mr. Shah. Meech’s forte is industrial electrostatics. With a standing of over 40 years, Meech has developed a wide range of products like ionizing bars, handheld ionizing air curtains, etc. for effective static neutralization and dust removal. With the experience gained from more than 200 successful web cleaning installations, Meech can offer both non-contact and contact web cleaning systems. ITT Enidine is again a world leader in energy absorption and vibration isolation products, providing solutions to a wide range of industrial markets. Electrostatics for effective static neutralization

voltaic or solar cells, precise fluid control is a must. HORIBA is the established world leader in offering a full line-up of gas, liquid, and vapor delivery products. Applied Energy System Inc. is one of the world leaders in the field of ultra high purity gas delivery systems like gas cabinets and panel for solar, semiconductor, nano technology and other high purity industries.

MACHINE TOOLS WORLD NOVEMBER 2016

High quality instrumentation valves

ITT Corporation is a high-technology engineering and manufacturing company operating on all seven continents in three vital markets viz. water & fluid management, global defense & security, and motion & flow control. Shavo feels fortunate to work with some of India’s top companies and institutions like Reliance, Tata’s,, Biocon, GE, Department of Space, Ministry of Defense and many more. It has in excess of 1000 live accounts. The company has a full service capability at its Pune office and is in the process of building a world-class service center in its Bangalore factory. “Our service support is the key pillar of the value we provide,” says Mr. Shah. – P.K. Balasubbramaniian

For more information Web: www.shavogroup.com

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

w w w . m a r p o s s . c o m

EVENT PROFILE

Seco’s Global Aerospace Summit 2016

eco works closely with aerospace manufacturers to create and provide solutions that increase productivity and bolster profitability. We offer a globally networked resource dedicated to solving your challenges and supporting your operations. Through cooperative partnerships with aerospace manufacturers and entities around the world, we monitor trends, identify challenges and develop solutions that overcome the industry’s most demanding applications. Aerospace Industry has been growing by leaps and bound in India. To partner aerospace customers in their challenges, Seco organised “Global Aerospace summit 2016” on 21st and 22nd September at Bangalore. Event Highlight:

• Machining of trending materials in Aerospace: The Aerospace Industry faces many challenges, with a primary focus on reducing weight & increasing fuel efficiency. Today, metallurgists, chemists and plastics engineers work constantly to develop the materials of the future. • Latest machining methods: Thin

MACHINE TOOLS WORLD NOVEMBER 2016

wall machining, Dynamic milling: Each process and material demands a unique machining technique. Thin wall machining and dynamic millings are the major trends in machining methods. • Component solutions: Engine Component, Landing gear Component, Airframe Components: Seco’s Component Engineered Tooling (CET) offers a comprehensive approach to process design and optimization that ensures you achieve the highest levels of productivity, efficiency and cost effectiveness. • Seco’s Engineering Services: When striving to perfect a anufacturing

process, having the right tooling partner is critical. Seco provides an extensive unique engineering service, providing full applications support and the necessary expertise to understand your productivity requirement and deliver a winning solution. • Seco Global Competence Centres: Seco’s Technical Centres are used to engage with our existing and potential customers to facilitate the transfer of expertise and knowledge, for product introduction, industry specific events and engineer customer specific solutions. Event Special:

• Live demonstration on latest machining trends in collaboration with DMG MORI • Power hours – Interaction with Seco’s Global Aerospace Expert With active participation of major aerospace customers, this event really turned into collaborative platform to share knowledge, reciprocate experiences and discuss solutions for challenges in Aerospace Industry.

INTERFACE

Ador impresses visitors at India Essen Ador Welding Ltd. has been synonymous with welding in India for over 64 years. A pioneer and leader in welding industry, Ador has progressively extended its knowledge and expertise to cater to the existing and perceived user needs at home as well as in the Middle East, Africa and South-East Asia. The company offers a comprehensive range of welding consumables, equipment, services and automation solutions to ensure excellence in welding and fabrication in every key sector. P.K. Balasubbramaniian speaks to managing director Satish Bhat to ascertain the innovations being showcased by the company and its initiatives to maintain its leadership position. Excerpts: Mr. Satish Bhat, Managing Director, Ador Welding Ltd. Q. Whatâ&#x20AC;&#x2122;s the show you put up at India Essen Welding & Cutting International Trade Fair 2016 staged at BEC Mumbai during 5-7 October? Well, we had an impressive stall in a vantage position at IEW&C 2016 where we displayed some of our first-of-theirkind innovative products. Our Pulse-MIG Equipment drew the attention of everyone. This is Synergic Pulsed MIG/MAG/ FCAW Welder with intelligent 3-in-1 control, based on material type, material thickness and joint type requirement. Pulse MIG is a revolutionary product developed by us indigenously as a result of our rigorous R & D. It is ideal for both thin as well as thick sheet metal. It is a boon to major fabricators who can now weld sheet metals as thin as 0.6 mm â&#x20AC;&#x201C; 0.8 mm without affecting the parent metal. The high pulse current does no harm to the heat affected zone. The equipment is an import substitute costing 20% less compared to the imported one. The machine can be used with advantage in wagon

MACHINE TOOLS WORLD NOVEMBER 2016

manufacture. It would enhance productivity and quality in the fabrication of railcoaches. Fabricators like ICF Perambur, TEXMACO and Jessops would find this equipment an imperative. Our estimation is that we would be able to sell about 200-250 machines per annum.

Q. What else was new in your stall? Our Welding Fume Extractor was yet another cynosure. In welding, fumes are inevitable. But they need not come in your way, affecting your health or productivity. Our Welding Fume Extractor is designed to contain or minimize electrical and electronics pollution. The equipment is inverter-based. It sucks the fume from the workplace. The filter cleans the air from different kinds of dry dust, welding aerosols and other dry contaminants from most industrial processes. The Welding Fume Extractor comes in different sizes. The smallest one is portable and can be taken wherever welding is

INTERFACE going on. The biggest one weighs 100 kg and comes with a 3 metre arm length. We also supply integrated systems for fume extraction. At a time, the Extractor can suck and ventilate fumes from 10 welding booths. Evacuation of fumes keeps the work environment clean and productive.

Q. What measures do you take to reduce costs and enhance profitability? We do value engineering and value analysis to see how we can reduce the production and the end product cost without compromising on quality and functionality of the product. In doing so, we look at various options in terms of design, supplier, material, etc. We explore all permutations and combinations to ensure lean manufacturing so that the resultant savings can be passed on to the customer.

We offer complete range of products for a given application. When it comes to consumables, we offer nickel-chromium based products for better and ease of maintenance. In order to enhance operational efficiency, we use low cost automation. We also reuse energy wherever possible so as to optimize energy cost inputs. These are some of the measures.

Q. Are your products futuristic? Yes they are. We have a complete range of innovative products in place. With Pulsed-MIG, there is no technology gap. If you take consumables, the range is comprehensive. Wherever needed, we recommend Automation solutions in order to reduce the customerâ&#x20AC;&#x2122;s process time. At Ador, R & D is continual and ongoing. We are even looking at automating gouging with a new range of machines. The pressure vessel industry would benefit from this immensely.

Q. How do you propose to maintain your leadership position?

Ador stall at India Essen Welding & Cutting Fair 2016

MACHINE TOOLS WORLD NOVEMBER 2016

First and foremost, we are proactive and satisfy the customer needs by offering him a complete range of contemporary products. On the other hand, we keep on innovating to come up with breakthrough products and solutions. We also improve our efficiency and response time and offer good after-sales service. These are notwithstanding the fact that we keep on improving our existing products and performance to become more agile & cost-competitive. And it goes without saying that we are totally technology driven.

TECH TRENDS

Accusharp Gun-Drills Make Deep-Hole drilling more efficient and easy for you.

eep-Hole Drill, as initially invented for ‘Gun-Drilling’ application in Europe during the Second World War; and since then is popular as ‘GunDrill’. However, over last 75 years, its applications are extended in Auto and other engineering metal cutting industries for Deep Hole Drilling. Still these Deep-Hole Drills are yet popularly called as ‘Gun-Drills’, even if used for other applications. Accusharp Cutting Tools have entered into this new segment of Round Tools for Deep-Hole Drilling applications. The applications are for deep holes drilling on Crankshaft, Engine blocks, Turbo Blades, Paper Rollers, Machine Tools, Fixturing, etc. Standard geometry for Gun-Drill has been shown herewith. However, it may change according to its applications for different work materials, and machining parameters. Moreover, any change in the cutting edge geometry will have effect on bore surface finish, geometrical accuracy, drill centring, chip shape, chip removal, process reliability, and useful life of the drill, etc.

Our standard grinding geometry can take care virtually of all drilling operations successfully. However, for any special working conditions, like deep drilling long chipping material work piece or material that is difficult to machine, we design and manufacture Gun-Drills with special geometries, accordingly. Our present range of Gun-Drills is

of Diameters between 4 and 30 mm., having length up to 1000 mm.

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

Trouble shooting guide: Problem:

Probable Cause:

Probable Solutions:

Premature drill point wear

Machine vibrations, Loose clamping of the work piece.

1) Check the guide bushes. 2) Improve rigidity of the clamping fixture.

Crater wear

Improper guidance for the drill into the work piece

1) Check the guide hole diameter 2) Improve rigidity of the clamping fixture. 3) Work with reduced feed rate at the start.

Groove marks on the hole

Rubbing of the drill in the hole

1) Increase feed 2) Check filtration quality coolant quality 3) Stop spindle rotations before drill retraction

Hole entry dia. enlarged

Tool set up error

1) Check bushing, guide ways. 2) Improve work clamping more rigid.

Moreover, guidance from our technical experts would always be available for any critical problems other than the above common issues to resolve.

MACHINE TOOLS WORLD NOVEMBER 2016

TECH TRENDS

Sparkonix shaping mould making in India since four decades

ver two-thirds of the several thousand mould manufacturers in India are relatively small players (< 30 employees) spread across the length of the country. The larger, organised manufactures consist of less than a third of the total manufacturers, and are located in large industrial clusters across the country. Sparkonix’s Electric Discharge Machines (EDMs) have been serving the distinct demands of both the small as well as the

larger mould manufacturers in India, for over four decades. A Journey of innovations From pioneering the EDM technology in Indian market to being one of the few companies, globally, to develop customised EDMs, Sparkonix’s journey over the last four decades is a list of numerous innovations. The innovations, focused on helping manufacturers to compete globally, range from introducing advanced controllers with high speed machining, accurate performance, lower cycle times to conducting machining with minimal monitoring. The manufacturers have benefited in multiple ways from lower labor costs, higher productivity, dependable performance to fastest ROI. A wide range of EDMs, that suit everyone’s needs Sparkonix offers over 20+ standard EDMs and a wide range of customised EDMs to suit the wide range of demands from small and large manufacturers. The range of products includes ZNC as well as Manual EDMs, EDM Drills and Metal Arc Disintegrators catering to various sizes of moulds and machining requirements. With a wide product portfolio,

MACHINE TOOLS WORLD NOVEMBER 2016

characterised by several unique features, Sparkonix’s EDMs are a proffered choice for all types of customers in meeting their specific mould manufacturing needs. Installations across 110+ Industrial Clusters Starting from a job-shop in by-lanes of Aligarh in the North or Coimbatore in South to a large multi-national located in sprawling industrial outskirts of Ahemdabad in the West, Sparkonix EDMs have installations across every key industrial cluster in India. Over the last forty years, Sparkonix’s EDMs have touched every part of India, with the indigenous technology in EDM playing a key role in driving the growth of mould manufacturers. For more information, Website: www.sparkonix.com

Sparkonix is launching new, advanced EDM Drills at IMTEX 2017. Visit Hall No. 1A, Stall No. B103 to see the technology in action.

Taming power quality is now child's play

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

Intelligent Microprocessor-based, High Efficiency, Energy Savers specially designed for CNC machines

Our equipment are approved by major OEMs and exported (up to 2000 KVA) to countries in Europe, Middle East, Africa

Our Allied Products: n

Active Harmonic Filters K-Rated Transformers Light Energy Management Systems

KVAR MAX - Real Time Power Factor System

n n

and Asia Pacific. So leave power quality and energy management to the experts â&#x20AC;&#x201C; Unity Controls. With our nationwide network we are only a phone call away!

405, Sapphire Arcade, 42 M.G. Road, Ghatkopar (E), Mumbai 400 077, India

The power quality & energy experts

+91-22-2501 3832 / 33 sales@unitycontrols.in www.unitycontrols.in

Ahmedabad l Bangalore l Chennai l Delhi l Gurgaon l Hardwar Indore l Jalandhar l Jamshedpur l Kolkata l Kanpur l Mumbai l Pune l Rajkot

l l

vijayshreyaarts@gmail.com

UNITY CONTROLS PVT. LTD

TECH TRENDS

Minimised cabling & assembly costs at the field level The extensive IP 67-rated I/O range available for EtherCAT P minimises wiring requirements and facilitates the highly flexible, decentralised data acquisition of all I/O signals in a machine or system. It is based on the one-cable solution EtherCAT P, which integrates proven EtherCAT technology with a power supply for connected devices.

ith EtherCAT P, Beckhoff combines ultra-fast EtherCAT communication and power supply (2 x 24 V DC/3A) in a standard 4-wire Ethernet cable. It enables direct power supply for both EtherCAT P slaves and the connected sensors and actuators in such a way that separate power lines can be eliminated, considerably simplifying system cabling. This makes EtherCAT P the ideal sensor, actuator and measurement bus, providing advantages both for connecting small remote I/O stations in terminal boxes and for decentralised I/O components located throughout the actual process. EtherCAT P Box modules for all data acquisition requirements A full range of EtherCAT P system and I/O components in protection class IP 67 is currently available for the 24 V I/O level. For connecting sensors and actuators, users can integrate any of the wide range of well-established EP Box modules from Beckhoff in the new EPP versions for EtherCAT P. These include a variety of 4, 8 and 16-channel digital input box modules; 4, 8, 16 and 24-channel digital output modules; numerous 4, 8 and 16-channel IP 67 I/Os with combined digital inputs/ outputs; as well as RS232 and RS422/

MACHINE TOOLS WORLD NOVEMBER 2016

Three examples of the wide range of EtherCAT P I/O products with IP 67 protection: EtherCAT junction, digital input box (8-channel) and analog input box (4-channel) for ±10V/0…20 mA. RS485 serial interfaces. There are also new EPP Box modules for analog input and output quantities, such as ±10V/0...20 mA, differential/absolute pressures, and data from resistance sensors, thermocouples & incremental encoders. Free and flexible choice of topology, as enabled by EtherCAT, is equally possible with EtherCAT P. The following IP 67 infrastructure components are available to set up the required network architecture in the field: • EPP1111 EtherCAT P Box with ID switch • EPP1322 EtherCAT P junction with power feed-in and junctions with or without power refresh (EPP1332/ EPP1342) • EPP9001 EtherCAT P/EtherCAT connector with power transmission • EPP9022 EtherCAT P Box for diagnosing Us (system and sensor supply) & Up (peripheral voltage for actuators)

Significant benefits for machine engineering applications EtherCAT P – which is now fully supported by the EtherCAT Technology Group (ETG) – reduces material costs for machinery, time and cost of installation as well as the frequency of errors in the installation process. In the machine itself it also minimises the installation space required for drag chains, cable trays and control cabinets. The entire automation process benefits from the reduced size of sensors or actuators, made possible by the new EtherCAT P cables. Overall, equipment manufacturers now have considerably more freedom when designing their machinery & more leverage to reduce machine footprint.

Email: info@beckhoff.co.in Website: www.beckhoff.co.in

TECH TRENDS

Open & flexible CNC architecture with TwinCAT 3 By Hitesh Prajapati & Pavan Sadarjoshi

The open TwinCAT 3 architecture offers users the option to choose the language that is best suited for the task at hand. Modules written in different languages can communicate in realtime via the TcCOM interface.

The open TwinCAT 3 software architecture offers users the option to use C/C++ or Matlab®/ Simulink® as programming languages for real-time applications, in addition to IEC 61131-3. In other words, users can choose the language(s) best suited for the task at hand. Modules written in different languages can interact in real-time via the TcCOM interface. Microsoft Visual Studio® provides a platform for the configuration, programming and diagnostics of all TwinCAT modules.

ith PC-based control Beckhoff offers an open and scalable hardware and software platform for scalable CNC applications. It can be adapted precisely to each application and degree of complexity. TwinCAT automation software forms the universal platform for the control of PLC, motion and CNC functionalities, visualisation, safety technology, measurement technology, Condition Monitoring

MACHINE TOOLS WORLD NOVEMBER 2016

and robotics. TwinCAT NC I/CNC covers the entire range of classic CNC path controllers up to the high-end system for complex motion and kinetic requirements. TwinCAT NC PTP makes extensive motion functions available for positioning tasks. The TwinCAT Kinematic Transformation library enables the mapping of robot kinematic systems in software for seamless and cost-effective integration into the control system. With the modular runtime concept,

TwinCAT 3 offers the basis to further open up CNC functionality. This applies to both the NC I and CNC packages. “Modular runtime” means that different modules can interact in real-time; this interaction can be realized through cyclic or acyclic data exchange. Cyclic data exchange is configured through mappings. Between two runtime modules, input and output variables are ‘linked’ with each other and cyclically exchanged according to the task cycle.

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Like in TwinCAT 2, acyclic communication, e.g. for parameterization and configuration, is implemented through the Automation Device Specification (ADS) protocol. In contrast to TwinCAT 2, the TwinCAT 3 system offers the option to call methods from one module directly in another module via a defined route. Naturally, this event-based direct communication can only work reliably if the rules are defined in a corresponding standard. This standard is the TwinCAT Component Object Model (TcCOM), developed by Beckhoff. In many parts it is based on ideas from the COM that is also used in the Windows system – but obviously adapted to application in a real-time context. For CNC applications, TcCOM is used to offer users the option to supplement or replace certain CNC components with their own code segments. With C/ C++ and Matlab®/Simulink®, TwinCAT 3 provides further languages that are particularly suitable for expressing complex algorithms in a simple manner. Intellectual property protection through user-specific code implementation With TwinCAT NC I and CNC, Beckhoff offers an extensive range of useful functions. To integrate user-specific code segments, users can replace subfunctions with their own algorithms at defined interfaces. The sub-functions must follow the TcCOM rules and also implement specified interfaces. The code itself is usually written in C/C++. In principle, algorithms can also be created in Matlab®/Simulink®. Convenient debugging in Microsoft Visual Studio® simplifies implementation and testing. Programmers thus have a versatile development environment with several languages and user-friendly debugging tools available. Advanced software engineering is also offered in Visual Studio® which can be used effectively

for automation applications, such as version control with a source code control tool. For example, users can implement transformations that are not available in the NC I or CNC packages. This provides a big advantage in that customers can retain full control of their intellectual property. Modifications and adaptations can be completed quickly and conveniently. Another area of application is overwriting of controllers and pilot-controls. For certain machine types it can make sense to adapt such configurations, in order to achieve higher accuracy and higher performance in special cases, for which interfaces are also defined. User-generated software can be safely linked with the machine via industrial hardware dongles (Beckhoff licence key or USB sticks). The configuration

takes place in the TwinCAT engineering environment. The TwinCAT runtime validates the licenses in real-time, which means that the software can be protected effectively. TwinCAT 3 provides with Visual Studio® an enhanced engineering tool for the rapid and convenient development and testing of algorithms. The versatile runtime concept enables custom modules to be added safely and flexibly based on the TcCOM rules. As a result, users have a range of convenient options for implementing and protecting their in-house expertise. For more information,

Email: info@beckhoff.co.in Website: www.beckhoff.co.in

The PC- and EtherCAT-based CNC solution from Beckhoff integrates all machine functions into one hardware and software platform. This powerful system is characterized by high performance, openness and flexibility. The universal TwinCAT automation software and the fast EtherCAT fieldbus system, Industrial PCs, Control Panels, I/O components and drive technology combine to offer a complete solution for CNC machining. This way, the productivity of manufacturing facilities can be increased, the controller design becomes ‘leaner’ and the costs for hardware, engineering, commissioning and maintenance are lowered considerably. The Beckhoff CNC platform is suitable for all industries, processing technologies and machine kinematics: from compact dental machining centers and woodworking machines to complex plasma cutting and welding machines. The CNC solution from Beckhoff is scalable and modular, meeting the exact requirements of modular and multifunctional machine concepts.

NOVEMBER 2016

MACHINE TOOLS WORLD

TECH TRENDS

MICO Generators from eldec

Full hardness and short processes for the tool and mold making industry

ool and mold making professionals routinely face many challenges unique to their industry. .In order to ensure the stability of the tools produced, very hard grades of steel are required, however, specialists must also be able to precisely shape this material for use in creating demanding components for things such as car body manufacturing. In other words, quality in the toolmaking process has an enormous impact on quality in automobile manufacturing. It is clear that under these conditions the final surface hardness of the tools is essential, and additional hardening of the cutting edges is usually necessary. The production planners at Werkzeugbau Laichingen, in Ulm, Germany, have been relying on technology from eldec: Their cutting edges are hardened by mobile and robust MICO generators. This flexible technology significantly decreases and simplifies the production process. Experts often describe toolmaking as a link between development and production with a considerable impact on the industrial value added. This is why the industry is considered a trendsetter for the continued development of production technologies ¬and is always in search of new solutions to improve workflows and quality. Cutting-edge hardening is no exception. This process hardens the features of the tool that later have to

MACHINE TOOLS WORLD NOVEMBER 2016

bear the greatest load in the punching or embossing machine. The stability of the cutting edge is decisive in determining the length of the tool life. Benefits of Induction Hardening Toolmakers generally use edge-layer hardening where the outermost layer of the cutting edge is heated to about 800 or 900 degrees Celsius (1,472-1,652 degrees Fahrenheit), depending on the material. The “quenching”, where the real transformation takes place, then happens by natural cooling in the ambient air. As a result, the surface of the edge is harder and more resilient to wear (toolmaking typically requires a hardness of between 54 and 56 HRC), while the core of the material retains its toughness. Various methods are

available to achieve these results. Toolmakers primarily use either flame hardening, the very expensive laser hardening or, alternatively, induction hardening. Why is that? “For starters, all these methods have flexible applications. Even large, bulky components with complex geometries can be produced manually or automatically when using lasers”, explains Stefan Tzschupke, Head of Business Development Generators at eldec. “However, induction hardening offers significant advantages in terms of processing quality and time, as well as safety and cost. Our technology is becoming increasingly important for a growing number of toolmakers.” A quick look at the characteristics of the eldec procedure confirms this assessment.

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The cutting edge is heated by induction. This way, the tool reaches the required temperature much quicker, because the heat is delivered directly to the volume underneath the surface. With flame or laser hardening, only the surface itself is heated at first. eldec energy sources also make it possible to precisely control power, current, or temperature, enabling users to respond optimally to special requirements as well as the ambient conditions of the process. As a result, the hardening pattern is very uniform. “Another benefit is that the process generates no toxic or explosive gases that might contaminate the workplace”, adds Tzschupke. “Finally, its good energy efficiency makes our technology much more environmentally friendly than flame hardening.” Significant Reduction in Cycle Time The company Werkzeugbau Laichingen is a new eldec customer that relies on the advantages of induction hardening. At its locations in Laichingen and Leipzig, the German company has comprehensive knowledge and experience ranging from tool design to complete production processes and comprehensive services for pressing and shaping tools. The specialists also provide the in-house presses for the start and phase-out of series production. “We are able to respond to customer needs on extremely short notice, as missing or incomplete tools can cost

a lot of money. We are continuously working to improve and further shorten our production processes”, says Gottlieb Schwertfeger, who is in charge of purchasing and quality management at Werkzeugbau Laichingen. “In pursuit of this goal, we recently changed the processes for cutting-edge hardening, which had been taking too much time overall.” In the past, tools were mostly treated on site by flame hardening. The alternative was laser hardening at external contractors – an additional logistical effort that has now become unnecessary thanks to the fast induction hardening process. Since the fall of last year, the company has used a MICO generator from eldec as the energy source. This flexible energy container is perfect for toolmakers. A generator, cooling system, and hose bundle are packed into a compact housing that is available with casters if required. Users are able to easily move the machine wherever it is needed on the factory floor and an intuitive user interface with a touchscreen simplifies the configuration. The processes at eldec also ensure that MICO generators have high stability and a long service life as they are developed for challenging manufacturing applications. Before shipping, they undergo comprehensive testing and are held to

extremely high quality standards. Developing In-House Know-How “We are more than satisfied with the technology”, says Gottlieb Schwertfeger of Werkzeugbau Laichingen. “We’re already saving a lot of money. While we are improving our processes, we’re also simultaneously developing new knowhow around the technology which will later directly benefit our customers. For example, we are optimizing the hardening and subsequent annealing processes to improve the fit and configuration of the device for the relevant active part of the tool. The quality and efficiency of the process are continuously being perfected.” The technology is being used in a wide variety of punching, bending, and forming tools. It creates a uniform hardness distribution on many straight and arched surfaces and radii. The flexibility of the applied technology is very important. For eldec, the above application example has something of a model function, since experts are seeing a lot of market potential for their flexible generators, as Tzschupke confirms. “Our new MICO series is providing a major solution for the energy source and cooling system. It covers a wide range of services and can be fitted with many different tools, which gives toolmakers a lot of options for implementing perfect and efficient hardening processes. We want to bring these strengths to the market even more than before in the coming years.

NOVEMBER 2016

MACHINE TOOLS WORLD

TECH TRENDS Thanks to its stability, the KOMET DIHART® hi.max monoblock reaming tool is suitable for universal use with high feed rates and cutting speeds and many different materials.

Now even easier to use: The indexable inserts with three cutting edges can be fitted to the new KOMET DIHART® Freemax tool in any order. Pictures: KOMET GROUP

KOMET W Easy-to-use reaming tools ®

At AMB 2016, the KOMET GROUP presented a variety of new product solutions under the trade fair slogan “THE CUTTING EDGE – Total Productivity Solutions”. The highlights include newly developed reaming tools such as KOMET DIHART® Freemax, hi.max and Fullmax Champions, which impress with their increased ease of use and improved performance. 72

MACHINE TOOLS WORLD NOVEMBER 2016

ith the KOMET DIHART® Freemax, the KOMET GROUP has successfully developed a new high-precision indexable insert reaming tool that is even easier to operate than the current versions on offer. In previous tools, each insert had to be assigned a specific insert seat (identified by the letters A, B, C, etc.) due to the requirement for concentricity, but this positioning has now become redundant in the new concept. Users can fit the precision-ground indexable inserts with three cutting edges into the new KOMET® DIHART® Freemax tool in any order, making it virtually impossible to equip the tool incorrectly. The new KOMET DIHART® hi.max monoblock reaming tool is just as easy to use and can be used as a universal tool for high feed rates and cutting speeds due to its stability. It is available in a coated version and an uncoated version for carbide and cermet cutting materials and lends itself to use with many different materials. The diameter is particularly easy to measure thanks to the fact that the cutting edges are arranged opposite one another in pairs. The uneven spacing of the cutting edges in particular ensures that the most stringent requirements for concentricity of the drilled hole are met. The monoblock construction

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In addition to the versatile KOMET DIHART® Fullmax universal reamer, what are referred to as “Champions” are now also available, and these are specially adapted for use with particular materials.

is synonymous with high levels of stability and process capability. KOMET® is also presenting a new product for solid carbide reaming: In addition to the versatile KOMET DIHART® Fullmax universal reamer, which is available ex stock in the main dimensions and with a tolerance of H7 as well as in dimensions of 1/100 mm, what are referred to as “Champions” are now also available. They are characterised by a geometry and coating that are both optimised, as a result of which they provide a performance that is up to 30% greater in mass production. For example, the KOMET DIHART® Fullmax K, which is designed for machining cast iron, has two more cutting edges than the universal reamer for identical diameter ranges and therefore ensures even higher productivity. Owing to its extremely smooth coating and newly developed chip breaker geometry, the KOMET DIHART® Fullmax N is suitable for machining aluminium, whereas it has not yet been possible for the universal variant to be used for this purpose. The KOMET DIHART® Fullmax H is designed for hard machining. Optimised cutting edge preparation and an optimal combination of geometry and coating achieve an excellent surface finish and a long tool life in hardened materials up to 62.

NOVEMBER 2016

MACHINE TOOLS WORLD

TECH TRENDS

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

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

MACHINE TOOLS WORLD NOVEMBER 2016

Mr. Rushil Shah, Managing Director, Shavo Technologies Pvt. Ltd. source, such as a cylinder, tube trailer, or hydril. When our source gas comes from a compressor, or liquid source such as a dewar, the inlet pressure is fairly stable, and the effect of the decaying inlet characteristic on set point is negligible. How It Works To see how decaying inlet works, let’s consider a few Tescom regulators for the same application. Parameters: Our application is a compressed gas that is packaged at 3500 PSIG. Our process requires a 200 PSIG set point. Scenario A: We’ll look at the BB - 1, which is rated for 3500 PSIG max inlet pressure, and has a PSIG/ 100 PSIG decaying inlet

characteristic. Assuming that we start with full inlet pressure of 3500 PSIG, and that the source pressure will decay to 500 PSIG before it is either changed out or recharged, the net change on the inlet of the regulator is 3000 PSIG. If the regulator is initially set for an outlet pressure of 200 PSIG with 3500 PSIG on the inlet, then the outlet pressure will rise by 210 PSIG to 410 PSIG. 3000 PSIG change in inlet pressure ÷ 100 PSIG = Factor of 30; Factor of 30 x 7 PSIG decaying inlet characteristic = 210 PSIG increase. Scenario B: The 44 - 2200 and 44 – 5200 have much lower decaying inlet characteristics (1.5 PSIG/100 PSIG). Using the same operating conditions in the previous example, we find that these regulators will see a pressure rise of 45 PSIG on the outlet, from 200 PSIG to 245 PSIG. Clearly, we get better outlet pressure stability with these regulators. Scenario C: To further reduce the decaying inlet effect, we should consider taking the pressure reduction in two steps, or stages. We typically use a twostage regulator like the 44 – 3400 to do this. The 44 -3400 is composed of two 44 – 2200 regulators

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built into the same body and internally connected in series with one another. The decaying inlet characteristic of the 44 – 2200 is 1.5PSIG/100 PSIG. The first stage is preset at a nominal pressure of, say 500 PSIG. The second stage is adjusted to our original 200 PSIG set point. When the source pressure decays from 3500 to 500PSIG, the first stage sees a net decrease of 3000 PSIG on its inlet. The outlet pressure of the first stage will increase by 30PSIG, to 530PSIG. The second stage now sees a net increase of 30 PSIG on its inlet. The outlet of the second stage will go down by. 45PSIG (.3x1.5 decaying inlet characteristic =.45PSIG). To anyone reading a typical pressure gauge on the downstream side of the two-stage regulator, the decaying inlet characteristic is transparent. Controlling decaying inlet characteristic Two-stage pressure regulators are frequently employed as cylinder regulators for packaged specialty gases. The flows are typically lo, and the two-stage reduction allows the operator to provide stable delivery pressures

to the process. There are times when a single - stage regulator is used on the cylinder, which feeds a header in a lab or process facility. Points of use regulators are installed along the header, permitting individual users to adjust their pressures accordingly. The use of a single stage source regulator, along with point-of-use regulators, provides the two-stage reduction necessary for controlling decaying inlet characteristic. For higher flow applications, Tescom offers regulators with balanced main valves, like the 44 - 1300. The 44-1300 is so highly balanced that its decaying inlet characteristic is a very low. 1PSIG/100PSIG with a 0 – 300 PSIG control pressure. For a 3000 PSIG reduction on its inlet, the 44 – 1300 would yield a 3PSIG increase on its outlet, nearly transparent to anyone working with this regulator. The 44-1300 is often used as a tube-trailer regulator because of its high flow, and extremely low decaying inlet characteristic. These qualities allow users to employ only one regulator to provide the required working pressure for their process. Mistaken Identity Many times, unknowing regulator users observe the decaying inlet characteristic and mistake it for a leaky regulator. In the non-flowing condition, the user observes that the set point has climbed above the original set point, and believes the regulator is creeping. One quick method to confirm that the regulator is not creeping is to observe the gauge reading for a short period of time. If the pressure has stabilized at a few pounds above the original set point, then this is

probably decaying inlet. If the pressure is slowly climbing, and not stabilizing, then the regulator seat is contaminated, and the regulator must be removed for servicing. By confirming that the source pressure is a compressed source such as a cylinder, you can quickly correlate the drop in inlet pressure to the increase in set point. Sizing a regulator There are several reasons to consider the decaying inlet characteristic when evaluating regulator first and foremost, can the system handle the increase in outlet pressure? What if the outlet pressure decays to a point where a relief valve triggers, or rupture disk ruptures, for example? Second, can the process itself tolerate the pressure swing involved? In our BB-1 example mentioned earlier, could the process tolerate a 210PSIG increase on the set point? Are gauges another instrumentation downstream of the regulator sized to handle this increase in pressure? Our responsibility as applications specialists is to consider all possibilities when selecting a regulator for our customer’s application. When we take a few minutes to teach our customer about the nuances of pressure regulators, the customer is grateful, and looks to us as regulator experts, ensuring that we’ll be the first company contacted for future applications. Furthermore, by taking into account the decaying inlet characteristic when you size a regulator, you can avoid any surprises and unhappy customers that would otherwise result when the regulator is placed into service. If you need help with the decaying inlet characteristic of a particular regulator, please call us and we’ll provide you with this information.

For more information Web: www.shavogroup.com

NOVEMBER 2016

MACHINE TOOLS WORLD

TECH TRENDS

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

“

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

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

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

MACHINE TOOLS WORLD NOVEMBER 2016

Turning and milling in a single setup: the TNC 640 alternates between machining modes as desired according to the program operator to identify missing information or inconsistencies in the program prior to machining, and without any risks to workpieces, tools or machines. It displays the workpiece at random viewing angles and simulates both milling and turning operations in a single view. Not only cuboids are displayed but also cylindrical forms such as cylinders, tubes and rotationally symmetric blanks. During simulation, several new view options expose a precise and freely selectable view of details. The graphic simulation is so detailed that the machine operator is able to identify undesired machining effects from NC programs, such as substandard surfaces, at an early stage. With maximum 3-D simulation resolution, the control can also display the block end points with corresponding block numbers in the display of tool motion as a 3-D line graphic. With externally created NC programs generated with CAM systems this facilitates the analysis of point distribution and pre-evaluation of the expected surface. The operator can choose to view only the workpiece, only the tool paths or both simultaneously. Views also enable display of the original workpiece blank dimensions as a frame with highlighted

main axes, or with the workpiece edges as lines for improved spatial perception. The “transparent workpiece” view option also enables a view of inside machining, even with rotationally symmetric workpieces. Color highlighting of the workpiece with a new color used for each new tool helps the operator to identify individual work steps and makes it easier to assign the tools used. The operator can also display the tools either completely or transparently and of course hide these at any time. Several advantages are provided for the operator by 3-D simulation on the TNC control. For example, he can rapidly and simply run through machining programs created on the machine. But simulations on the control are also highly useful from programs he adopts from CAD/CAM systems, because the 3-D simulation graphic of the TNC 640 takes into account the kinematics model saved on the control, optimally modified according to the actual machine tool geometry, to realistically simulate machine movements. Milling and turning in one setup Does your workpiece, after complex milling operations, also have to be set up on a lathe for further machining? Here the

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blank form update feature. Based on the defined blank, the control calculates the newly created intermediate product with each step to adapt the following machining cycles accordingly. This avoids air cuts and optimizes approach paths.

The new 3-D simulation graphic: displays that are rich in detail focus on undesired effects TNC 640 helps you to save a great deal of time! A milling/turning machine equipped with the TNC 640 machines the workpiece in one run, combining milling and turning in any sequence. For this purpose, the control simply alternates between turning and milling mode according to the program and completely independent of the machine and axis configuration. During switchover, the TNC 640 assumes all necessary internal changes (such as switching to diameter display, or setting the datum in the center of the rotary table), as well as machine-dependent functions (such as clamping the tool spindles). In this way the TNC 640 not only saves space as well as money for an additional machine, but thanks to doing all operations on a single machine, it also avoids inaccuracies possibly caused by workpiece rechucking. The operator can create turning contours as usual in the HEIDENHAIN plainlanguage dialog, and he also has contour elements such as recessing or thread undercutting as well as cycles for turning shoulders, recessing, contour machining and thread machining. He can also use FK free contour programming to easily create contour elements or simply import contours in DXF format with the help of the DXF converter. In more sophisticated contour turning cycles, the TNC 640 uses the same techniques as used for milling. Here, too, there is no need for the TNC programmer to learn new ways of programmingâ&#x20AC;&#x201D;he build on what he already knows and quickly find his way into the world of turning on a milling machine. Another highlight of the TNC 640 is the

Optimized motion control for clean surfaces and perfect contours An insufficient quality of data in NC programs frequently causes an inferior surface quality of the milled workpieces. The Advanced Dynamic Prediction feature (ADP) expands the previous look-ahead of the permissible maximum feed rate profile, thereby enabling optimized motion control of the feed rate axes with 3-axis and 5-axis milling. In this way, clean surfaces can also be milled with short machining times on contours characterized by strong point distribution deviations in adjacent tool paths. The control dynamically calculates the contour in advance and can therefore use acceleration-limited motion control with smoothed jerk to adapt the axis velocity at contour transitions in good time. ADP shows its strengths for example during bidirectional finish milling through symmetrical feed behavior on the forward

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

Achieving maximum contour accuracy and surface quality - machining without (above) & with Advanced Dynamic Prediction (below)

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

NOVEMBER 2016

MACHINE TOOLS WORLD

TECH TRENDS

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

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

MACHINE TOOLS WORLD NOVEMBER 2016

also can be used productively. • As the working cost is increasing, more automation is required so that an operator can run more than one machine. • With cost of power increasing all around the world, more energy efficient motors should be explored. • The fuel prices are increasing at a phenomenal rate and it is essential to produce fuel efficient vehicles. This calls for components with higher quality standards and a need to explore different materials to reduce vehicle weight. Consequently, machines with capability to grind these components efficiently need to be devised. To resolve the above issues, our engineers did brain storming and devised various options: 1. To reduce the floor space there should not be any compromise in terms of the rigidity and stock removal capabilities of the grinder. We designed a grinder similar in size to our smallest model. At the same time, we increased its rigidity by adding weight to make it equivalent

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

Diamond Roll Dresser

TECH TRENDS www.mtwmag.com

Servo Regulating Wheel Drive

Linear Guideway costs to an optimum level. a. Power Cost: The maximum power consuming motor is the grinding wheel motor. We procure the motor such that during idling time of grinder in each cycle it would draw very low current, while providing full torque during the grinding process. Such motors have rating of Eff 1 or better. The other options include soft start for grinding wheel motor or Variable Frequency Drive for regulating and grinding wheel motor. These options avoid peak current required for start-up of the motor. b. Employees Cost: Machine automation is designed in such a way that the operator can run more than one machine at a time. In mass production plants, the focus is to have one skilled person to look after the setting and inspection of finished components for all grinders. Loading, unloading and other routine operations are done by unskilled employees. CNC options also reduce the operator intervention to a large extent and thereby reduce the cost. At the time when customer sends the plant layout, we give

suggestions and inputs to reduce material handling and make it ergonomically convenient in order to reduce operator fatigue. Variable Frequency Drive is installed to achieve Constant Surface Speed for Grinding Wheel. This helps in reducing the dressing frequency even when the wheel diameter is reduced. Hence, the grinding wheel is used to its optimum level. c. The other consumables like oil, coolant, diamonds and wheels are selected with the help of various manufacturersâ&#x20AC;&#x2122; input and expertise, to suit each application. 4. The increase in fuel prices and depreciation of Indian currency has put a lot of burden on manufacturers to improve the fuel efficiency of vehicles. This calls for more close tolerance in manufacturing parts. Quality Parameters are a combination of Size Tolerance, Roundness, Cylindricity and Surface Finish. We use Precision Linear Guideways to achieve practically friction free movement. This enables the slide to move with high accuracy, as close as 0.25 microns and helps in maintaining size in close tolerance.

To achieve roundness in 1 to less than 1 micron, it is necessary to have rigid spindles and vibration free grinding. We mount Automatic Wheel balancers, which balance wheel with vibration level less than 1 micron. This also helps improve Cylindricity. Coolant supply while dressing the wheel has to be forced at the point of contact of diamond and wheel. Proper forced coolant supply helps to dress well, which in turn helps in improving surface finish on component. Coolant supply during grinding is conventionally done by free flow of coolant on the part. Due to air turbulence because of wheel rotation, most of the coolant does not reach the actual grinding area. With redesigned nozzles and flapper to stop air turbulence, the coolant now reaches grinding hot spot to almost 90% level. The overheating of parts and burning marks are reduced and surface finish improved. The above are some of the innovations & adaptations incorporated in the machine to meet the demand of the industry for better & greener tomorrow.

NOVEMBER 2016

MACHINE TOOLS WORLD

TECH TRENDS

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

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

Part stacking magazines for various types of components

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

Multiple CNCs machines can be handled based on cycle time. 80

MACHINE TOOLS WORLD NOVEMBER 2016

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

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

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

Burr can sometimes be a serious hindrance to automatic machine tending

A complete robotic cell tending to two CNC turning centers 82

MACHINE TOOLS WORLD NOVEMBER 2016

A typical compliance unit to compensate for component offset with respect to chuck Other considerations Other considerations to be factored in are to ensure the safety of human operators. Since robotic accidents can even be fatal, it is important to completely cordon off the area with safety fences. Despite this, human access will be required, in the form of refilling and emptying magazine stacks. CNC machines also require frequent tool offset resetting and other minor changes. Doors and other openings need to be interlocked with safety switches and sensors. Conclusion Finally having invested a great deal on the CNC machines and the machine tending project, it is always good to give some more thought to optimize the areas that tend to slow down the entire process. Non-machining activity like door open / close, chuck open close and where applicable tail stock and other accessories must be optimised for automatic operations and their speed can be considerably increased as sensors can be used to interlock their operation and prevent collision. The process of tool offset resetting should also be automated where it is very frequent, as no human should be present in an automated cell with 2 or 3 CNCs and one robot, or else the entire cell will come to a standstill while fixing one machine.

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TECH TRENDS

Automotive aluminum meets its match with new Kennametal platform The new KBDM PCD face milling system from Kennametal allows customers to machine very large components in a single pass

nyone who’s replaced a head gasket on an internal combustion engine knows a smooth, flat surface on both cylinder head and block is needed for proper operation. No one understands this better than automakers, who strive for predictable, controlled surface finishes and high production output, together with maximum tool life and the lowest tooling cost per machined component. Many machinists might think, “What’s the big deal? Aluminum is one of the easiest materials around.” And while that is certainly true of the ubiquitous 6061-T6, nothing could be further from the truth when it comes to the aluminum alloys used in automotive applications. Grades 319 and 390, for example, are readily cast into the complex shapes needed for engine blocks, pistons, heads, pulleys, and similar parts, but due to their high silicon content—easily 20 to 30 times that of 6061—they’re like cutting sand. Fortunately for those charged with machining these abrasive metals, there’s a better alternative than carbide cutting tools, one that produces mirror finishes and produces tens of thousands of parts per edge. “Finishes of 2 to 3 μm Ra are easily obtainable, as is tool life between indexing of 40,000 engine blocks, cylinder heads, and other automotive components,” says Tim Marshall, Senior Global Product Manager for Indexable Milling at Kennametal. “This new face milling platform uses a fine-pitch aluminum body with wedge-style clamps and adjustable pockets. A variety of polycrystalline diamond (PCD) inserts are available, from mini-tips for light finishing cuts to full face wipers, standard cartridge inserts,

MACHINE TOOLS WORLD NOVEMBER 2016

and 1/2 in. (12.7 mm) axial cutters for heavy roughing and shoulder cutting.” Designed for high volume machining He’s talking about the KBDM PCD face milling system from Kennametal. Designed for high-volume machining, the KBDM is stocked in standard sizes of 2.5 8.0 in. (63 - 200 mm), although Marshall is quick to point out the company’s custom solution capabilities. “We can offer cutters up to 21.5 in. (550 mm) in diameter. This allows customers to machine very large components in a single pass. We also have options for integral shank bodies, HSK mounting, left hand cutter rotation, as well as special edge preps and nose radii.” There’s more to the KBDM than a robust body design, however. Since automakers often create their own proprietary aluminum alloys, Kennametal has developed two PCD grades to complement it: KD1400 uses small diamond grains and offers excellent chipping resistance and good wear attributes, while KD1425 uses large diamond grains, giving it excellent abrasion resistance and thermal stability but only slightly lower performance where chipping is a concern. Both are capable of very high cutting parameters— depending on the alloy and setup rigidity, Kennametal recommends an initial cutting speed of 3280 ft/min (1000 m/ min) and feedrates of .004 in. per tooth (0.01 mm), although substantially higher values are possible. Benchmarking “A major machine builder conducted cutting tests for us against several competitive solutions,” Marshall says. “Using a 24-tooth, 6.0 in. (150

mm) diameter face mill at 80% radial engagement and 0.04 in. axial DOC (1 mm), we ran at a feedrate of 0.006 in. IPT (0.15 mm) and 9600 ft/min surface speed (2926 m/min). This comes out to 6112 rpm, with a table feed of 880 IPM (22,350 mm). It was really moving. Even so, the KBDM produced a 14.7 Ra surface finish, several points better than the other cutting tools.” “It’s simple to set up,” Marshall says. “You can easily get everything within a couple microns. That’s one of the keys to successful face milling, not only for proper balance at high spindle speeds but also for achieving the desired surface finish—when you’re finishing a deck face on a block or head, both are critical.” Adjusting the KBDM is a straightforward process—use an optical presetting device whenever possible, and DON’T OVERTIGHTEN!

CASE STUDY

Haas: The machines that changed the world of Motorsport

EO 1 is Edoardo Oldrati with Gunther Steiner, Haas F1 team principal

Italian machine tool and manufacturing journalist Edoardo Oldrati recently paid a visit to the homes of the Haas F1 Team and Stewart-Haas Racing, in Kannapolis, North Carolina. In both HQs – adjacent to one another on Haas Way, he discovered a commonsense approach to sourcing and developing engines and technology, a determination to ultimately make as many parts as possible in-house, and, of course, workshops full of busy Haas CNC machine tools

ll eyes were on Haas F1 Team when it took its place on the starting grid for the 2016 Formula 1 World Championship, the first American F1 team to do so for 30-years. What many may not have known at the time – certainly more so on the European side of The Atlantic – is that before entering F1, Haas Automation Inc. founder, Gene Haas, had already enjoyed a long and illustrious career as a team owner in NASCAR, the spectacular, fastand-furious, US-based stock-car series, famous for its wheel-to-wheel racing on mostly oval, banked circuits.

MACHINE TOOLS WORLD NOVEMBER 2016

The Stewart-Haas Racing (SHR) NASCAR team, and Haas F1, are headquartered in Kannapolis, North Carolina – a city rich in the knowledge, expertise and technologies that go toward designing and building 200+ mph (320 km/h) race machines. SHR is one of the top teams in the NASCAR Sprint Cup championship, and can boast a long list of victories and poles. At the time of writing, SHR driver Kevin Harvick is leading this year’s championship, with teammate Kurt Busch in 8th place. If Harvick wins, it will be his second championship for the team since he won in 2014.

A stellar debut

A team owner moving from NASCAR to F1 is unprecedented. Many can be forgiven for thinking the plan, when it was announced, was overly ambitious by nature, all motor racing disciplines are infamously unforgiving, none more so than the one that claims to be the sport’s pinnacle. But, the US team’s impressive debut at the first grand prix of the season, in Melbourne, Australia, silenced many of the skeptics. Haas F1’s French driver, Romain Grosjean, came in sixth, winning points on his inaugural outing. To put this extraordinary feat into perspective, it

CASE STUDY www.mtwmag.com

was 2002 that a new Formula 1 team last achieved points in its first race of the year. Haas F1 is still punching above its weight. However, “We must remember that we’re débutants,” warns Gunther Steiner, the team principal – the man charged with the ominous responsibility of delivering on Gene Haas’ vision. “This is a very technologically challenging championship, so it isn’t easy to consistently achieve the same level as other teams that have been racing for years.” To compete at this level, Haas F1 has applied a similar strategy used by Gene Haas to great effect in the world of NASCAR: building relationships with advanced technology partners and buying-in critical parts, as allowed by F1 regulations. The Haas VF-16 uses power units and gearboxes supplied by Ferrari, while the carbon fiber, monocoque chassis was made by Haas F1 Team in partnership with Dallara, another well-known Italian company. Haas F1 Team also makes plenty of its own parts, machined in-house. “In our workshop we make racetrack equipment and parts for the wind tunnel tests,” explains Steiner. “In the future, however, we want to increase the number of components we make, perhaps even becoming a parts supplier to Ferrari!” An ambitious aim, especially considering the complexity of some of the components used in Formula 1 cars. “In production terms we already have an excellent set of machine tools at our disposal, but we need to nurture

technicians and operators in order to develop the necessary know-how,” says Steiner. “It takes time.” “We’re learning a lot,” adds Brad Harris, CNC Operations Manager of Haas F1. “Developing effective work cycles to make parts for the wind tunnel has been a major challenge, particularly as we’re competing with the production departments of other teams, which are already operating to the highest standards.” Identifying the right process

According to Harris, the main difficulty lies in identifying the right process to make these parts: “In particular, we’re focusing on reducing the number of setups needed, thus increasing production efficiency. Moving forward, we can turn our attention to the more advanced and complex components needed for the racing cars themselves.” While Haas F1 continues to establish itself and build on its solid start, the NASCAR team is setting the benchmark. The NASCAR workshop at Kannapolis is full of Haas CNC vertical machining centers and CNC lathes, including VF6TRs with trunnion rotary tables, Mini Mills, VF-2s and VF-4s with HRT210 rotary tables. “Compared with other motor racing championships, NASCAR requires the team to manage a much greater number of cars,” explains Stewart-Haas Racing Shop Foreman, Todd Frazier. “We have 16 cars for each driver, including specific models for some races, such as Daytona, and new evolutions with greater performance. With four drivers at SHR, this means as many as 64 cars per season.” Manufacturing excellence

EO 3 is Edoardo Oldrati with Jim Wall, Hendrick Motorsports Engine Development Manager

The cars are under continuous and very rapid development; for this reason output is a steady flow of small batches. Manufacturing technology plays a fundamental role in allowing the evolution process to take place. “I’m convinced that machine tools and cars evolve hand-in-hand: to make more ‘evolved’ cars we need better performing

machines,” says Frazier. “In particular, we need to implement the ideas of designers in a shorter timeframe, and this is where Haas machine tools can help, with their versatility, simplicity and reliability.” One of the team’s main suppliers is Hendrick Motorsports, located less than 6 miles (10km) south of SHR (Hendrick is an institution in the NASCAR world, with 30 years of experience, and innumerable wins to boast of). With the growth of SHR, the collaboration has transformed into a strong technical partnership, which currently means Hendrick Motorsports supply’s the chassis and engines for SHR cars. The collaboration with Hendrick is a two-way street. For 8 hours a day, lines of Haas CNC machining centres create a noise worthy of a NASCAR team. “The first Haas machine arrived in 1996, says Jim Wall, Hendrick Motorsports Engine Development Manager. “Today we have 47!” Hendrick has two main workshops: engine and car production. “Initially, we focused more on engines, but as many other requests for components started to arrive, we achieved a fairly balanced split between engine construction and vehicle production,” explains Wall. Unprecedented workload

To give some sense of the workload, around 900 finished race-engines will leave the Hendrick production plant this year alone, all machined in-house from forgings, destined for the team’s own cars, as well as many other cars on the NASCAR grid. Amazingly, the shops at Hendrick only work a single shift: “So, we need to carry out many processes in a way that doesn’t require night-time supervision,” says Wall. “For this reason, the reliability that Haas machines guarantee is fundamental. Furthermore, they are user-friendly and highly versatile – characteristics that allow us to process a wide range of parts. It’s also important to be able to count on a partner like Haas for support, given their ability to act quickly, & ensure that spare parts are available immediately.”

NOVEMBER 2016

MACHINE TOOLS WORLD

CASE STUDY

King’s College Hospital installs neuroinspire surgical planning software A neuromate stereotactic robot system and neuroinspire surgical planning software have been installed at one of London’s largest and busiest teaching hospitals, King’s College Hospital

enishaw is pleased to announce that a neuromate stereotactic robot system and neuroinspire surgical planning software have been installed at one of London’s largest and busiest teaching hospitals, King’s College Hospital.Mr Richard Selway and Mr Irfan Malik, consultant neurosurgeons at King’s College Hospital, have already successfully used the systems for several stereoelectroencephalography (SEEG) cases for epilepsy, since the installation in January 2016. Selway said, “We are delighted to be able to offer robot-assisted brain surgery to our patients at King’s. The increased precision and efficiency of the machine allows fantastic accuracy when targeting the most

MACHINE TOOLS WORLD NOVEMBER 2016

sensitive areas of the brain. It is likely to revolutionise certain aspects of surgery, particularly for children with severe epilepsy or in the surgery of brain tumours.” Malik added, “In the short time we

have been using the robot we have seen marked improvements in accuracy; something which is of course crucial in the field of brain surgery. This will allow safer surgery with quicker recovery for our patients.” Stuart Campbell, Clinical Sales and Development Manager for Renishaw’s neurological products said, “We are very excited to have installed a neuromate system at one of the UK’s largest teaching hospitals with a focus on neurosciences. The neuromate system will contribute greatly to the epilepsy programme, and Renishaw looks forward to working with King’s College Hospital as it develops their procedures and services around the robot.”

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Airport / Aviation Bhogapuram International Airport Company

Airport / Aviation Automobile

PROJECT

Hydro Power Iron & Steel Manufacturing Ports & Shipping

UPDATE

Railways

Plans to establish a Greenfield Airport at Orvakal village to serve air transport needs of the Kurnool region. Orvakal is a village and a Mandal in Kurnool district in the state of Andhra Pradesh. The Kurnool district administration has acquired 1080 acre for the project. Directorate General of Civil Aviation (DGCA) has issued no objection certification for this project.

Place: Andhra Pradesh

strip. Apart from this it would have manufacturing facilities, pilots-aid complex, infotech area and research and development facilities.

Place: Gujarat Contact: Sameer Bundela, Land Acquisition Officer, GUJSAIL Complex, Nr. Torrent Sub Station, S.V.P.I. Airport, Ahmedabad380004, Gujarat. T: 079-22882000/2068, E: lao@gujsail. org, director_cad@gujarat.gov.in

Automobile Ashok Leyland

Contact: V Ravikumar, Sr General Manager (Project), Near PF Office, Marri- palem, Vishakhapattanam-, Andhra Pradesh. T: 040-29803753, M: 9949095277, E: sembiacl@gmail.com, mdbiacl@gmail.com

Chennai based Commercial vehicle major is gearing up to set up new manufacturing base in the state of Telangana and Andhra Pradesh. The plan is to set up bus assembling and building facilities and later on a truck plant is also planned.

Civil Aviation Department, Govt. of Gujarat

Place: Andhra Pradesh

The civil aviation department plans to establish Aviation park at Bagodara near Ahmedabad. Gujarat government has allocated 90 hectare of land at Bagodara in this regard. The project would be taken up in phases. The park will have facilities for training, air operation regulations, state-of-the-art theatre, training simulator complex, an aviation and aerospace management school, an aircrew training school, a helipad and an air

Contact: Alok Saraogi, Vice President (Brand Marketing and Corporate Communi- cations), No.1 Sardar Patel Road, Guindy, Chennai-600032, Tamil Nadu T: 044-22206000, F: 044-22206001, E: alok.saraoji@ashokleyland. com Mahindra & Mahindra Automobile major has expressed interest in setting up a vehicle manufacturing plant in the state of Assam.

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PROJECTS

Place: Assam Contact: Roma Balwani, Sr VP & Group Head - Corp Comm, Mahindra Towers, Media Cube, Worli, Mumbai - 400018, T: 022-24975176,

Hydro Power

M: 9650990565, E: deepna.mehta@gmail.com

Place: Karnataka

Iron & Steel JSW Group Plans to set up a downstream unit for cold rolled and galvanised steel apart from a captive power plant of 18 MW.

APGenco APGenco plans to float tenders for the 960 (80x12) MW hydro-electric station connected to the Polavaram canal project. The construction is likely to start by April 2017 and complete in 40 months.

Place: Andhra Pradesh Contact: J.Sammaiah, Chief Engineer/ HPC&Hydel Projects, Vidyut Soudha, Khairathabad, Hyderabad-, 500082, Telangana. T: 040-23499321, 9493120074 NTPC Ltd The company has successfully commissioned Koldam Hydroelectric Project (HEP) comprising 4 units of 200 MW each recently for NTPC. The generating equipment was supplied and commissioned by Bharat Heavy Electricals Ltd (BHEL).

Place: West Bengal Contact: Mithun Roy, Sr. Manager (Corporate Communications), JSW Centre, Bandra Kurla Complex, Mumbai 400051, Maharashtra. T: 022- 42861000, E: mithun.roy@jsw.in, contact@jsw.in

Manufacturing Trident Group Plans to line investment towards the expansion of its Budhni plant capacity of terry towel manufacturing in the next two years.

Place: Madhya Pradesh Contact: Susmita Hazarika, Vice President (Branding), E-212, Kitchlu Nagar, Ludhiana-141001, Punjab. T: 0161-5039999, F: 5039900, E: info@tridentindia.com

Place: Himachal Pradesh Contact: Deepna Mehta, DGM, NTPC Bhawan, Core-7, Scope Complex, 7 Institutional Area, Lodhi Road, New Delhi-110003, T: 011-24387195, 24360100,

MACHINE TOOLS WORLD NOVEMBER 2016

were recently invited.

Contact: M.R. Hedaoo, Chief Engineer, Panambur, Mangalore-575010, D.K. District, Karnataka. T: 0824-2407493, 2407341, F: 2408390, E: mrhedaoo@ yahoo.co.in, ce@nmpt.in

Paradip Port Trust Plans development of new coal berth for handling of coal imports at Paradip Port on BOT basis. Bids are current invited.

Railways Indian Railways Plans to build MumbaiAhmedabad high speed rail corridor. The work on the bullet train project is likely to start in 2017. Railway administration is keen to build a terminal at the Bandra-Kurla Complex (BKC) while the Government of Maharashtra insist and is ready to offer a plot at Bandra Reclamation. The first bullet train is likely to run by 2023 covering distance between Mumbai and Ahmedabad in two hours at 320 - 350 kmph.

Place: Paradip Odisha Place: Mumbai Maharashtra Contact: K. Ramachandra Rao, Chief Engineer, Administrative Office Building, Paradip Port Trust, Paradip-754142, Odisha. T: 06722- 222026/67, E: ceppt@paradipport.gov.in

V O Chidambaranar Port Trust Plans to assign development of North Cargo Berth-IV for handling of contain- ers and clean cargo through Public- Private Partnership on design, build, finance, operate and transfer (DBFOT) basis V.O.Chidambaranar Port.

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 North Central Railway Plans to assign the design, supply, erection, testing and commissioning of 132 KV, 3-phase double circuits transmission line.

Place: Uttar Pradesh Place: Tamil Nadu

Ports & Shipping New Mangalore Port Trust Plans to assign maintenance dredging at New Mangalore Port for the years 2017-18, 2018-19 and 2019-20. Bids

Contact: Vanitha M, Admin Head, VOCPT, Tuticorin-628004, Tamil Nadu. T: 0461-2352091, F: 2352301, E: info@vocport.gov.in

Contact: K.M. Singh, Dy. Chief Elect. Engineer (Const.), NCR, A Block (Ganga), GM Office Complex, Subedarganj, Allahabad. T: 0532-2435073, F: 2435073, E: ceecon@ncr.railnet.gov.in

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MACHINE TOOLS WORLD

PRODUCTS

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

Following are some of its unique features:

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

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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.

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 toolwork 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.

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PRODUCTS www.mtwmag.com

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

Missile Lube 1 XXL and 1 XXXL are well suited for honing of ferrous and nonferrous 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.

Mitutoyo Quick Vision Active A highly cost effective CNC Vision Measuring system with Touch Probe option Quick Vision Active CNC vision measuring system is an easy-to-operate, spacesaving model with advanced functionality to meet many contact and noncontact measuring requirements. It is highly efficient and flexible, offering a wide field of view with interchangeable objective zoom lenses to meet the challenges of measuring small to large features. The 8-step zoom lens can achieve a magnification range of 0.5X to 7X while maintaining crisp image quality. With the choice of optional 1X, 1.5X & 2X objective lenses, it is possible to further widen the magnification range on the screen. Quick Vision Active is available with measuring ranges of 250 x 200 x 150 mm or 400 x 400 x 200 mm, with or without the touch-probe measuring option. QVPAK software uses edge detection and pattern recognition to locate and orientate the coordinate system with minimal operator input, ensuring accuracy and repeatability of the measurement results.

Features: 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

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Accuracy : E1(X,Y) = (2.0+0.3L/100); E1(Z) = (3.0+0.5L/100); E2(XY) = (2.5+0.4L/100) Programmable 4-quadrant LED ring light Programmable LED stage and coaxial light High resolution and high speed CMOS colour camera High quality zoom optics with interchangeable objective lenses Compact design Powerful yet user-friendly QVPAK software

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PRODUCTS

PEDM : Broken tap & drill removing is now an easy and clean job Ratnaparkhi electronics a market leader in EDM technology since 1989 has come up with yet another handy Indian made product for the most hectic and time consuming job I.e removing broken drills and taps. This portable simple and economical maintenance unit can be taken out at any location and the tool can be fitted on any angular job with its strong magnetic base. This unit comes with a portable trolley and magnetic stand for easy mounting and works on a single phase supply and requires normal water. Taking out the broken tap is now a easy without damaging the threads at the surface. A copper or brass rod/tube or strips make a hole through the tap/drill giving the space to remaining pieces to come out smoothly without damaging the surface threads.

Features:

For Product Enquiry Contact Ratnaparkhi Electronics Ind. Pvt. Ltd. E-52, M.I.D.C,Satpur, Nasik. Pin.:-422007. Phone: 0253-2351125, E-mail: vgp@ratnaparkhiedm.com; reiplnsk1@gmail.com

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Portable, Simple, Economical Removes broken drills, taps, screws using appropriate circular / flat Electrode. Angular drilling possible. High Pressure pump to flush debris. Magnetic stand for easy mounting. Spark off after reaching depth. Spark off for interlocks. Auto retrace during gap-short. Power Supply 230VAC, 50Hz

Welding Fume Extractor, King Extractor-II-MU 3 Welding Fume Extractor, King Extractor-II-MU 3 is a mobile mechanical high efficiency self-cleaning filter designed for workplaces. The filter cleans air 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.

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

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The 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.

A ACCUSHARP CUTTING TOOLS PVT. LTD. ACE MANUFACTURING SYSTEMS LTD.

BACK PAGE

COMPANY NAME

PG. NO.

COMPANY NAME

ENGIMACH - 2017

N NICKUNJ EXIMP ENTP P LTD

G GROB MACHINE TOOLS INDIA PVT. LTD.

H ACTCAD ENGINEERING SOLUTIONS PVT. LTD.

ADOR WELDING LIMITED

ANCA MACHINE TOOLS PRIVATE LTD

HAASTEC

HEIDENHAIN OPTICS & ELECTRONICS INDIA PRAIVATE LIMITED

I APEX PRECISION MECHATRONIX PVT. LTD.

B BECKHOFF AUTOMATION PVT. LTD.

IMTOS 2017

JYOTI CNC AUTOMATION LTD.

L BHARAT FRITZ WERNER LTD.

17 LAPP INDIA PVT. LTD.

BIRLA PRECISION TECHNOLOGIES LIMITED

C CAPITAL FIRST CNC SOFTWARE, INC.

83 15

D DOWEL ENGINEERING WORKS

R RAJKOT MACHINE TOOLS SHOW - 2016

RATNAPARKHI ELECTRONICS IND. PVT. LTD.

RENISHAW INDIA (PUNE)

ROHIT POLISHER

50-51

M MACHAUTO EXPO - 2017

MACHINE TOOL TECHNOLOGY INDONESIA 2017

MAPAL INDIA PRIVATE LIMITED

MARPOSS INDIA PVT. LTD.

SANJAY TOOLS & ADHESIVES

73 & 81

SHAVO TECHNOLOGIES PVT. LTD.

SIDDHAPURA MACHINES

SOLITAIRE MACHINE TOOLS LTD.

SPARKONIX (INDIA) PVT LTD

U UCAM PRIVATE LIMITED

UNITED GRINDING GMBH

UNITY CONTROLS PVT. LTD.

U-TECH ASSOCIATES

E EFFICA AUTOMATION LIMITED

ELECTROTHERM (INDIA) LTD.

EMAG INDIA PVT. LTD.

J 8-9

PG. NO.

MGM-VARVEL POWER TRANSMISSION PVT. LTD.

MITUTOYO SOUTH ASIA PVT. LTD.

INSIDE BACK COVER

MMC HARDMETAL INDIA PVT. LTD.

INSIDE FRONT COVER

WIN INDIA - 2016

Y YASKAWA INDIA PVT. LTD.

YG CUTTING TOOLS CORPORATION PVT. LTD.

FRONT GATEFOLD

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Mr.

Sudheendra

Inside Story

C. R.

President - India Operations, United Grinding GmbH

My Lifeâ&#x20AC;&#x2122;s Goals

Aim & Ambition: My aim & ambition in life is to be successful in my professional career. In our hectic work schedules, it is always difficult to maintain a perfect balance between professional & family life, I have managed well so far. Vision: Always have the goals & interest of the company at heart. Make an influence on others to act on the same principles by honest & fair leadership. Instill a sense of loyalty & belonging towards the company from the young team at the Office. Social Goal: Do my bit for social causes specially for the not so privileged childrenâ&#x20AC;&#x2122;s education. Business Goal: To work hard & give my 100%. Never avoid or shy away from any challenges / difficult responsibilities either internal or external.

My Leisure Choices Favourite Tourist Spot: Love visiting Europe in winter when there is a carpet of snow & its so calm & quiet. Back home I try to visit Bandipur or Nagarhole forest with family & friends as & when possible. Beautiful locations in Malnad region is also another favourite. Music I like : Like all kinds of music except heavy metal. Sports I Love : Having played cricket for the State side, my love for the game still remains. Try to play for my club whenever time permits.

Ask my Taste Buds Favorite food: I am a Vegetarian. Love Indian food with so many different cuisines from the different regions of our country.

In Awe of I Admire: I know many people who are working quietly & tirelessly without much fanfare devoting all their free time, holidays & weekends for the development of schools, health centers in the small villages & towns, even around Bangalore. I am in awe of them & respect them.

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

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