Machine Tools World - January 2017 by Divya Media Publications Pvt. Ltd.

Volume 02 No. 08 | January 2017 | ` 150

Pages 166 | RNI No. MAHENG/2015/64267

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Executive Publisher

Contents

Vol 2 Issue 08 | JANUARY 2017

TECH PROFILE

Shirish D.

CEO Shekhar D.

Editor Shilpa Dongre

Marketing Team Ladoji Pendurkar, Amol Powle, Bhavin Shah, Bharat Shah, Vinod Surve, Kamlesh Balkrishna, Kavita Chaudhari

Designer & Layout

Clever changing system Triple cutting Tritan-Drill as replaceable head system

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

Online Division Ganesh M., Pradeep M. Pillalamarri

Circulation Executive

BUSINESS NEWS

Satish Kadam, Amol Ranshur

Branch Offices (Zonal)

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

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

COVER STORY

CARB-I-TOOL sees increase in demand for tools for machining

MMC Hardmetal : Technology innovation with perfection Mr. Prashant Sardeshmukh Director, MMC Hardmetal India Pvt. Ltd.

WEST (Maharashtra & Gujarat) Pune Sandeep - 09822751645

COMPANY SPOTLIGHT GROB Group: Growth with innovation

MACHINE TOOLS WORLD JANUARY 2017

Rajkot (Saurashtra) Swapnil Bhatia: 09227909005

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

DVS Technology to exhibit at IMTEX17

METAL CUTTING

Gujarat Dinesh Shah - 09327344559

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.

Autodesk to end sale of Perpetual Licenses of Delcam Software

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

“COSMOS MACHINE TOOLS” Scripting the story of faster....

VL Series from EMAG live at IMTEX 2017

PRECIHOLE: Leader in Deep Hole Drilling & Hole...

ProfitTurning releases latest version of ESPRIT CAM software

TECH TRENDS

FARO expands its footprint in Augmented Reality

34 Nicolas Correa : 60 years of technology excellence

40 High Precision: A World On It’s Own - Must Be Respected

Mastercam & Emuge establish partnership

159

PRODUCTS

Visit us at :

Stall No. A103, Hall No. 3A BIEC - Bangalore

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

Contents CUTTING TOOLS COMPANY SPOTLIGHT

METROLOGY IN FOCUS

Vol 2 Issue 08 | JANUARY 2017

GRINDING & CUTTING IN FOCUS

YG Cutting Tools : Global leadership in End Mills

Renishaw: The Masters of Metrology

EMAG : Global leadership through cognizance &....

COMPANY SPOTLIGHT

IN FOCUS

98 United Grinding: Precision with Perfection

AUTOMATION & ROBOTICS INNOVATOR

68 50 Our advantage is consistent production from carbide itself

FARO: The trust for perfection

EDM COMPANY SPOTLIGHT

92 Solitaire with New Dressing Attachments to Centerless...

METAL WORKING FLUIDS COMPANY SPOTLIGHT

54 Indian Company with Global Business Culture

111 Bettinelliâ&#x20AC;&#x2122;s Solutions for Motion Control & Automation

TECH TRENDS

114

Application of Linear Encoders on Machine Tools

79 Sparkonix to launch new generation EDMs & Industry 4.0 solution at IMTEX 2017

101 Hangsterfer fluids : The safe & green choice of every.....

118

ROBOTICS: The flexibility factor

IN FOCUS

56 Birla Precision : The mark of excellence

YG Cutting Tools: The spirit of innovation 4

MACHINE TOOLS WORLD JANUARY 2017

80 Ratnaparkhi Electronics Industries: The game changer

104 NYNAS : Global leadership in Metal Working Fluids arena

140 Machine Tools to Drive the Manufacturing Sector of India

KF5600

L2600SY (Robust Y-Axis Turning Center)

(Next generation VMC)

XF6300 (Flexible Performance & state-of-the-art 5-Axis VMC) Visit and Experience Our New Technology during

HYUNDAI WIA INDIA PVT. LTD. #4/169, Rajiv Gandhi Salai, (OMR), Kandanchavadi, Chennai - 600 096, Tamilnadu, India Tel. +91 76049 03348 e-mail. sales@hyundai-wia.com, service@hyundai-wia.com http://www.machine.hyundai-wia.com

IMTEX 2017

2017. 1. 26 ~ 2. 1 Booth No.

Hall 4, Stall No. A134

TECH PROFILE

Clever changing system -

Triple cutting Tritan-Drill as replaceable head system

eplaceable head systems in machining manufacture are first choice when it comes to meeting the demands of rising raw material prices, resource efficiency and streamlining of stocks. Reason enough to further develop the triple cutting edged Tritan-Drill with which MAPAL has defined a new standard in drilling as a replaceable head variant, and to bring the first standard triple cutting edged replaceable head drill to the market. On the TTD-Tritan-Drill, tool head and tool holder are joined by Hirth serrations. This connection is particularly stable so that all the benefits and the performance level of the solid carbide equivalent are fully retained with the replaceable head variant. The stability of the connection

MACHINE TOOLS WORLD JANUARY 2017

derives among other things from the triple cutting possibility that is predestined for a replaceable head system. The three cutting edges ensure a homogeneous load on the connection so that the forces occurring during machining are transmitted uniformly to the steel tool holder. In addition the connection guarantees optimum torque transmission with at the same time high changing and radial run-out accuracy. As a result, it can be used reliably and stably even in difficult drilling situations, such as with inclined bore entrance or in cross bores. The tool is perfectly centred via its pronounced drill tip and ensures very good circularity â&#x20AC;&#x201C; and that at lower costs, because with the new replaceable head

system, the cost-intensive carbide is limited to the tool head. Lower costs are thus guaranteed even with large diameters. The Tritan - Drill as replaceable head variant TTD will be displayed at the IMTEX 2017 in Bangalore and will be available as a universal variant for the machining of steel in the diameter range from 12 to 32 mm.

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

want to produce actuator drives precisely and cost-effectively.

The key for the highest machining performance: innovative tangential tools combine operations for a reduction of idle time and machining time. www.mapal.com | Your technology partner for machining

Highest machining performance

develop highly accurate combination tools for optimal processes.

Editorial Board

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

Mr. Arjun Prakash Managing Director Effica Automation Ltd.

Mr. GK Pillai Managing Director & CEO

Mr. Rupesh Paparaju Director,

Walchandnagar Industries Ltd.

Bettinelli Automation Components Pvt. Ltd.

Ms.Samina Khalid Marketing Manager

Mr. MIHIR Baxi President – Global Sales

Renishaw Metrology Systems Ltd.

Jyoti CNC Automation LTD

Editorial Index A Accusharp 54 Ador Welding 130, 152, 160 ANCA Machine Tools 12 Arhan Technologies 159 AutoCrib 144 Autodesk India 12 B Bettinelli Automation 111 Birla Precision 56, 162 C Cleantek 154 COSMOS GROUP 29 D DesignTech Systems 71 Dijet Industrial 50, 66 Dormer Pramet 61 DVS Technology 14 E Effica Automation 118 Electrotherm India 156 EMAG INDIA 16, 94 ESPRIT 18 ExxonMobil 18 F FARO Technologies 22, 68 Fatty Tuna India 40 Fourleaf 120, 161 G GROB Group 36 H Hangsterfer 101, 160 Heidenhain 114 Hypertherm 28 L LAPP INDIA 140 Losma India 104 M Makino India 88

MAPAL India 6 MARPOSS INDIA 70 Mastercam 14, 24 Meiban Engineering 157 Mitutoyo South Asia 161 MMC Hardmetal India 46 N NCSIMUL SOLUTIONS 62 Nickunj Eximp Entp 82 Nicolas Correa 34 Nikopas Engineering 158 NYNAS 104 P Pilz India 136 Precihole Machine Tools 38 R Ratnaparkhi Electronics 80 Renishaw 67, 74 Rollon India 122 S SBS Precision Systems 100 Schmersal Group 110 Seco Tools India 64 Shavo Technologies 126 Solitaire Machine Tools 92 Sparkonix 79 Speroni India 72 Spraymet 26 U United Grinding 98 Unity Controls 162 V Vollmer Group 89 W Walchandnagar 153 Y YG Cutting Tools 45, 58

For editorial contribution contact editor@divyamediaonline.com

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 JANUARY 2017

Mr. Jayant Vaidyanathan VP - Sales & Application Tsugami Precision Engineering India Pvt. Ltd.

MTW Overseas Associates USA Nancy TARTAGLIONE, Mepax USA n.tartaglione@mepax.com / usa@mepax.com

GERMANY Sebastian OLLIER Mepax Deutschland, Tel: +49 711 222 54 456, deutschland@mepax.com

FRANCE MEPAX SA, Romain CLASS Tel.: +33 1 39 02 77 78, FRANCE

SPAIN Sofiane JEDIDI Mepax España Tel : +34 963 255 886, spain@mepax.com

ITALY Valeria VILLANI Tel.: +39 339 8610117, Via Firenze, Milano, Italia

UK Liz Jones Tel: +44 (0)1227 276016 , l.jones@mepax.com

RUSSIA Garri ZALTS Mepax Russia Tel: +7 495 576-7666 / gizalec@yandex.ru

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

6-7-8-9-10 DECEMBER, 2017

The Exhibition Center, Gandhinagar, Gujarat, India.

ASIA'S MOST DYNAMIC

INNOVATION & TECHNOLOGY TRADE SHOW

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+91-93288 99503 +91-79-40048594

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

bjhala@imtos.com

Solutions for Complex Profile Geometries Multi Axes Machining Centers Five Axes Vertical Machining Center

» Reduced lead time » Enhanced efficiency » Improved tool life

It combines Multi operational dynamics with rigidity to meet high precision machining requirements.

Moving Column Vertical Machining Center - Multi Axes

Moving Column Horizontal Machining Center- Five Axes Blisk

Medical Implants

Fuel-system (Manifold)

Pelton Wheel

Impeller Profiles

Banjo beam | Rear Axle

Witness The Cutting Edge Technology Hall 1A, Stall A102 26 Jan - 1 Feb 2017, BIEC, Bangalore

Bharat Fritz Werner

BUSINESS NEWS

CARB-I-TOOL sees increase in demand for tools for machining CARB-I-TOOL is a premier Australian cutting tool that has been operating for over 40 years. Specialising in the production of engineering and woodworking tools for the Australian, Asian and European markets; their headquarters consists of a large factory, showroom and storage facility. Over the last few years, CARB-I-TOOL has seen an increase in demand for tools for the machining of plastic and composite materials. To keep pace with this demand, they recently invested in an ANCA MX7 Linear to focus on producing their range of compression routers (single and multiflute) and other solid carbide tooling for materials such as MDF, plastic, carbon fibre, aluminum composite material and special tooling for exotic materials. These are used in a wide range of industries including automotive, aerospace, marine and general engineering. The investment of the MX7 Linear complemented their existing MX7 machine and enabled CARB-I-TOOL to offer a first-hand comparison between both types of machines and

drive systems. The MX7 Linear is driven by linear motors on the X- and Y-axis while the MX7 is driven by ballscrews. It is evident when viewing the tools ground on the MX7 Linear, the surface finish on all surfaces of the tool is to a very high quality. The finish on the flute is highly polished. Ross Storay, CARB-ITOOL production manager said, “When grinding tools on the MX7 Linear we achieve a mirror finish on the flute without a spark out pass or using a fine grit wheel.” As well as being pleasing to the eye, it is recognised that highly polished flutes and gash

surfaces improve chip evacuation and aid tool performance during machining. Polished flutes have a smoother surface and the swarf (or chips) can exit more freely from the flute. CARB-I-TOOL sales manager Mark Hamilton commented, “I have received feedback from our customers advising me that tool life is increased and performance is better from tools ground on the MX7 Linear.” Mark adds, “This can only increase customer loyalty, as our customers know that when they buy a tool from us they can be confident the tool will perform to a high standard.”

Autodesk to end sale of Perpetual Licenses of Delcam Software Autodesk will no longer offer new perpetual licenses for Delcam software - PowerMill, PowerShape, PowerInspect, ArtCAM, and FeatureCAM, from January 31, 2017. The purchase of new licenses by both new and existing customers will only be available by subscription wef 1st Feb 2017” said Pankaj Gauba – Head - Digital Manufacturing – Autodesk India & Middle East. With its shift away from selling perpetual rights to use a specific version of software, Autodesk will continually innovate and improve products and supporting services that customers subscribe to, allowing access from multiple devices at any time, making them

MACHINE TOOLS WORLD JANUARY 2017

easier to deploy and manage, and reducing file compatibility issues. Existing or new perpetual licenses purchased up to January 31st, 2017, remain valid. Customers retain their perpetual software license and can continue to use it in accordance with their perpetual license agreement. All software products covered by a maintenance plan will continue to receive benefits such as technical support, the latest software release, previous version and other licensing rights, and product updates. Subscribing to Autodesk products gives you access to the same full version of Autodesk software as the equivalent

perpetual license - but with a flexible, pay-as-you-go approach for a software budget that is easier to manage. To provide customers with greater purchasing flexibility, Autodesk has introduced multiyear (2-year and 3-year) terms for new subscriptions. This locks customers in to current subscription pricing, protecting them from any future increases. Maintenance plans ensures a perpetual license holder receives benefits such as Basic Support, options for more advanced support, and access to the latest software and product enhancements. A maintenance plan agreement must be applied to each separately

Mr. Pankaj Gauba Head - Digital Manufacturing Autodesk India & Middle East

purchased perpetual license. Customers with current maintenance plans will have the option to renew their maintenance plan and continue receiving the corresponding benefits. Autodesk has no plans to stop offering maintenance plan renewals. However, it is important to renew the maintenance plan on time to continue to access the benefits.

BUSINESS NEWS

DVS Technology to exhibit at IMTEX17 DVS Tooling will be exhibiting at the IMTEX in Bangalore from 26th January to 2nd of February. One highlight at the booth in Hall 4 Stall C117 will be the new machine concept DVS UGrind – an innovative workshop machine for the efficient and flexible hard finishing of small batches. Thanks to the multifunctional tool revolver for grinding, turning and measuring operations as well as the intuitive operating software with integrated processing and measuring cycles as well as automatic calculation of the most efficient process strategy, machining time for the manufacturing of shafts and chucking components can be reduced by up to 50%. Depending on the configuration required by the user, the DVS UGrind carries out external and internal, face and cone surface grinding as well as hard turning operations highly productively with minimum travel. The integrated measuring probe controls and monitors machining until the required final dimension has been achieved, which means time-consuming processes such as successive feeding and re-measuring are no longer required. Optimised lever arm ratios and the thermo-symmetrical structure of the DVS UGrind guarantee a high degree of dynamic and thermal machine stability and thus ensure constant reproducibility of the required manufacturing qualities. PRÄWEMA Antriebstechnik GmbH from Eschwege in northern Hesse, global market and technology leader in the gearing honing segment, will be presenting its latest innovation in the top technology field for optimising gearing surfaces - the so-called “Vario Cross Honing” technology. By using a specially developed oscillation method during the honing process, “Vario Cross Honing” enables surface roughness to be reduced even further, resulting in

Mastercam India opened its presence

Mr. Vineet Seth, MD Mastercam India

another increase in the surface quality of geared components. This innovation, yet another benchmark in gearing machining from PRÄWEMA, allows gearing manufacturers to produce wear- and noise-reduced vehicle gearboxes with higher torque transmission. PITTLER T&S GmbH, based in Dietzenbach in southern Hesse, will be presenting the PV315, which is the very latest addition to the PV³ family of machines for Power Skiving as well as complete machining and has been specially adapted to the requirements of commercial vehicle components such as gearbox components like ring gears.

For more information www.dvs-technology.com

MACHINE TOOLS WORLD JANUARY 2017

CNC Software, Inc., is pleased to announce the opening of Mastercam India Pvt. Ltd. This new organization is based in Pune, India and shall maintain a presence throughout India, the Middle East, and surrounding regions. Vineet Seth, the Managing Director of newly-formed Mastercam India, commented that his new organization is comprised of a highly experienced, well-established team of professionals from sales, marketing, technical, and channel expertise gained in the Indian CAM market over many years. Vineet explains that the addition of his new team would increase Mastercam’s overall staffing levels in India in excess of 100 people, which is a demonstration of CNC Software’s ongoing commitment and investment in this market. “CNC Software is excited about growing the market in India and wants to build on the success we have had over the last 33 years, and continue to be the #1 CAM software in the world,” says Gene Welti, CNC Software, Director Asia Pacific Sales. Website: www.mastercam.com

BUSINESS NEWS

Mastercam India opened its presence

Mr. Vineet Seth, MD Mastercam India

For more information www.dvs-technology.com

MACHINE TOOLS WORLD JANUARY 2017

BUSINESS NEWS

VL Series from EMAG live at IMTEX 2017

Vertical production machines are EMAG’s territory. It all began with the VSC series, which laid the foundation for the successful machine concept of the vertical pick-up turning center. This machine concept runs through nearly the entire product range of the manufacturer, and it takes on its latest form in the VL series. EMAG will be presenting the modular standard machines this year at IMTEX in hall 2b, booth A108. VL machines are part of EMAG’s modular standard series. As the

term suggests, these machines are built on a common machine base but allow the use of an extremely wide range of technologies, similar to the modular platform systems seen in the automotive industry. There are now modular machines available for turning, gear hobbing, and chamfering processes; for grinding (chucked parts and shaft parts); for induction hardening; and also in special designs for laser welding or PECM technology. Essentially, they are available for virtually all the technologies offered

by the EMAG Group. The machine base of these modular machines is made out of Mineralit® polymer concrete. This material has exceptional vibration damping properties, which is the basis for the machines’ excellent process quality. The working spindle is the heart of the pick-up automation system which is an essential part of every modular machine. It includes a parts storage unit in every machine, from which the pick-up spindle loads and

unloads itself independently. This lowers non-productive time to an absolute minimum as there are only a few seconds between the machining processes. The vertical pick-up turning centers of the VL series were developed particularly for the production of precise chucked parts. There are now five versions of the VL machine to cover the widest possible range of parts. The smallest machine is the VL 2, designed for chucked parts with a diameter of up to 100 mm. It is followed by the VL 4, VL 6, and VL 8 machines which allow for an increase of 100 mm in diameter with each model increase.

For more information www.emag.com

MACHINE TOOLS WORLD JANUARY 2017

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

ProfitTurning releases latest version of ESPRIT CAM software ProfitTurning releases in the latest version of the ESPRIT CAM software, represents years of groundbreaking research. A lathe roughing strategy that significantly reduces machine cycle time, ProfitTurning has hurdled a grueling series of tests, delivering a performance that promises to take machinists, engineers and industrialists to greater levels of precision, quality control and productivity. ProfitTurning™ is a high-speed lathe roughing strategy developed by DP Technology Corp. for OD/ ID/face cutting and other tasks. Fast, secure and efficient, it also extends tool life by significantly minimizing wear. Compared to conventional ramping methods, ProfitTurning™ reduces machine cycle time as well as the frequency tooling inserts need to be replaced. DP Technology’s R&D Director

of Product and Engineering Ivan Kristic reveals the science behind ProfitTurning™’s performance: “ESPRIT 2016’s ProfitTurning™ toolpath maintains consistent cutting forces and chip loads, allowing cutting speeds to be significantly increased. By employing trochoidal turning and controlled engagement techniques, the ProfitTurning™ toolpath also reduces vibration

and residual stresses, which in turn makes it particularly well-suited to thin walls or hard materials, especially super alloys. The net result is significantly reduced cycle times and maximized productivity.” ESPRIT 2016 uses a physics-based cutting engine which provides the foundation for the technologies such as ProfitTurning™.

While traditional cutting strategies consider only the geometry of materials, ESPRIT 2016 taps deeper into the science of how different industrial materials can be cut in the most efficient ways possible. Its new toolpath technology uses the principles of physics to formulate unique strategies for each cutting challenge. To do that, ESPRIT 2016 inputs all relevant factors in the toolpath algorithm such as tool material, tool shape, workpiece material, tool speed, feed rate, chip deforming, chip load, machine tool power, acceleration and deceleration. This helps establish complete control of the cutting environment, allowing for optimal cutting everywhere along the toolpath. For more information Website: www.espritcam.com

ExxonMobil launches website for Industrial Lubricants Digital Knowledge To help industrial operators more easily find the information they need to properly protect their equipment, ExxonMobil has introduced a new digital knowledge center full of educational content on its redesigned Industrial Lubricants website, mobil. com/industrial. ExxonMobil lubrication experts provide insights to help equipment owners across a wide range of industries stay on top of current trends and improve equipment performance. Available via the website’s Technical Resources section, visitors have access to best practice maintenance tips and key insights on industry trends that are impacting a

MACHINE TOOLS WORLD JANUARY 2017

wide range of industrial sectors, such as general manufacturing, mining, oil and gas, power generation and food and beverage.

This content includes: ‘Expert Answers’ – Taken from ExxonMobil’s Mobil SHC™ Club industrial lubricants community, these short articles answer a range of lubrication-specific questions sourced from real customers. It also includes insights from ‘Industrial Application Expertise and Tips’ – A mix of indepth articles and quick tips authored by ExxonMobil field and technical experts providing best practice guidance on critical lubrication topics,

such as safety, used oil analysis and lubricant selection. Further insights are available from ‘Industry Insight’ – also authored by ExxonMobil experts, these industry trend articles outline “big picture” considerations that can help industrial operators enhance productivity and profitability. The website will also showcase real-world case histories showing how customers across a range of industries captured substantial benefits with Mobil-branded lubricants and ExxonMobil’s field engineering support. “Successful industrial companies value working with ExxonMobil because they know we have the

expertise to help them make informed maintenance decisions that can enhance operational safety, reduce environmental impacts and boost their productivity,” said Chima Eze, global industrial lubricants brand manager at ExxonMobil. “The new educational content available in our redesigned Industrial Lubricants website supplements our field engineers’ work to help industrial operators, managers and equipment maintenance professionals to stay on top of current trends and achieve their equipment goals,” Eze said. For more information mobil.com/industrial.

BUSINESS NEWS

FARO expands its footprint in Augmented Reality FARO has announced the acquisition of MWF-Technology GmbH, an innovator in mobile Augmented Reality (AR) solutions. MWF’s breakthrough technology enables large, complex 3D CAD data to be transferred to a tablet device and then used for mobile visualization and comparison to real world conditions. This enables real time, actionable manufacturing insight for inprocess inspection, assembly, guidance and positioning. Located near Frankfurt, Germany, MWF’s mobile AR solution (FARO AR Inspect) has been utilized by some of the top aerospace and automotive companies in the world in their assembly workflows to dramatically reduce cycle time and significantly reduce manufacturing costs. This solution includes both an innovative compression software tool for converting 3D CAD data into a mobile format, enabling intuitive navigation through the 3D data, and a hardware kit that includes a 3D ready iPad and alignment tools. FARO AR Inspect, along with FARO TracerM guidance and positioning technology, dramatically increases productivity for factory metrology and construction BIM-CIM customers

MACHINE TOOLS WORLD JANUARY 2017

by making information about the surrounding real world interactive and digitally manipulatable. Additionally, AR Inspect complements FARO Virtual Reality (VR) Viewer (showcased at Intergeo 2016), which enables an immersive and interactive experience in a simulated 3D environment. Among many other benefits across multiple applications, it facilitates more time and cost effective decisions in the design cycle by enabling teams to spot flaws or potential risks before implementation. “We are very excited about expanding our portfolio of virtual reality solutions into actionable, mobile Augmented Reality with MWF,” stated Dr. Simon Raab, FARO’s President and CEO. “With the introductions of Mobile AR and VR solutions, we are at a seminal moment where we can enable our customers to evolve their thinking and actions beyond doing it the right way to doing it the best way every time. They will benefit from error detection at even earlier stages of the production, construction or design process. As an industry pioneer, FARO continues to be committed to driving technological innovation that creates increasingly more value for our customers.”

BUSINESS NEWS

2nd edition of ADDIT3D to take place in June 2017 Additive manufacturing is moving forward together with ADDIT3D, the only professional trade show in Spain for this sector. It will be held next year for the second time, from 6 to 8 June at Bilbao Exhibition Centre. After an initial stage of asking many questions about how to make the most of a revolutionary concept that offers great opportunities, companies are starting to get a clear view of the real possibilities for their production environments. In this context ADDIT3D will be an important event where companies can look for specific applications for parts, materials, software and design solutions and CAM based on new technologies. Exhibitors and visitors agreed that their participation at the first International Trade Show on Additive and 3D Manufacturing was a great success, thanks to the quality and the amount of participating companies represented, as well as the approach and content of the technical seminars.In 2017 the conference

programme, coordinated by ADDIMAT, will cover once again the sector’s major challenges and will offer cutting-edge answers and solutions to improve the product value chain. ADDIT3D will also have an exhibition area for companies of additive manufacturing and 3D systems and machinery, industrial applications, raw materials, consumables, 3D printing services, software, 3D scanners, R&D and training.Professionals attending this benchmark event in Industry 4.0 will

come from the following sectors, mainly: automotive, aeronautics, railway, capital goods, metal-mechanic transformation, prototyping, moulding and die casting, and medicalprosthetics. As ADDIT3D is being held at the same time as five other industrial events – SUBCONTRATACION, International Fair of Manufacturing Processes and Equipment; MAINTENANCE, Industrial Maintenance Fair;PUMPS & VALVES, International Trade Show for Pump Systems, Valves and Equipment for Industrial Processes; FERROFORMA, International Hardware, DIY and Industrial Supplies Fair; and FITMAQ, International Fair of Bargain & Used Machinery – it will increase its value as a place for business and knowledge transfer, and will generate interesting synergies at all levels. ADDIT3D is organised by ADDIMAT, Spanish Association for Additive and 3D Manufacturing Technologies, and Bilbao Exhibition Centre.

Mastercam & Emuge establish partnership CNC Software, Inc.,(www. mastercam.com) developers of the manufacturing industry’s leading Mastercam CAD/CAM software, announced it has established a partnership with Emuge Corporation, a leading manufacturer of high performance taps, drills, end mills, and other rotary tools. Both companies will share technical data and best practices on machining applications and programs, participate in joint seminars and training events at

MACHINE TOOLS WORLD JANUARY 2017

each other’s technology centers, and collaborate to develop and promote advanced, high productivity machining solutions for North American manufacturing professionals. “We are excited to establish a partnership with Emuge who, like CNC Software, has consistently provided innovative, industry-leading solutions for manufacturers. We are looking forward to working together, leveraging our extensive resources and expertise to offer the very latest technology for our customers,” said Meghan West, President of CNC Software, Inc. “We are very pleased to partner with Mastercam and see the relationship as an excellent way to further enhance our metal cutting solutions for customers throughout the U.S. and Canada. Mastercam

has an outstanding reputation across the industry for providing leading CAD/CAM solutions for the latest machining technology, which aligns well with our customer base and approach,” said Bob Hellinger, President of Emuge Corp. Emuge and Mastercam are planning upcoming training and seminar events for 2017.

Customers will be notified and information on events will also be posted on their respective websites.

For more information www.mastercam.com

BUSINESS NEWS

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

Typical Spray Materials used with Plasma Spray Metals and its alloys: Steels,

Ni alloys, Co alloys, Moy, bronze, copper, Babbit, etc. Ceramics: Chromium Oxide, Aluminium Oxide, Al Oxide + TiO2, ZrO2, etc. Carbides: Tungsten carbide, Cromium carbide, TiC Hardness range of coatings: From SOFT 60Rb (Bronze) to HARD 70 Rc (ungsten carbide)

Benefits of Plasma Sprayed Ceramic over Hard Chrome Environmental: Less hazardous as there is no Hexavalent chrome involved dust disposal; easier than bath liquid.

Performance: 3-4 Times more wear resistant than Hard-chrome; Micro porosity holds lubrication; Selective area coating is possible; Higher thickness up to 300 microns per side is possible. Limitations: Ceramics are brittle and are to be handled carefully. The process is not as widely available as hard-chrome.

Spraymet Surface Technologies Bangalore-based Spraymet Surface Technologies Pvt. Ltd., headed by Mr. P.T. Bindagi, Technical Director and a veteran metallurgist, is engaged in thermal spray, ENP plating and weld surfacing. While

their main plant is in Bangalore, the second plant is located in Pune, to stay closer to its customers especially from the automobile sector which is demanding technical excellence, proximity and service all at the same time. Spraymet has the distinction of having pioneered the carbide coatings in the steel mills and galvanizing line roll coating. Spraymet owns a few proprietary coatings like Moly bend (Spraymet MoB) for metal-to-metal wear, and Ductile matrix carbide (Spraymet DMC) for plastic process feed screws. Mr. Bindagi is working towards expanding applications in turbine industry, medical implants, and other frontiers. In his quest to spread knowledge, Mr. Bindagi also picks students from universities for project work related to tribology and wear metallurgy. Spraymet has helped the industry save a lot of money and helped conserve its scarce resources.

â&#x20AC;&#x201C; P.K. Balasubbramaniian

MACHINE TOOLS WORLD JANUARY 2017

Visit us at Hall 2A, A-102 26th Jan - 01st Feb 2017

BUSINESS NEWS

Hypertherm expands community service time program to 32 hours of paid time off per year Hypertherm, a U.S. based manufacturer of plasma, laser, and waterjet cutting systems, today announces an expansion of its Community Service Time program for 2017. As of next month, the company’s CST program will increase from 24 to 32 hours, providing all Associates with an additional eight hours of paid time off each year to volunteer in their community. Hypertherm envisions the expanded hours will help its Associates dedicate more time to volunteer roles that require a fairly substantial time commitment such as coaching, mentoring, and tutoring. It will also help nonprofits who have trouble finding volunteers able to make a regular weekly or monthly commitment, and nonprofits who need help during non-traditional hours. “We are excited to offer this expanded benefit to all Hypertherm Associates many of whom already serve in excess of 24 hours a year,” said Jenny Levy, Hypertherm’s vice-president of corporate social responsibility. “By expanding our investment in CST, our hope is more Associates can make recurring volunteer commitments, deepening their effectiveness at the organizations in which they serve.” Launched in 2003, Hypertherm’s

Community Service Time program has grown from an initial 16 hours per Associate, in part because the company has found the program benefits both the community and its Associates who return to work more energized and engaged. Today, more than 80 percent of Hypertherm’s global Associate population volunteers, serving an average of 15.5 hours a year. Combined, that amounts to more than 18,000 hours so far this year and nearly 100,000 hours since the program’s inception. Hypertherm’s Community Service Time program is one part of its commitment to Corporate Social Responsibility. In addition to volunteer time, the company also awards thousands of dollars in grants through its HOPE Foundation and has ambitious environmental stewardship goals that include

producing more efficient products and zero landfill waste by 2020. Learn more at www.hypertherm. com/CSR. 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.

For more information, Website: www.hypertherm.com

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)

MACHINE TOOLS WORLD JANUARY 2017

METAL CUTTING

COMPANY SPOTLIGHT www.mtwmag.com

“COSMOS MACHINE TOOLS” Scripting the story of faster growth in 30 years of partnership with trust philosophy

Journey of Team Cosmos Cosmos Philosophy

As a philosophy, the company believes in making a significant difference to its customers as strongly believes that “if the Philosophy is right, the Product has to be Right. The FAILURE of the COMPANY typically does not come from the COMPETITORS, but ITSELF. To further stressed, how IMPORTANT it is to put in place a CULTURE in the company to RESIST such failure by CHALLENGING ITSELF - all the time, through CONSTANT INNOVATION. “When the RATE of CHANGE OUTSIDE the organization exceeds, the rate of CHANGE INSIDE , THE END IS IN SIGHT”. Make sure the CHANGES WITHIN the ORGANISATION OUTPACED the CHANGES OUTSIDE. Whatsoever good products we have... if basic philosophy and culture is not in place.... the company has no long future. It is the toughest part for any industry leader to demonstrate and set such examples. ..!!! “At Cosmos, our philosophy is to

partner our customers in their progress. We always look at the requirements from the chair of our customers. We first understand their needs before developing the product,” COSMOS GROUP :

Established in 1987 with a vision to deliver excellence in the machine tool industry, Cosmos Machine Tools today is a renowned group that has interests in the field of manufacturing and marketing of CNC Machine Tools, Machine Tool Accessories and Precision Components. With the TIME and Pace of Market maturity and Demand, COSMOS kept adding the Business Verticals under ONE ROOF.

Cosmos Head Office

1. Oldest Division is Imported CNC Machines Solution offering from Taiwan and Japanese renowned Principles for manufacturing applications from Human Body implants to 30 tons of Steel Roll Turing solutions to various reputed companies with 30 years of Rich Experience. 2. In 1999, Second Vertical, Precision components machining with major as Export Customers was started, and presently having more than 40 advance and multitasking CNC Machines, CMM with factory space of above 80000sq.ft. with 18+ years of Manufacturing Experience. 3. In 2005 A Joint venture with Golden sun Taiwan was signed, for manufacturing Precision Accessories for Machine Tools like Turrets, Rotary tables, Index tables etc. 4. In 2009, started CNC MACHINE TOOL MANUFACTURING with high Precision Surface Grinding machines manufacturing under guideline of German Consultant. 5. In 2011 with wide experience of Machining Challenges and looking to Global Exchange Rate situation we took a decision of moving COSMOS VMC PLANT from Taiwan to India which we were running with Taiwan associated partner since 1999. COSMOS VMC’S are fully designed in Taiwan and are 100% manufactured in India, under Japanese Consultants guidelines and SOP’S to achieve high accuracy and consistent quality. MAKE IN INDIA Benefits :

Asked her view about Make in India concept, Ms. Khambhaita said the concept is wonderful and there is lot more to be done on this front. “The Central

JANUARY 2017

MACHINE TOOLS WORLD

METAL CUTTING

COMPANY SPOTLIGHT

Cosmos Vmc Machine government is doing an excellent job but it should ease certain rules and regulations to boost Exports which will make the campaign a huge success,” she said and added that at Cosmos, it’s only about quality and consistency. “We have 65% ratio of repeat orders which is a huge success, and keeps us motivated. Sharing her vision for the company, she said, “We are machine tool passionate people and understand the current as well as future needs. Make in India concept will surely benefit us but it is not the only thing on which we rely on. Quality of machines has to go up further. We will adopt all international processes to bring in sustainable growth at Cosmos.” “There is a very big gap between Indian and global machine tool manufacturers. The difference is because of difference in culture and mindset and we know we can’t bridge this huge Gap on our own, so we are taking external help of International quality experts, so that we can match the global standards, to rip the benefits of MAKE IN INDIA at later stage” said Ms. Khambhaita Price Sensitive Indian Customer Segment

Ms. Khambhaita said Indian market is definitely price sensitive. “But, its up to the

Our Assembly Line

MACHINE TOOLS WORLD JANUARY 2017

seller’s company Vision and Philosophy. India, as developing country, is one of the highest importer of high quality machine tools, which means there is a customer segment to buy good quality products. If we compare it with the pyramid, then the lower most layer is highly price sensitive while the upper layer want value for money with quality and reliability,” she said. VENDORS NURTURING is the Key for Consistent Quality :

I am surprised to see one common factor in all vendors feedback .... “MOST OF THE MTB’S ARE NOT PAYING ON TIME” remark and delayed above 6 to 8+ months and they end up absorbing all Interest which essentially should be on MTB’S Shoulders. Actually it is a story of Chicken and egg. So with this culture of MTB’S of not supporting vendors to Grow strong, the Vendors do not prosper and become healthy for bringing up their parts quality and advance system deployments to bring world class feel with the time. Some vendors even shared with deep pain that MTB’S are doing Big Exhibitions like IMTEX but actually all these are vendors money used by MTB’S and everytime 6 to 8 months delay cycle is a historic fact. Now in this cycle ... Can INDIAN MTB have the professional and quality committed vendors like in Taiwan or Japan... who actually are the success behind the RELIABILITY AND QUALITY BRAND FACTORS OF THEIR MACHINE TOOLS. There is a basic system fault what I am seeing it... until we all power up our Vendors. ... NO MACHINE TOOL

COMPANY CAN BRING UP THE QUALITY OF MACHINE TOOLS TO AN INTERNATIONAL LEVEL. Just go back 30 years and if we all study the TAIWAN / KOREA AND INDIA all were nearly in the same band of MACHINE TOOL ERA. ( +/- 20% MAX ) This Dream come true reality of INTERNATIONAL QUALITY can happen only by Nurturing Quality Vendors, to build a Mega MTB BRAND together. THE FOUNDATION OF BRAND IS IN THE PRODUCT QUALITY AND THAT TO CONSISTENT QUALITY WITH FIT AND FINISH TO MATCH INTERNATIONAL BUYERS EXPECTATIONS. ...!!! and I strongly feel that it has to be felt at every Vendors “VISION AND QUALITY POLICY CULTURE” to reach this heights. “VISION 2020,

COSMOS will be setting up a state of the art manufacturing facilities to bridge the wide gap of Indian and International MTB’S in terms of high reliability, quality, consistent performance and will be offering Machine Tools which can support achieving better accuracies and surface finishing results on customers end products, at par of International machines, and this will give them an edge over, to compete better in International and export market” Taking this opportunity Ms. BINA, on behalf of TEAM COSMOS, THANKED all their CUSTOMERS and BUSINESS ASSOCIATES, VENDORS for giving their support and having TRUST in TEAM COSMOS and reassured them to be their PARTNER IN PROGRESS FOREVER . ...!! Sustainable Growth is in the Blood of TEAM COSMOS, and the best part is COSMOS LEADERS are enjoying this Journey of achieving OPERATIONAL EXCELLENCE IN THE FIELD OF MACHINE TOOL MANUFACTURING says Ms. Bina with Great Enthusiasm. Ms. Bina is heading the Sales and Marketing with her Innovative and Unique approach to drive a Growth Vision of TEAM COSMOS. It was also an eye opening to know more in depth about COSMOS total strength as an Organization.

BANGALORE, 26.01. – 01.02.2017 HALL 3A, BOOTH B113

GLOBAL ONE

“Our goal: to be the number one for our customers worldwide”

germany

SOFTWARE SOLUTIONS CELOS® – The app-based control and operating system which serves as an entry point to digitalisation as well as exclusive technology cycles.

SERVICE & SPARE PARTS Customer first – Top quality service at fair prices, such as spare parts with our best price guarantee.

CLX / CMX Evolution of ECOLINE – more options, technology and quality at competitive prices.

AUTOMATION New, innovative automation solutions such as the Robo2Go – with free access and no robotics expertise necessary.

“In the future DMG MORI will focus even more on quality and customer responsiveness. We will set a course for this together. We promise stability and continuity in our partnership with you, our customers and suppliers.”

For more information and to download a brochure, visit www.dmgmori.com

TECHNOLOGY SOLUTIONS Our technology centres – Overall technological and industrial expertise including additive manufacturing.

japan

METAL CUTTING

COMPANY SPOTLIGHT

Nicolas Correa : 60 years of technology excellence house for more than 20 years. Robust machines with higher cutting capability, high speeds & high accuracy. Reliability, Accuracy, Flexibility & Robustness are the key features of Nicolas Correa machines Key application areas of products

Mr. Parag Alekar, C.E.O. Nicolas Correa S.A. India Branch Company infrastructure & global alliance

Nicolas Correa is a 60 years old company manufacturing Milling Machines. Nicolas Correa is one of the top leading European machine tool manufacturer in Medium & Large size machines. This is the only machine tool company who is listed in Spanish Stock exchange. We have two manufacturing plants in Spain & one in China (for Chinese market). We have the biggest assembly area @ 100,000 sqm in Spain. Manufacturing plants consists of our own manufactured machines on the shop floor for manufacturing our product range. Machines manufactured in Spain are supplied globally. We have commercial subsidiaries in Germany, China, India & USA. Industrial Subsidiaries in Spain & China. Nicolas Correa major market is Germany, China, Italy, India, UK, USA, Turkey, Spain & rest of Europe. 80% of the turnover is from Export. Key technology your products representing

Nicolas Correa is respected for Bridge type & floor type milling machines and well known for the universal heads with head changer supplied with the machines. The universal head have international patent with 324000 positions with high torque. These heads are manufactured by Nicolas Correa in-

MACHINE TOOLS WORLD JANUARY 2017

Nicolas Correa machines are most suitable for Infrastructure, Energy, Capital Goods & Die/Mold Industry. Our presence in this market is remarkable. Precision components like Engine Block (16/20 Cylinder), Turbine Housings, Gear Boxes are major application areas. Also our machines are supplied in large numbers for Components like Railways Crossings, Switches which require heavy cutting applications. Presence of Nicolas Correa machines in Railway Industry is huge, since majority of the components are done in precision with high productivity due to flexibility available on our machines. The universal head technology helps in reducing number of set-ups which in turn improves productivity.

Die/Mold Industry utilizes machines from Nicolas Correa for large size Dies where pre-machining as well as finishing have to be done on one machine. Major Tool rooms use our machines for Skin panel dies. Machine Tool Industry, Construction equipment manufacturers share almost 30% of the production of Nicolas Correa. This is due to robust & high precision product range. Future trend of your product

Our machines are well known for high precision & Robustness. Presently company is in the process of introducing new machines which can be utilized better for Aerospace & Railway Industry. We foresee a good opportunity in this Industry in the coming years. We have already introduced Multitasking machines in the market two years back. We have seen a good application oriented demand for our machines, mainly in Valve & Aerospace applications. Overall we are expecting a great future for our machines in coming years.

Fox M

Visit us at :

26th Jan to 1st Feb 2017

Hall 1B, Stall A 106

METAL CUTTING

COMPANY SPOTLIGHT

GROB Group: Growth with innovation

s a global player in the development and manufacturing of machines and production lines, the heart of the GROBGroup beats in Germany since 1926. Our customers include the world`s most prestigious car manufacturers, their suppliers and many other renowned companies from various industries. With our production plants in Mindelheim (Germany), Bluffton (Ohio, USA), SĂŁo Paulo (Brazil) and Dalian (China), and worldwide service and sales subsidiaries, we are represented around the globe. The GROB Group generates worldwide revenue of over 1 billion euros with a workforce of about 5,600 employees. Product Portfolio

The product portfolio ranges from the universal machining center all the way through to highly complex production systems with individual automation, and from manual assembly stations through to

fully automated assembly lines. Our know-how in designing production systems combined with state-of-theart technology, enables Grob to offer solutions for high volume production. Those solutions are individually designed to meet the specific customer needs. The production systems mainly consist of modular machining centers (G-series) and special-purpose machines, interlinked with the latest automation solutions. With its universal machines, GROB has for the first time in its successful machine building history introduced a standalone machining center which proves the technological know-how and developing competence of the GROB engineers in this market segment. The universal machining centers G350, G550 and G750 successfully complement the G-series and open up an even larger application range for the existing portfolio. As all modules from the G-series, they originate from the same modular construction system, are characterized by their compact design and enable excellent visibility and best accessibility to the work areas. Elaborate high technology, made by GROB

With our machines and installations GROB offers highest quality and reliability and is also very flexible in the machining of the latest engine generations, whether diesel or gasoline. Developing new technologies has been an important part of the company success since the beginning. By this

there are always new technologies which do also set standards within the machine building industry. Demanding high-class technology which distinguishes the 90-year success story of GROB. New machines, retrofitting, re-use and integration of existing machining cells as well as connection to third-party installations, are our challenges which we meet day by day. Also at the moment the GROB development department engages in the requirements of the technological changes. Our engineers thus provide solutions within the coating technology for engine components, e.g. for the cylinder surfaces of the engine block, for the machining of high-strength turbine housings as well as for frame, structure and chassis components. At the same time production equipment for electro-motors, but also assembly lines for battery and fuel cell technology are built. In addition, in the age of Industry 4.0 GROB does a big step into the digital future with the in-house developed industry software GROB-NET4Industry for preventive maintaining and networking of production equipment. It is our incentive to develop technical innovations for an economic production in accordance to our customersâ&#x20AC;&#x2DC; requirements. Energy saving, conservation of resources and the utilization of environmentally friendly materials and technologies are important factors for our daily work. Branch of trade

No matter whether automotive, aerospace, mechanical engineering, tool and mold industries, medical or energy technology â&#x20AC;&#x201C; our machines cover a convincingly broad range of possible applications and provide the optimum solution for just about any material. For further information please contact: Herrn L.J. Naidu Tel. +91 (40) 4202-3336, Fax +91 (40) 4202-3336 E-Mail: info@in.grobgroup.com

MACHINE TOOLS WORLD JANUARY 2017

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

G-Series

Horizontal 5 axis machining centers

Visit us at :

Precision at the highest level

26th Jan to 1st Feb 2017 HALL No.3A, Stall No.B108 Contact: GROB-WERKE GmbH & Co. KG Mindelheim, GERMANY Phone: +49 8261 996-0 E-Mail: info@de.grobgroup.com GROB Machine Tools India Pvt. Ltd. Hyderabad, INDIA Phone: +91 40 4202-3336 E-Mail: info@in.grobgroup.com

GROB_Indien_Anzeige_Magazin_die_and_mould_April_2016_DINA4.indd 1

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

www.grobgroup.com

02.05.2016 08:11:57

METAL CUTTING

COMPANY SPOTLIGHT

PRECIHOLE: Leader in

Deep Hole Drilling

& Hole Finishing Technology

recihole Machine Tools is a leading manufacturer of deep hole drilling and hole finishing solutions. Our focus on this niche technology over the last 3 decades has made us the only recognized brand in India with the most complete range of solutions offered in this technology. Our strength is to be creative and customize an engineering solution that is perfectly suited to the needs of the customer. This is by no means an easy task, since deep hole drilling and hole finishing solutions have over 150 different applications spread across 20+ industries. Our solutions are most suited in Defense and Firearm, Oil & Gas, Automotive, Aerospace, Medical Implants, Seamless Tube Manufacturing, Energy, Die and Mold, Hydraulic cylinders etc. We pride ourselves in the ability to truly offer a world class solution and guarantee performance and productivity over the life of the product. We offer solutions for Gun drilling, BTA (STS) / Ejector drilling, Pull Boring, Trepanning, Counter boring, Honing, Lapping, Pull Reaming, Skiving and Roller Burnishing, Bottom Forming and Bottle boring. Our business processes and operational methodologies ensure that our total cost including material and labor tends to be substantially lower than competition. We are a one-stop shop for all deep hole drilling and hole finishing needs. We can drill and finish holes from Ă&#x2DC;1 mm to Ă&#x2DC; 400 mm and up to 12m in length. We are a ISO 9000 certified company that values product quality, our customers and employees. Our

MACHINE TOOLS WORLD JANUARY 2017

methodology, strict compliance to standards and use of best practices differentiates us from competition. In the last few years we have paid a lot of attention to optimize our products for improving ease of use, accuracy, performance, workmanship and aesthetics. This activity has resulted in tremendous improvement in key performance metrics like hole straightness, bore tolerance and surface finish achieved on our machines. Precihole Machine Tools has 3 manufacturing plants in Mumbai suburbs with a total of 100,000 sq.ft of floor space. Precihole also has a competent team of over 150 individuals that are responsible for designing, manufacturing and servicing our products. Precihole has a 50,000 sq.ft high precision component manufacturing shop with over 40 CNC and conventional machines for deep hole drilling and other manufacturing processes. This shop churns out parts for various industries as well as provides support to our customers till their machine orders are completed. The experience gained from our component manufacturing business is reflected in our machine tool solutions making them optimized for the respective applications. We have established global alliances with distributors and channel partners all over the world. They provide local service and support for our products in their respective markets. Although our primary market is India, we compete globally in key markets like USA, Europe, Balkans, South America, Middle East etc. We have exported our products to 20 different countries

Mr. Parag Kulkarni Director - Sales & Business Development Precihole Machine Tools Pvt. Ltd. in the last decade and this list is expanding rapidly. Our customers are very satisfied with our products and customer service. Precihole continues to innovate continually and bring new products to market. Our strategy is to spend time learning new application requirements from our customers and to invest in R&D. We work very closely with our tooling partners all over the world to ensure that our products keep up with new trends and developments in cutting tool technology. Our upcoming pipeline of cutting-edge new products will definitely continue to push the boundaries of this technology and energize the needs of the industry.

For more information, Website : www.precihole.com

Engineering precisely what you value

Berthiez Bumotec Dรถrries Droop+Rein Heckert Scharmann SIP Starrag TTL WMW

20% 60%

reduction in unit costs thanks to reduced investment costs.

reduced delivery times to secure short term orders.

Solutions for On-Road Vehicles

We look forward to meeting you. Hall 4, Stand C101

www.starrag.com

METAL CUTTING

TECH TRENDS

High Precision: A World On It’s Own Must Be Respected

his write-up raises the query of the accuracy of precision machines, in the light of today’s production environment and increased demands made by their users. There is growing demand for superior precision in production for obtaining high surface finish and close dimensional tolerances eliminating any further machining requirements. Examples: • Hard Turning substituting Grinding • Die –Mould applications eliminating further finishing / polishing operations

Mr. B.P. Poddar Vice President : Sales + Marketing Fatty Tuna India Pvt. Ltd.

MICRON - The thousandth of a millimeter is becoming more and more a “ MUST “. This requires COMPLETE ADHERENCE to the basic rules of PHYSICS and METROLOGY. An Long-standing Problem: Journey towards the precision in machining started in 1775 with Wilkinson , machining a bore of diameter 1800 mm with an accuracy of 1 mm. The dimensional unit for precision has changed gradually from millimeter thru Microns to Sub-microns and Nanometer and Angstrom units. Shall we go back by HUNDRED years ,when JIG BORING Machines were first designed and developed ..?? PRECISION Engineering was pushed to it’s extreme boundaries. Machines were required to manufacture small components for watch-making industry to produce accurate CENTER DISTANCES for

MACHINE TOOLS WORLD JANUARY 2017

MINIATURE WATCH MOVEMENTS. Positioning errors were also found to be caused by heat which is why hand-wheels were molded in clay to eliminate heat transfer between hand and the lead screw. Today undesirable heat originates from the axis drive motors that have replaced hand-wheels. The fact is that even most remarkable technical advances still run-up against the laws of nature , and these laws must be studied and mastered by appropriate means. Concept Of Precision Machines : Across the Industrial World ,Precision Engineering is increasingly seen as set of technologies that are key to successful international competitive development. Many advanced

METAL CUTTING

TECH TRENDS technological products necessitate manufacturing processes and machines operating in the regimes of: • Precision Engineering • Micro Engineering • Nano-technology Worldwide trend in industry reveals that two major thrust areas of manufacturing technology are : • Automation in Manufacturing [CAD /CAM / FMS / CIM ] • Manufacture with High Precision. [ Precision Engineering / Micro Engineering / Nano-Technology ] These areas are no more laboratory propositions but commercial reality. To meet requirements of High / Ultra Precision Machines, considerable efforts have been put in the design of machine tools and their elements, materials used in construction, machining methods, environmental controls required in manufacturing, inspection and assembly. Material selection is based on their properties : strength, weight, thermal expansion-which contribute to precision. Dimensional changes caused by thermal fluctuation and gradients are very important factors. Compensation and elimination of these effects are some of the design strategies. Effect of change in temperature and heat sources will cause change in size and shape and non-equilibrium conditions Desirable properties are: • Low distortion under thermal load • Re-stabilize in rapidly changing thermal loads • High resonance frequencies. Numerous conditions must be met, if work-piece accuracies are to be reached. The following are particularly important: • Substantial and symmetrical structure of main machine components • Protection of machine components

MACHINE TOOLS WORLD JANUARY 2017

against heat radiation • Careful scraping of slide-ways in accordance with specific compensation curves to ensure inherent flatness and straightness of slide-ways and their perpendicularity with respect to another axes . There is still no substitute for fine handscraping • Z-axis parallel to spindle. • Perpendicularity of spindle with traverses of other axes. Other conditions have to be met , such as: • Optimum layout of machine components and guides to ensure an even load distribution i.e. position of Z-axis screw in the same plane as the spindle axis , thus avoiding leverage. • Cooling of spindle bearings and associated mechanical components which also have to be kept at constant temperature under extremely varied dynamic conditions. • Cooling of cutting oil which progressively charged with calories and transfer heat to work-piece. • Ideal location of measuring systems with regard to the slide-ways and feed screws to reduce positioning errors resulting from reversal of forces exerted into slides. These and other sources of instability can lead to significant work-piece inaccuracies and loss of overall machining quality. The “ Micron “- Dreamland or Reality: Not so very long ago , only the manufacturers of measuring instruments , jig borers and metrology equipment talked in term of thousandths of millimeter and could claim to have some degree of control over how they were used. Today nearly all manufacturers and users of machine tools claim to be familiar with this microscopic unit of measurement and even specify it’s use in such a way they exceed the

capability of their own manufacturing & inspection facilities !!! The micron must be treated with good deal of consideration and respected. Do you know, for example: • Steel enlarges by 0.011 mm / 1000 mm /degree Celsius . Slightest change in temperature cause variations in few microns. • If 500 mm long aluminium component is only 2 degrees warmer than assumed temperature of 22 degrees of measurement machine , longitudinal measurement error will be nearly 0.030 to 0.040 mm. • Thermal effect on any object is significant not only in linear dimension but also in shape. • Change in temperature has different effect on various elements of machine and measuring equipment and take different time span to attain equilibrium. • Slightest heat radiation onto machine causes bending or deformation

MODULAR STANDARD MACHINES COMBINE VARIOUS TECHNOLOGIES AND GENERATE FLEXIBLE LINE SOLUTIONS PRODUCTIVE

FAST

FLEXIBLE

COMPACT

VISIT US!

01.26 - 02.01 I Bangalore

HALL 2B, A108

HIGHLIGHTS

Turning, gear hobbing, deburring / chamfering – including automation, all from one resource.

Process example: Soft turning the 1st side, soft turning the 2nd side, gear hobbing. Turnkey solutions for the complete process chain.

+ +

Modular machine integrated with automation. This concept leads to easy line set up.

+ +

System requires less operators and provides easy maintenance.

The TrackMotion automation system performs the entire part transportation process, including turning the parts.

The use of stacker pallets allows autonomous operation for hours.

Cycle times are minimized due to short travel distances for loading and machining.

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

More information

METAL CUTTING

TECH TRENDS of work-piece or the machine component. • Along with temperature ; dust, humidity, vibration, air velocity / air turbulence and noise have effect on measurement and machining. • Foundation on which machine rests is subject to the same physical laws ,and as a consequence can not be subjected to changes in temperature without exerting an effect on machine Many machine tool makers state accuracies in their brochures are having different meanings as per different standards. Standards and their meanings must be properly understood before getting carried away by Numerical Values or Numbers. There is no doubt that numerical control has impressively improved accuracy as far as axis positioning is concerned. Basic structure of machine, it’s design and dynamic performance are key factors determining stability and accuracy. What High Precision Means..?? Association between the accuracy required on a drawing and indicated accuracy of machine tool provides confirmation that machine needs sufficient accuracy in reserve to allow for the inevitable geometrical variations that occur, without upsetting into range of tolerance. Otherwise this will lead to the non-acceptance of workpieces . This involves not just geometrical errors in positioning or on machine itself, but an accrual of all the minor faults connected in one way or other way with machining and work-piece measurement. What Are These Influences?? What are these influences and to what extend do they affect the machines basic accuracy ?? Let’s consider ,if mean accuracy of 0.020 mm must be obtained for workpiece on machining center on 1000 mm cube, the sum of errors that can be imagined is as under:

MACHINE TOOLS WORLD JANUARY 2017

0.002 mm Repeatability of Tool change

0.002 mm

0.002 mm Loss of accuracy at second or subsequent clamping

Defect in fixture and / or work-piece resting face

0.002 mm

0.001 mm Total of Errors unconnected to Machine Accuracy !!!

Deformation of clamping the workpiece.

0.002 mm

0.002 mm Thermal / Environmental effect

Unpredictability of work-piece or machining process

Uncertainty of measurement

0.013 mm

0.007 mm Left for errors originated by machine itself under dynamic conditions, geometry and positioning , mechanical deformation under load and internal temperature deformations. It is decisive to consider the range of tolerances , total errors unrelated to machine , machine accuracies to understand the domain of high precision. It is inconceivable technically , but today’s reality that customers require some performances from machine tool that it’s basic design does not enable to give. As a consequence it will be wholly inappropriate for production problems which need to be solved. Many times choice falls on machines those are foremost economical but at the same time based on unrealistic specifications. Following examples will throw light to illustrate these remarks : • Spindle speeds of 20000 rpm and more are demanded • Spindle power 10 kW and more

• Rapid feed rates 40 mtrs. / min. and more • Positioning accuracy of 0.005 mm with repeating accuracy 0.002 mm We ask questions: • How to dissipate all excess heat that is unnecessarily generated ?? • How do we control acceleration and deceleration ?? • How do we control inertia moments ? • Do high speed spindles and their bearings compatible with high accuracy under heavy duty conditions?? Machines cannot be used for every conceivable job without certain limitations. There will always be some constraints that can not be ignored.

CUTTING TOOLS

COMPANY SPOTLIGHT

YG Cutting Tools : Global leadership in End Mills Company infrastructure & global alliance

About YG Group: YG-1 continues to create greater values for all its stakeholders with “One Mind and One Spirit.” YG-1 strives to achieve the best performances in various areas. Going forward, we will become a recognized global player in the world market, by continuously growing, developing, & creating collaborations through encouraging autonomy and cooperation with our affiliates. YG-1 has more than 30 subsidiaries, joint ventures & associate companies, globally. Business area: YG-1 is amongst the Top 5 companies globally in the End Mill manufacturing and sales industry. It is the largest, in the Republic of Korea (South Korea) based on its 30 years of know-how. YG-1 is expanding its range of products and items. YG-1 is the No.1 End mills maker (in round tools) in the world with 30 million pieces, 72 million pieces a year of Drill, 24 million pieces a year of Taps, being produced in 23 Production facilities worldwide and being sold in more than 75 countries. YG-1 has more than 5,000 employees working globally across various functions of R&D, Production, Sales & Marketing, Supply Chain, Finance, Human Resources, etc., creating value for all the stakeholders. R&D Center YG-1 has 2 R&D centers operating in Republic of Korea. The Songdo R&D Center is developing new technologies for YG-1 with ‘creative thinking and innovation’. It focuses on expansion of conversion research through vibrant inter-department communication. The Chungju R&D Center is equipped with high tech facilities to produce new materials and products. It focuses on internalizing and upgrading YG-1’s key technologies while working on R&D and production. YG-1 will be setting a R&D Center in India very soon. This will be especially focus on the requirements of

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seminars, perform trainings for pursuing proper use of our tools. On the other hand, YG-1 keeps introducing for each industry dedicated tools with high performance, reducing cycle time, increasing predictability and profitability gains for its customers. Key application areas of products

Mr. H D BANG YG Cutting Tools Corporation India Pvt. Ltd. Indian market. Key technology your products representing

Milling: YG-1 Milling tools are recognized to be one of the most cost efficient cutting tools, coming with unique geometry and special coating, in the world, satisfying many users by providing a mass increase in productivity. This is amongst the primary reason; YG-1 has become the largest manufacturer (round tools) of End Mills across the globe. Drilling: YG-1 Drilling tools are well known for its high precision and high technology, continuously impressing various manufacturers around the world. Threading: YG-1 Threading tools are highly acclaimed for their excellent quality and unique design, constantly remaining as the First choice amongst the customers. YG-1 also exposes itself in the Die & Mold and Aerospace industries, on one hand, enhancing each industry manager for each sector giving out technical support and resolving application problems, running trials / tests with customers, support exhibitions,

YG-1 products find applications across sectors & industries, viz., Aerospace, Die Mould, Automobile, Oil & Gas, Power, Information Technology, Electonics, General Engineering, Medical Equipment, etc. YG-1 is focusing on High-end products giving Better Performance to customers with various products. • End Mills: V7 Plus, TitanNox-Power, 4G-Mills, X5070, Only One & Modular End Mills • Hole Making: Dream drill high-feed, Flat-bottom, General, Inox, & i-ONE drill. • Threading Tools: Synchro Tap, Prime Tap, & Combo Tap. • Inserts: Milling, Drilling & Turning Future trend of your product

YG-1 is aggressively expanding its business areas, and now creating foot prints in the Indexable inserts sector. It has started humbly with basic inserts, but this is just a start. We are targeting to equip as many as possible fields viz., Milling, Drilling, Turning, Threading as well as Boring. By having in-house coating technology and machines, YG-1 will more firmly guarantee high quality products. We have recently introduced Milling & Drilling inserts. PVD-coated Turning is also available, and are planning to launch the CVDcoated Drilling & Turning inserts in 2017. As we continue to march ahead, YG-1 has introduced E-Catalogue & Smart Tool Recommendation pages on its website www.yg1.kr to support the customers. • Smart Tool Recommendation: http:// www.yg1.kr/finder/main/index.asp • E-Catalogue: http://www.yg1.co.kr/ toolselection/main/index.asp The customers or the users can access these pages and get proper recommendation of tooling required for their particular applications.

JANUARY 2017

MACHINE TOOLS WORLD

COVER STORY

MMC Hardmetal : Technology innovation with perfection Mr. Prashant Sardeshmukh Director, MMC Hardmetal India Pvt Ltd

MACHINE TOOLS WORLD JANUARY 2017

COVER STORY www.mtwmag.com

Q. Being the key player in the industry, Please brief us company’s journey from inception & share some of the milestones achieved? MMC Hardmetal India Pvt Ltd, popularly known as MMCI, is a fully owned subsidiary of Mitsubishi Materials Corporation, Japan. Mitsubishi is a world leader in offering Metal Cutting Solutions to varied industries. Mitsubishi started its Indian operations in a very small way as representative office of its Singapore subsidiary in 1998. MMCI was established in 2006 with its head office & stock center at Bangalore. MMCI crossed 100 Crores sales in fiscal 201011. We are celebrating 10th anniversary on our Indian operations this year. We inaugurated our first manufacturing facility last month in Aurangabad, Maharashtra State.

Q. Please brief us about company’s infrastructure & what are the technology alliances that has been made in order to out-front the competition? Mitsubishi believes in using world’s latest manufacturing technology to keep ahead of competition. Many new machines and new measuring equipment are now available mainly from Global Makers to ensure manufacturing accuracy of cutting tools. A further noticeable feature of new generation grinding centers is their considerably extended software for the measuring process with a 3D touch probe which ensures consistent size control over a large batch quality. Similar developments have also taken place in insert grinding technology. Machines for complete

Also, we hear customers’ voice and take decision before providing tooling solutions. MMCI will selectively use its new manufacturing facility in Aurangabad to provide total tooling solutions. We would like to continue to grow with double digit growth year on year. periphery grinding in single set up with contactless measurement is now possible. Mitsubishi acquired 51% stake in Hitachi Tool Engineering last year and there is a synergy between two companies to produce world class products by combining expertise of both the R&D centers.

Q. What are the products manufactured by your company? Mitsubishi is a world leader in providing metal cutting solutions. In its range are PVD & CVD coated carbide inserts, coated & uncoated cermet inserts, a wide variety of PCD & CBN inserts, state of the art technology milling cutters, solid carbide drills & endmills, special tooling solutions as per customers demand etc Mitsubishi caters to almost all segments like automotive, aerospace, oil & gas, railways, die & mould, medical engineering, energy etc

Q. What is your marketing strategy for India? In India, the customers expect MMCI to provide total solutions, so our sales and marketing strategy revolves around this. We are discussing with more companies to join MMCI as business partners in its effort to provide quick and uninterrupted service to customers.

Q. Product innovation through R&D is vital to be a leader in the competition, as per your opinion, how does R&D plays the role of catalyst in the success process? In today’s world, rapidly changing market demands requires special efforts to implement new technologies at competitive price, stipulated time frame & user friendly ways. This is one of the biggest tasks before cutting tool industry. We, at Mitsubishi Materials, are spending a major portion of our revenue on research & development and already came up with series of new products, making us one of the leading cutting tools brand globally. “Driving The Future” is MMC’s slogan. We develop the tools well in advance which the industry in going to need in future. For this, MMC, Japan works hand in hand together with various machine makers and CAD/ CAM suppliers. This gives us an added advantage of knowing the latest trends in machine building and software both.

Q. Quality standards are benchmarked by the product performance; please brief us how do you maintain the quality norms since from solution development to implementation? Mitsubishi Materials is not just a tool manufacturer. We are committed

JANUARY 2017

MACHINE TOOLS WORLD

COVER STORY

to promptly respond to customer’s challenges with the dedication of a professional craftsman and doing our best to actively contribute to their success. We strive to become the only tool manufacturer globally offering “your personal craftsman studio”, a unique service for our customers.

Q. According you what are the factors affecting to your business? Currently Indian Manufacturing Industry is going through a tough phase, while upcoming projects are looking for high-tech ultramodern tooling solutions, existing customers who are facing sluggish demands are requesting us to provide low cost solutions. Hence, cutting tools supplier needs to have total solutions in their product basket. Even though it is not a reason to worry but it is putting lot of pressure on bottom lines of all cutting tool makers.

Q. What are the key technological trends that are driving the industry? Conventionally, metal cutting industry

MACHINE TOOLS WORLD JANUARY 2017

was governed by machining of alloy steel, cast iron & aluminum alloys. But due to strict environmental policies, higher demands and to increase the resilience of the product, work materials are changing. High temperature alloys, high strength materials or composite materials are on demand. To cope up with these changes, MMC Japan is investing handsome amount of revenue on research and development to launch new grades, geometries or coating technologies. For example, we recently launched “SMART MIRACLE” end mill series with irregular helix & improved gash geometry for effective chip evacuation. This product is also powered by innovative coating technology called “TOUGH-Σ” to enhance both smoothness & sharpness of the cutting edge for a longer tool life.

Q. How do you perceive the future of the industry? Challenging materials, complex geometries, increasingly specialized quality and performance requirements are the main factors putting enormous pressure on development of cutting

tools. As a result product life cycle has reduced significantly, increasing development cost, manufacturing cost & service costs. Apart from this, skilled man power to establish the technology is a major concern. With Mitsubishi’s core strengths in developing varieties of cutting tool materials and coatings, opportunities are plenty.

Q. What is your vision for your company for near future? In the metalworking industry, there is no other choice except to adopt advanced technology by innovation. The machining demands in future would be so stringent that only advanced technology will be able to meet them. We at MMC sensed this well ahead of the actual needs and already came up with series of new products by marginal rise in the end price, making us one of the leading solution provider globally. Bottom line improvement is a prime requirement of all the customers & innovative technological products only will able to achieve required results which will ensure a WIN – WIN situation for both customer and us.

BIRLA PRECISION TECHNOLOGIES LIMITED Registered Office: B-15/4, MIDC Waluj, Aurangabad - 431 133, Maharashtra, India. Tel.: +91-240-2554301, 2554408, 2554947-8 | Fax: +91-240-2554302 Web.: www.birlaprecision.org | Email: itmth@indiantool.com

CUSTOMER CARE NO.: 0253 - 2352315

BRANCHES: Bangalore : Tel: (080) 22128347, Email: itmblr@indiantool.com Chennai : Tel : (044) 25342636/31076849, Email: itmchn@indiantool.com Secunderabad: Tel : (040) 27713177, Email: itmsec@indiantool.com Delhi : Tel : (011) 43575500/23278531/23276809, Email: itmdel@del2.vsnl.net.in / itmdlh@indiantool.com Ludhiana : Tel : (0161) 2722535, Email: itmldh@indiantool.com Kolkata : Tel : (033) 22485191, Email: itmkol@indiantool.com Pune : Tel : (020) 27614793, Email: itpune@eth.net Mumbai : Tel : (0253) 2352315, Email: itmmum@indiantool.com Ahmedabad : Tel : (079) 22123277, Email: itmahm@indiantool.com C & F Agent : LUCKNOW Tel: (0522) 2683392/2683393, Email: kumar_lko@rediffmail.com

CUTTING TOOLS

IN FOCUS

Our advantage is consistent production from carbide itselfâ&#x20AC;&#x153; Mr. Ravi Sane Country Head & Product Manager Dijet Industrial Company Limited

Q. What is the current scenario in the Indian and global cutting tool industry?

We know Indian market very well, but cutting tool industry has been relied upon automotive and related industries in developed countries in the past. Number of car production in developed countries are moving out and decreasing now so cutting tool industry also move to demanded market globally. Like even in India, Brazil and China the demand of cars or Automotive products is increasing day by day and many automotive manufacturing companies from Europe, US and Japan are setting up their manufacturing plants in these countries. Also trying to enter new market in different type of industries like Engineering, Aerospace and power generation industries. Our R & D department is working continuously to develop tools for these industries. Q. Which of your products are in the Indian market?

All range of our cutting tools especially indexable milling tools we are good at. Right now our main focus in India is Die

MACHINE TOOLS WORLD JANUARY 2017

and Mould machining Industries as well as turbine machining industries. Our High feed indexable tools, some roughing and finishing tools like indexable ball nose cutters are becoming very popular among our customers / end users and also some of our tools for Automotive components machining are becoming very popular. Q. What are the various technologies and

Q. What are the factors one need to consider while serving for Indian consumers and international consumers? Did the company make any necessary changes to its existing products to make them more appeasing to the Indian market?

We produce high quality products only in Japan. We are making and supplying consistent quality products for every market in the world.

product offered by the company?

Our advantage is consistent production from carbide itself to finish products so we always develop both side of material and geometry of tools can be given solution. Also we provide wide range of modular tooling system and especially shank is full carbide without steel for threading part so this series assure accuracy to be used finishing application not only for roughing.

Q. Could you please tell us the R&D effort of the company?

Diversification of materials is accelerating not only aerospace industry even automotive and other industries. Heat resistance alloy, Titanium ally, CFRP such as exotic materials are increasing and required tools can be machined those materials with high efficiently, long tool life. Our R&D department is trying to be able to throw such as

CUTTING TOOLS

IN FOCUS valuable tools into the market every day.

driven demand will be matched with such as requirement.

Q. What are the factors that the support the growth of metal cutting, endmill and

Q. The company recently, launched its

high impact custom cemented carbide?

Indian office, the reason behind this and

What is the demand trends you foresee in

what were the reasons behind deviating

the above mentioned segments?

from the dealer/distributor business

According to increase various production surely cause dramatic increasing demand above segments. It is certain that performance, cost is important. But most important key should be how manufacturers of above segments can be supplied to end users in all over the world on time.

model?

Q. How has the demand pattern from

First purpose we have opened office in Mumbai was to support distributors. We always work with local distributors closely and build strong, long time relationship. We try to grow at each market of the world together with local partners. We believe it is the best way to increase business at oversea market.

various verticals helped the metal cutting

sector and which are the emerging

Q. What are the quality approaches

sectors that will drive demand?

/ matrix adopted by the company to

Recently, coating technology was improved very quickly. It was one of the great help for the performance of cutting tools and contributed to improve productivity in many different type of industries. Requirement for environment, saving limited energy is rising in the world. So one of the products can be

enhance efficiency?

MACHINE TOOLS WORLD JANUARY 2017

We have acquired ISO9001, international quality management system on 1997. Also got environment management system ISO14001 on 2001. On 1992, we got â&#x20AC;&#x153;FORD Q1â&#x20AC;? which is quality certification from FORD Motors in United States as well so we are working on quality control always.

Q. How do you plan to get more customers and meet their requirements?

We are planning to participate to many exhibitions at different location to expand our brand name. Because we are still new comer in Indian market. We believe it can be one of the help. Q. Challenges faced by the company

Main materials for carbide like WC and also additive called rare metal, rare earth are quite tight in the world. We understand that this trend must be continued and recognize we have to develop new grade contain less such law materials as matter of urgent. We have been worked on this subject with knowhow was accumulated by our own R&D and almost achieve it but still carry on in the future. Q. What are your plans for future growth in India?

Actually our biggest export market is China at this moment. But we expect Indian market will be the same size within 10 years.

Visit us at :

26th Jan to 1st Feb 2017 Hall No. 3B, Stall No. B107

CUTTING TOOLS

IN FOCUS

Indian Company with Global Business Culture Mr. Ayaz Shaikh, Director Marketing, Accusharp Cutting Tools Pvt. Ltd.

Q. Please brief us about your company profile?

Accusharp Cutting Tools Pvt. Ltd; is an Indian company with global business culture. We are in the activities of design, manufacture, and supply of special cutting tools in Tungsten carbide and H.S.S. Over 17 years of experience, with the strength of product quality, and service reliability, the company has grown with 120+ employees, on a setup of 15,000 sq. ft. Our prominent presence is in the industry sectors like Automobile, Engineering, Machine Tools, Aerospace, Textile, Energy, etc. And we are considered today, as one of the prime source for special cutting tools for them. We can say, “We are for those, who are in Metal Cutting’! Q. You said, you are a company having ‘Global Business Culture’. Will you please explain this further?

This mainly applies to Products, Processes, People, and the organisational work culture.

MACHINE TOOLS WORLD JANUARY 2017

• The concept, approach and mission is to stand up as business partner for our customers. It means we must assist customers as their ‘Productivity Partner’. Our tools should ‘Cut Fast, and Cut Cost’, at customers’ end. This is how we help them to improve their production efficiency at reduced process and tooling cost. • Objective is not to sell only products; but also to provide entire solution for their product development and manufacturing processes. • Our business and manufacturing processes are ‘system oriented’ having SAP in place. Processes are supported by professionally competent people. We have been approved by ISO:90012008 certification for QMS. • Healthy work culture and human approach for employees, is the strong foundation for passion and team working across the organisation. • However, this is not enough for us to be in line with global business culture. We have three more important aspects,

and they have been addressed with due importance and implemented in all our business processes and activities: • Industrial Safety, • Environmental Care, and • Fair Business Ethics over and above the applicable legal compliance. Q. Did you find adopting ‘Global Business Culture’ a challenge or opportunity for your company?

• Of course, initially it was not easy for employees to understand and adopt the concept. Main challenge and task was to change their mindset. After training and awareness sessions by management experts, employees realised there is no option, but to adopt the global business culture, if the company has to survive longer and have sustainable business growth. • Apparently simple but not easy to adopt the concepts, like Cleanliness, Punctuality, Team working, Passion towards company objectives, and understanding respective functional

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IN FOCUS www.mtwmag.com

roles and responsibilities, were well explained to employees. It took a longer time to really implement them. And today, most of the things are in place and stand as our business strength. This process & changed work culture started initially at the top management level and then peculated down the line, across the organisation. • There was another driving element which worked as a catalyst. That was the demand from some of the MNCs to be in line with their business culture. Some of them were our existing customers, and some were potential customers, if we comply with the global business practices. Supplier audits conducted by them, at our end, for safety, health, environment, legal compliance and business ethics gave us lot of improvement, opportunities in our business practices. • We took this as an opportunity for strengthening sustainable business growth for us.

• Business results are promising and encouraging for us. Q. Where do you see yourself in the cutting tool market?

• As I said, “we are for those, who are in Metal Cutting”, you can see our presence in most of the domestic manufacturing industries. • Having a strong and leading position in Automobile and Engineering sectors, our prime focus is to become the first choice for customers in these niche industry sectors. • Secondary focus is to find more opportunities in the other industry sectors. • Moreover, now we are entering into exports of our tools. Q. How do you see today’s situation of manufacturing industry, from your business point of view?

• Cutting Tools, what we make, are ‘consumables’ for manufacturing industry; and our business activity is dependent on the manufacturing

industry operations and their growth. • We need to stand as a ‘Productivity Partner’ for customers. • Global business culture and work practices is the need of the day. • Auto Industry, Energy sector, and Construction industry are steadily growing in India. And I strongly believe, we shall have business future and a sizable market share there too. Q. What is your vision for your company for near future?

• Our Vision is “To stand as a model organization, becoming the first preferred choice company in the Indian engineering industry, for designing, developing, manufacturing and supplying metal cutting tools; along with strong technical support to customers. Acquiring the highest local market share, our further ambition is to be the leader in export sector, for metal cutting tools.” And I can tell you, our Global Business Culture shall make this company vision to happen.

JANUARY 2017

MACHINE TOOLS WORLD

CUTTING TOOLS

IN FOCUS

Birla Precision : The mark of

excellence Q. Being the key player in the industry, Please brief us company’s journey from inception & share some of the milestones achieved?

Indian Tool Manufacturers (ITM) - A Division of Birla Precision Technologies Limited, pioneered in the year 1937, is involved in the manufacture and supply of High Speed Steel Cutting Tools in India. Intensive Research and Development work has been an integral part of ITM’s total operation on a continuous basis. ITM Products popularly known as “Dagger Brand” made from the finest High Speed Steel and conforming to stringent international standards are now exported to European and American Markets apart from being sold throughout India through an extensive Channel Partner Network, comprising of numerous branches and the industry’s single largest distribution network currently. Our second division, manufacturing CNC Tool Holders, the erstwhile Birla Kennametal Ltd was established in 1986, as a joint venture company between BPT and Kennametal Inc, USA In July 2007. BPT acquired the stake of Kennametal in the JV consequent upon which Birla Kennametal was renamed as “Birla Precision Technologies” (BPT). BPT continues to be an exporter worldwide – USA, Germany and APAC, in recent times to the Far East including China supplying rotating tool holders in AT3 class. Besides, BPT also sells in domestic market in a large way to all major domestic customers. Our third division, Birla Accucast makes machined castings and supplies to all major Automotive customers of India and Worldwide like Cummins and Honeywell.

MACHINE TOOLS WORLD JANUARY 2017

Shri Vedant Birla, CMD, Birla Precision Technologies Ltd. Q. Please brief us about company’s infrastructure & what are the technology alliances that has been made in order to out-front the competition?

We have 4 plants located Maharashtra - 1 in Nashik & 3 plants in Aurangabad. We have 9 branch offices across India & a distribution network of 350+ dealers across India. We had JV with Kennametal, a US$ 4 Billion Conglomerate, Forst of Germany and Perucchini spa of Italy, all in this Company. We are investing heavily in R&D and hired International R&D team. We will be adding new products in coming years to provide value added solutions to our customer. Q. What are the products manufactured

Taps and Tool Bits are manufactured in cutting tool division. We manufacture rotating tool holders, collets, pull stud and work holding mandrels in our tool holder division. We manufacture Shell-Molded Bearing Housings, Turbine Housings, Manifolds, Rocker Levers, Shifter Forks, etc. in Casting Division. Q. What is your marketing strategy for India?

Our primary focus is to place the customer first and we are in the business of value selling rather than product selling. We aim to make our customer more competitive with his customer. We are also connecting with customers through – Exhibition, direct mailers, technical seminar, e-mail marketing, Linked-in, Facebook.

by your company?

An extensive range of High Seed Steel Cutting Tools in various grades (M2, M35, M42, & T42) and a catalogue product range of various types of Drills, an assortment of Milling Cutters, Reamers,

Q. Product innovation through R&D is vital to be a leader in the competition, as per your opinion, how does R&D plays the role of catalyst in the success process?

R&D helps in pushing the limits of the

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IN FOCUS www.mtwmag.com

products & creating better solutions to customer demands of high productivity & quality. As the emission norms are getting stringent we are seeing that customers are asking for more close tolerances with higher feed rates to meet the demand. R&D is playing a major role in meeting these demands & grow the business. We aim to spend around 2% of our Revenue each year on R&D. Q. Quality standards are benchmarked by the product performance; please brief us how do you maintain the quality norms

Q. According you what are the factors

cross-organizational services are offered and used by participants of the value chain. In our automotive division, we are geared up with all our customers for Euro 6 norms which come into India in 2020, requiring a 10 year jump to be done in 5 years for India.

affecting to your business?

We are not seeing the growth in the overall consumption in the market. The major reforms are yet to take place which is most important factor right now to see the growth like GST, reverse hockey stick effect of Demonetisation etc.

since from solution development to implementation?

Q. What are the key technological trends

We are quarterly conducting the product benchmarking exercises of our product not even with the best in the market but with all peers. We have developed a robust internal process for new product development which requires the Product to be passed through different screens which start from customer needs to commercial aspects.

that are driving the industry?

We are already at the verge of industry 4.0. Industry 4.0 is the current trend of automation and data exchange in manufacturing technologies. Over the Internet of Things, cyber-physical systems communicate and cooperate with each other and with humans in real time, & via the Internet of Services, both internal and

Q. How do you perceive the future of the industry?

Technology will drive the industry in future & it will hold the key in the long run. The industry competition will definitely grow, however will help to benefit the customer & supplier in a greater context. Q. What is your vision for your company for near future?

In short run we will be concentrating on connecting to the customer & increasing our product offering in term of value chain & quality of the products. In long run we want to be recognized as world leader in engineering solutions to our customer.

JANUARY 2017

MACHINE TOOLS WORLD

CUTTING TOOLS

IN FOCUS

YG Cutting Tools: The spirit of

innovation

Currently producing 30 million pieces of End Mills, 72 million pieces of Drills, and 24 million pieces of taps a year. YG-1 manufactures quality products in 23 Production facilities worldwide and is being sold in more than 75 countries. Q. What are the applications of cutting tools in various industries? How do you plan to cater to the various industries?

Mr. Hokeun Song, Chairman, YG-1 Co., Ltd. Q. Your company is one of leading names

Q. Please brief us more about your

in Cutting Tool manufacturing segment.

company`s global reach & latest initiatives

Please brief us more about company’s

in cutting tools’ space?

Achievements.

YG-1 is amongst the Top 5 companies globally in the End Mill manufacturing and sales industry and also the largest, in the Republic of Korea (South Korea). Based on its 30 years of know-how. YG-1 is continuously expanding its range of products and items. YG-1 has almost 5,000 employees working globally across various functions of the R&D, Production, Sales & Marketing, Supply Chain, Finance, Human Resources, etc., creating value

We, YG-1 continue to create greater values for all its stakeholders with “One Mind, One Spirit”. By continuously growing, investing, developing and creating collaborations, YG-1 continuously strives to achieve the best performance in various areas and also to be more highly recognized as a leading global company in the world market. YG-1 currently holds more than 30 subsidiaries, joint ventures and associate companies, globally.

MACHINE TOOLS WORLD JANUARY 2017

YG-1 products find applications across sectors and industries, viz., Aerospace, Die & Mold, Automobile, Oil & Gas, Power, Information Technology, Electronics, General Engineering, Medical Equipment, etc. YG-1 is focusing on High-end products, offering the highest performance to customers with also a full range of various products. According to the specific needs of each customer, YG-1 especially puts special emphasis and also a great amount of investment on developing new products and recruiting highly skilled individuals. Obtaining Industry Managers and also Product Managers to specialize and focus on specific industries for better services and customer support. YG-1 also holds a quality product range available for specific industries. End Mills: • TitanNox – Aerospace Industries – For Stainless Steel, Titanium and Inconel machining - materials • 4G-Mills – General Engineering, Automobile and Die & Mold industry – For pre-hardened material up to 55 HRC • X5070 – For Die & Mold industry – For

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High Hardened steel. • ALU-POWER & D-POWER – General Engineering & Aerospace Industries – For Aluminum, Graphite & CFRP • Only One – For general industry, Coated PM60 – Can replace Coated Carbide End Mills

Q. What is the current scenario of the cutting tools industry?

Currently, the cutting tool industry is witnessing a slow growth; however with the initiatives under “Make in India”, is expected to boost up in the future. Q. What are the future prospects for the

Hole Making: • Dream Drill High-Feed – Automobile & General Engineering Industries • Dream Drill Flat-bottom – Specific applications across Industries • Dream Drill Inox – Aerospace & General Engineering Threading Tools:

• Synchro Tap – Automobile & General Engineering Industries • Prime Tap – Aerospace & Automobile Industries • Combo Tap – General Engineering Indexible Inserts The Universal Line - a huge investment in indexible inserts for Milling, Drilling, and Turning for a variety of industries with unique geometries and carbide grades, for machining a wide range of applications and materials for all industries

economy and continuously designs professional and flexible statistics for the future. By understanding the importance of the domestic manufacturing in India, this is why YG-1 has opened the new facility in India and is planning other larger investments in production and development.

cutting tools segment?

YG-1 is very positive about the India market and is expecting a major growth. The cutting tool industry currently is upbeat by the steps taken from the government to promote manufacturing sector, under the made in India initiative. With the growth of manufacturing in the country, the cutting tool industry is expecting a major boost. Q. What is your quality policy for the business?

For the Best Customer Value, Through the Best Quality of Products, Process and People! Q. According to you, what are the measures taken by Indian manufacturers in order to compete with global players?

With highly experienced individuals in the company, YG-1 understands the

Q. Could you brief us about your new product range? What are values are added in the services you provide to your customers?

We have recently introduced new products across categories & for specific industries as below: End Mills: • TitaNox-Power – For Titanium machining • Only One – For general industry to replace coated carbide End Mills for unstable machinery Hole Making: • Dream Drill High-Feed – 3-Flute Solid Carbide Drills with Coolant Holes for Faster Drilling for Automobile and General Engineering Industries • Dream Drill Flat-bottom – Specific applications across Industries

JANUARY 2017

MACHINE TOOLS WORLD

CUTTING TOOLS

IN FOCUS

Threading Tools: • Synchro Tap – Automobile & General Engineering Industries • Prime Tap – Aerospace & Automobile Industries Indexible Inserts

The Universal Line - For a variety of industries for Milling, Drilling, and Turning for a variety of industries for machining a wide range of applications and materials for all industries. Value Added Service for Our Customers

As YG-1 continues to march ahead, YG-1 has introduced the E-Catalogue & Smart Tool Recommendation pages on its website www.yg1.kr to support the customers with additional service. • Smart Tool Recommendation: http:// www.yg1.kr/finder/main/index.asp • E-Catalogue: http://www.yg1.co.kr/ toolselection/main/index.asp The customers or users can access these pages for accurate data of recommendations of tooling required for each particular application. Q. What are your future plans to maintain a substantial market positioning in the cutting tools market?

YG-1 is aggressively expanding more of

MACHINE TOOLS WORLD JANUARY 2017

its business areas, and creating foot prints in the indexable inserts market. It has started humbly with the most popular inserts in the market, but this is just a start. YG-1 is targeting to equip as many fields as possible. viz., Milling, Drilling, Turning, Threading as well as Boring. The range of Inserts of YG-1 currently, viz., Turning, Milling & Drilling, will be available from January 2017. By having an in-house coating technology and a huge amount of machines, YG-1 will more firmly guarantee high quality products. YG-1 currently has 2 large R&D centers operating in the Republic of Korea (South Korea). The R&D centers focus on, improving the existing products & technologies; and to develop much more innovated products with new designs, materials & new applications. The Song-do R&D Center is developing new technologies for YG-1 with ‘creative thinking and innovation’. It focuses on the expansion of conversion research through vibrant interdepartmental communication. The Chung-ju R&D Center is equipped in focus with high tech facilities to

produce new materials and products. It focuses on internalizing and upgrading YG-1’s key technologies while working on R&D and production. Over time, YG-1 will be establishing a R&D Center also in India to cater to the specific needs of the domestic customers. Q. What factors bestow the success of your company?

The success of our company is our people; YG-1 is a one big family irrespective of nationality. It is because of our family, that we are marching ahead. Apart from the members, New Products, Quality Control & Quick Delivery are our key success factors. YG-1 keeps introducing New Products with upgraded technology resulting in always a Better Performance for our Customers from time to time. The phrase, “If it’s not perfect, it’s not YG-1”, is not just a slogan but the way of life for us at YG-1. Strict Quality Control is the basis of all YG-1 products. YG-1 is well known for its Quick Delivery (fast & intime) amongst Customers. This is a key point for YG-1’s Customers. All this has helped us to Meet & Exceed Customer Expectations time and again, YG-1 is leading to Customer Satisfaction.

TECH TRENDSTOOLS CUTTING

TECH TRENDS CUTTING TOOLS www.mtwmag.com

Dormer Pramet launches new chip breakers Dormer Pramet has launched several new inserts & a grade to support turning in specific materials

he new chip breakers – developed under the company’s Pramet brand - target finishing and medium to roughing turning operations in steel and cast iron, high temperature alloys and stainless steel. Firstly, the NF1 and NF2 positive chip breakers support turning applications in stainless steel. The balanced shape of these new inserts offers excellent chip control, with low cutting forces promoting both high durability and productivity. The NF1 is a universal chip breaker for finishing to medium machining, peripherally ground to provide a very good surface finish. The versatile NF2 chip breaker incorporates a small stabilizing T-Land and covers a wide range of applications from semifinishing to light roughing. Pramet’s new FF2, FM2 and RM3 inserts for steel and cast iron provide very good chip control at low feed and depth of cut with a high quality

machined surface finish. The FF2 chip breaker has a positive rake angle and depth of cut from 0.15mm for fine finishing applications in low carbon steels. The FM2 chip breaker is for finishing to medium machining with depths of cut from 0.2mm. Featuring a protective land, it is suitable for continuous and interrupted operations. The highly resistant RM3 chip breaker is for roughing applications in steels and suitable for unfavorable machining conditions. Finally, Pramet’s new SF2 and SF3 positive inserts provide a highly secure and dependable option for turning applications in high temperature alloys. The SF2 chip breaker is for fine turning at the lowest possible feeds, while the SF3 chip breaker with its positive inclined cutting edge supports finishing operations. Especially effective when used on small and slender components, both inserts offer a sharp cutting edge with

minimal radius. This promotes low cutting forces which, in turn, prevents work hardening and ensures a high quality surface finish. Meanwhile, in addition to the new assortment of inserts, a new grade for turning stainless steels has also been launched. The T7325 grade becomes the first choice for productive machining of stainless steels. It has been developed to complement the existing T7335 grade, which is recommended for use in unstable machining environments. Also suitable for interrupted cutting, the latest T7325 grade features a functional gradient substrate and special MT-CVD coating. This combination offers high cutting strength, reduced built-up edge and resistance to the formation of cracks. As a result, the grade provides a high level of operational reliability, performance and tool life. Pramet is a product brand of Dormer Pramet.

JANUARY 2017

MACHINE TOOLS WORLD

CUTTING TOOLS

TECH TRENDS

NCSIMUL SOLUTIONS: A unified all-in-one platform NCSIMUL SOLUTIONS is an unified and software all-in-one platform to manage the complete machining process including processing, cutting and tool management, DNC G-code file management, real time machine monitoring and technical content publishing

ased in France, Germany, China and the USA, the company established in 1983, collaborates with manufacturers in defense, transportation, energy, industrial equipment and medical devices sectors worldwide. “Tomorrow, manufacturing will be “smart” to produce the next generation of products. We are ready to meet the challenge and have everything you need to win: an innovative portfolio based on cutting-edge technologies, thorough knowledge of the market, and the expertise of our teams, going back 30 years.” NCSIMUL SOLUTIONS Product: • NCSIMUL 4CAM | the all-in-one CNC programming solution • NCSIMUL MACHINE | CNC machining simulation • NCSIMUL TOOL | Cutting tool management • NCSIMUL DNC | CNC program lifecycle management

• NCSIMUL MONITOR | Real Time machine monitoring • NCSIMUL PUBLISHER | Technical content publication NCSIMUL 4CAM is the new NCSIMUL SOLUTIONS module, enriching the existing CAM process to simplify CNC programming and provides unparalleled flexibility on the shop

MACHINE TOOLS WORLD JANUARY 2017

floor.It allows to change, in one click, the target machine, without any CAM reprogramming. NCSIMUL MACHINE is the most advanced CNC machine verification software for simulating, verifying, optimizing, and reviewing machining programs based on the real characteristics of your NC machine (machining, drilling, riveting). NCSIMUL TOOL, based on know-how in the field of machining and mastery of the digital process, is a business solution that comprehensively addresses the needs of all professionals involved in the cutting tool management process. With NCSIMUL DNC it is easierthan ever for process engineers andworkshop operators to manage and control their NC deployments. All types of NC links, including RS232 serial, Ethernet, NFS, Samba, FTP, and Mazak are supplied standards..

NCSIMUL MONITOR returns machine status, either manually from the NC console or automatically. It delivers native support for OPC, the international interoperability standard for industrial automation. NCSIMUL PUBLISHER addresses the needs of the manufacturing sector. It is the the most proven solution for the creation, management and publication of Process and Quality documents.

For more information, Website: www.simtek.in

CUTTING TOOLS

TECH TRENDS

Seco Expands Line of Highly Effective Parting-Off Blades to Fit VDI Turrets

eco Tools line of 150.10-JETI family of parting-off blades and square-shank blocks now includes a new VDI block design. Adapters directly hold the 150.10-JETI parting-off blades onto the VDI turret and offer streamlined delivery of high-pressure coolant to the cutting zone without the use of hoses. These blades and adapters quickly and efficiently remove heat during parting-off operations, resulting in high levels of productivity and long, predictable tool life. Coolant is delivered internally to the adapter via the turret and then reaches the cutting zone through the coolant holes in the blades. The fast, direct transfer of coolant to the cutting edge is made possible by Seco’s advanced Jetstream Tooling® technology. The 150.10-JETI family safely and effectively evacuates chips for better finished part quality and tool life. Adjustable edge heights optimise positioning.

The 150.10-JETI expansion includes face mount adapters for VDI30, VDI40 and VDI50 turrets and star mount adapters for VDI25, VDI30 and VDI40 turrets. The adapters hold 20-mm and 25-mm HSS parting-off blades. The range is also compatible with MDT reinforced blades with internal coolant.

Seco precision thread chaser holders

eco Tools recently adapted its line of reliable, accurate thread chaser holders to support Steadyline® vibration damping bars and Capto tooling. With special carbide-pin locating systems, patented pocket seat surface patterns and high-pressure coolant delivery, these holders guarantee consistent insert positioning, superior rigidity and effective chip evacuation Adapted for tooling with Capto C6, Capto C8 or Steadyline GL50 connections, these new holders accommodate a wide selection of multi-tooth chasers or single-tooth inserts that efficiently perform external and internal threading operations, providing increased options and added flexibility for push or pull configurations. Previously available in a square shank design, Seco’s thread chaser holders produce API and common licensed thread profiles across the full range of OCTG materials. The combination of a chipbreaker

MACHINE TOOLS WORLD JANUARY 2017

geometry and direct coolant delivered through the insert and chipbeaker creates optimal chip formation with increased tool life. Maximum pressures reach 70 bar on the new Steadyline and Capto versions of the thread chaser holders and 200 bar on square shank holders. Thread chaser holders rely on top and axial clamping forces to maintain a tight insert grip during the threading process.

These clamping forces result in long, predictable insert life and lower tooling costs. Together these holders and inserts can reduce the number of passes it takes to continuously produce high-precision full thread profiles. Seco Tools is a leading manufacturer of high performance metal cutting tools. Seco’s product range includes a complete programme of tools and inserts for turning, milling, drilling, reaming and boring as well as complementary tool holding systems. With more than 25,000 standard products, Seco is a complete solutions provider for the metal cutting industry and equips machine tools from the spindle down to the cutting edge. The company is headquartered in Fagersta, Sweden and represented in more than 50 countries worldwide with 40 subsidiaries, distributors and channel partners. Website:www.secotools.com/in

CUTTING TOOLS

TECH TRENDS

Aerospace Material Called CFRP: Drilling Solutions from Dijet, Japan

hen it comes to Aerospace a component machining it starts with difficult to cut materials, complex designs, and accuracy etc. the efforts put by mankind in this line were long term efforts were put to reach on today’s position and still this continuous improvement process is on, various R & D centres are still working to bring more and more ease in manufacturing as well as making it simple, durable and cost effective, and for more safety. Dijet Industrial Co. Ltd. has also developed tools for machining these aerospace applications considering the ease and safety in manufacturing for Dijet customers across the World. Demand for Aerospace machining tools is increasing as the Airplane manufacturing Industry is booming rapidly across the world. Following chart itself indicates the approximate Demand. Considering huge demand for the Aircrafts the need for fuel efficiency is the biggest criteria so usage of light weight materials likes Titanium, Aluminium or CFRP are being used most commonly. Now-a-days most widely used material for airframes in the aerospace is CFRP or CRP (Carbon fibre reinforced polymer or Fibre reinforced plastic is very strong, very light weight and expensive composite material. It is also referred as Carbon fibre. It may be called as replacement of strong and light weight metals. In following chart you can see the change pattern of material usage in Aircraft industry. Almost 50% of material used is CFRF. What is CFRP? CF: Carbon Fiber R : Reinforced P : Plastics

• Glass Fiber Reinforced Plastics (GFRP) It excels comparatively at a low price and electric wave permeability. • Carbon Fiber Reinforced Plastics (CFRP) It is used as succession material of aluminum alloys. • Boron Fiber Reinforced Plastics (BFRP) Strength and bulletproof are large, and it is often used for military arms. Aramid Fiber Reinforced Plastics (AFRP,KFRP) It excels in the impact-proof in strengthening by the Aramid fiber (Kevlar) Characteristic value of CFRP: 1. Specific strength is 10 times of Iron 2. Density is 25% of Iron & 60 % of Aluminum Problems while Machining CFRP 1. Excessive wear on the tools, tool life is short. 2. Difficult to achieve high surface finish quality due to delamination and burrs. 3. The state of surface finish is different from arrangement of fiber, edge sharpness and depth of cut. Dijet has developed new tools to Machine CFRP & for materials like Inconel, Monel, Aluminum etc. and already those tools have been proved all over the world for performance and quality.

For more information, Website: www.dijet.co.jp

MACHINE TOOLS WORLD JANUARY 2017

METROLOGY

IN FOCUS www.mtwmag.com

across a metal cutting production system that can build the required quality into the process. Q. What is the future of your products in India?

Renishaw: The Masters of Metrology Mr. Brett Allard, Director - Sales & Marketing, Renishaw Metrology Systems Ltd. Q. What are the milestones your company has achieved till date?

Many – Renishaw is relatively young as a business, having been founded only in 1973. It would be fair to say that the growth has been rapid – today the Renishaw Group currently has more than 70 offices in 35 countries, with around 4,000 employees worldwide with a group turnover of around £450m GBP. Renishaw has been recognised with 18 Queen’s awards for business innovation and export showing how we continue to strive for excellence, and continue developing. In India, Renishaw have been trading for around 35 years, and set up a local company in 2000. Since then, we have added an 80000 square foot manufacturing facility and now employ in excess of 350 people in the market Q. What product technology you represent?

Renishaw is one of the world’s leading engineering and scientific technology companies, with expertise in precision measurement and healthcare. The com-

pany supplies products and services used in applications as diverse as jet engine and wind turbine manufacture, through to dentistry and brain surgery. It is also a world leader in the field of additive manufacturing (also referred to as metal 3D printing), where it is the only UK business that designs and makes industrial machines which ‘print’ parts from metal powder. The core of the business is in the metrology (science of measurement) field. In this area we offer products and solutions that build in metrology across a metal cutting production process, from ensuring a machine is capable of manufacturing to required tolerances through our Calibration division, to post process inspection of components / systems using our award winning 5 axis CMM systems. In between these phases we offer products to check and calibrate cutting tools, verify dimensional accuracy during the manufacturing process, and gauging systems that give pass / fail information about components. In summary, Renishaw is unique in being able to offer a full range of products

Renishaw will continue to see India as a key market in our Global offer, and as such will launch products in India in line with the rest of the group. We make no differentiation between India and any other advanced Global economy. We do more heavily promote some of our entry level products such as the Primo probing system (designed at users new to probing) as there are clear benefits to the market from the deskilling of operators in programming the system, and the peace of mind that crash protection cover gives. However, in general we will continue to offer our full spectrum of product. Q. What is your vision for forthcoming years ?

Renishaw see India as a growth market. With the current rate of change, India will be classed as a high tech, advanced economy in the near future & the Make in India Strategy will drive this through the domestic production of increasingly more complex and critical systems for Aerospace, Space, Defence and Automotive projects. Our metal additive manufacturing (3d printing) offer means we are well placed to move forward as this technology moves from disruptive into the mainstream – this is already happening in certain segments such as Aerospace where production parts are now being printed. Renishaw has always heavily invested in Research and Development - this continues at pace. With the market conditions, our leading edge technology & a strong local team, my vision is to continue to lead the market in metrology and further strengthen this position through education. Educating customers of the massive benefits that process control brings to them in productivity & quality gains. This ultimately leads to increased profitability, which makes Indian industry more competitive in a Global marketplace.

JANUARY 2017

MACHINE TOOLS WORLD

METROLOGY

IN FOCUS

FARO: The trust for perfection Company infrastructure & global alliance

FARO is the world’s most trusted source for 3D measurement, imaging and realization technology. The Company develops and markets computer-aided measurement and imaging devices and software. Technology from FARO permits high-precision 3D measurement, imaging and comparison of parts and complex structures within production and quality assurance processes. The devices are used for inspecting components and assemblies, rapid prototyping, documenting large volume spaces or structures in 3D, surveying and construction, as well as for investigation and reconstruction of accident sites or crime scenes. FARO’s global headquarters are located in Lake Mary, Florida. The Company also has a new technology center and manufacturing facility consisting of approximately 90,400 square feet located in Exton, Pennsylvania containing research and development, manufacturing and service operations of its FARO Laser TrackerTM and FARO Factory Array Imager product lines. The Company’s European regional headquarters is located in Stuttgart, Germany and its Asia Pacific regional headquarters is located in Singapore. FARO has other offices in the United States, Canada, Mexico, Brazil, Germany, the United Kingdom, France, Spain, Italy, Poland, Turkey, the Netherlands, Switzerland, India, China, Malaysia, Vietnam, Thailand, South Korea, and Japan. Global Alliance – FARO in recent news:

FARO Partners with Siteco Informatica to Launch a Breakthrough in Affordability and Flexibility for Mobile Mapping Applications in Construction. This partnership pairs FARO´s worldwide sales network with Siteco´s technical expertise in mobile mapping systems to launch the new RoadScanner C “Compact Edition”. Under this partnership arrangement, FARO will provide a global sales network to market the Road-Scanner C and Siteco will sell, install and support the systems.

MACHINE TOOLS WORLD JANUARY 2017

The Road-Scanner C is a state-of-the-art system that is more flexible than competitive systems and priced to appeal to a broad market of users who need to capture existing infrastructure for applications such as utility pole location, electric transmission and distribution lines, etc. Key technology your products representing

FARO is showcasing @ IMTEX: • FARO Scan Arm HD - The FaroArm® is a portable coordinate measuring machine (CMM) that allows manufacturers easy verification of product quality by performing 3D inspections, tool certifications, CAD comparison, dimensional analysis, reverse engineering, and more. The all-new FARO Edge is the most advanced, state-of-the-art FaroArm ever produced. Features: CAD based inspection, Dimensional Analysis, First Article Inspection, In Process Inspection, Incoming Inspection, Reverse Engineering, Machine Calibration, Alignment • FARO Laser Tracker Vantage - The FARO® Vantage and VantageE Laser Trackers are extremely accurate, portable coordinate measuring machines that enable you to build products, optimize processes, and deliver solutions by measuring quickly, simply and precisely. The Vantage and VantageE both provide full support for FARO’s patented Super 6DoF (Degrees of Freedom) TrackArm solution which enables a Vantage Tracker and one or more FARO ScanArms to work together to create an integrated 3D measurement system. Super 6DoF completely eliminates line-of sight challenges and significantly expands measurement range while maintaining superior accuracy. Features: Large Part Inspection, Alignment, Tool Building and Setup, Machine Calibration, Cad-based inspection, Dimensional Analysis, Robot Calibration, Incoming Inspection

Mr. Beng Chieh Quah, Head of Marketing, Asia Pacific FARO Technologies • FARO Cobalt Array Imager - The FARO® Cobalt Array Imager is a metrology-grade non-contact scanner which captures millions of high resolution 3D coordinate measurements in seconds. The Cobalt Array Imager is equipped with dedicated on-board processors – an industry first. The smart sensor allows unique multi-imager array configurations which expand the scan area to deliver rapid, automated and comprehensive inspection; dramatically improving cycle time. The actionable data is then displayed as simple go/nogo result or an easy-to-read dimensional deviation color map. Features: Tool Inspection, Sheet Metal Inspection, Assembly verification, Mould & Die Inspection, Dimensional Analysis. Key application areas of products

• • • • • • •

CAD Based Inspection Reverse Engineering Large Part Set up Dimensional Analysis Alignment Machine Calibration Tool Building and Setup

Future trend of your product

As the world is growing towards automated technology, FARO is optimistic about its products arena. Considering India as a success story for new launches, FARO will launch tech products which are with easy interface & with ease of use to end user.

High-speed, 3D, on-machine scanning system for part setting and in-process control

at: See us galore 7, Ban 1 0 2 X B123 IMTE , stand A 3 ll a H

Transform your manufacturing with Renishaw From the latest in precision measurement and process control, to metal 3D printing systems, Renishaw can help to improve your manufacturing processes. We offer a range of innovative products including systems for machine tool calibration and probing, shopfloor gauging, 5-axis CMM inspection and additive manufacturing. The game-changing SPRINT system opens up completely new process control opportunities for high-value and high-volume manufacturing. Incorporating a new generation of on-machine scanning technology that delivers a step change in the benefits of process control, the SPRINT system enables fast and accurate form and profile data capture from both prismatic and complex 3D components.

For more information visit www.renishaw.com

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 general products advert IMTEX 1216.indd 1

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METROLOGY

TECH TRENDS

TBD HS: Programmable System for non-contact high speed tool breakage detection

ndustrial realities, where productivity represents the priority to achieve, aim to implement tool measurement solutions, which prove to be quick, accurate and reliable. Aware of such need and willing to develop an application that could avoid affecting production efficiency, Marposs presented TBD, the Tool Breakage Detector, a time-saving laserbased solution for broken tool detection on machine. TBD on milling machines and machining centres permits to keep under control the process, thanks to a very short tool checking cycle. Fast and reliable detection achievable by the TBD allows to reduce production time and to avoid expensive work-pieces scrap due to wrong cutting process by damaged or broken tools. All functionality is contained within the TBD unit compact housing, which can be mounted outside the machine area, saving space on the table. It is possible to choose among different working modes, which endow TBD with a great flexibility. Switching the power to the maximum gives TBD the chance to recognize a tool placed at a longer distance (up to 2 meters), with a standard capability to check the breakage. If a smaller tolerance is required, the reduced power can be set obtaining a smaller beam. Furthermore, an user can choose the filtering level of the signal. In fact, during the checking cycle, some coolant drops could interrupt the beam or coolant stuck on the tool could create variation in the signal received. Setting “Hi Filter” makes the software of the TBD more restrictive in order to give the more reliable response. On the other hand, choosing “Low Filter” TBD responds in a faster way, as the filter is less severe. Lastly, it is possible to choose the appropriate range of spindle speed, up to 5000 rpm.

MACHINE TOOLS WORLD JANUARY 2017

The new TBD HS Global Shopfloor Metrology Solutions Leader MARPOSS has recently introduced the new TBD HS, High Speed, on its wide range of products for tool checking on milling machines and machining centers. The new TBD HS is a programmable system for non-contact checking hi-speed tools, particularly committed to those applications where there is the need for hi-speed spindles, up to 80.000 rpm. Thanks to its rotary switch selector, the TBD HS is able to recognize the tool in two different ways, depending on the actual rotational speed, thus minimizing cycle times, generally crucial in this kind of process. Selecting “Quick Recognition”, the tool checking is performed for 10.000 rpm spindle speed and its multiples; on the other hand, it is possible to choose “Hybrid Recognition” if the speed is 1.000 rpm and its multiples or 10.000 rpm and its multiples. With a reflective, clean tool an impressive 150 msec checking time is achieved, approximately half the time compared to the standard TBD. High spindle speeds and small tool dimensions lead to the need for a fine

adjustment for positioning the TBD HS in a very precise way: that is the reason why an effective system has been designed to make accurate and easy the searching procedure of the tool verification position. Once TBD installed and tool approximately pointed, now is even more quick and simple to optimize the laser beam and to find the checking position. The tool breakage detection performed by the TBD HS is improved by the presence (upon request) of a blower for cleaning the receiver glass: taking advantage of the usual standard inlet, both in terms of air flow and pressure, it has been developed a solution able to protect the glass from swarf and scraps without increasing the air consumption. Moreover, when the conditions are particularly harsh because of the aggressive presence of shavings, there is the chance to substitute the standard protection glass with one in sapphire crystal: being 9 out of 10 its hardness degree on the Mohs scale, this kind of protection lets the receiver performance always at its maximum, no more damaged by the extreme machine conditions. Website: www.marposs.com

METROLOGY

TECH TRENDS www.mtwmag.com

3D Printing Empowers Students to Design Innovative Vehicles

stablished in 2008, DSK International Campus (DSKIC) in Pune, India is a prestigious design campus and a joint venture between DSK Group of India and lnstitut Superieur de Design Rubika of France (Rubika) under the supervision of the Chamber of Commerce and Industry of Grand Hainaut. DSKIC and Rubika provide professional training in animation, video game and industrial design driven by comprehensive coursework and an industry-centric approach to training through strong relationships with renowned companies such as Tata Motors, Decathlon, 3DPLM, Volvo and more. DSKIC is committed to inspiring creativity and cultivating well-rounded designers with the help of advanced technologies in 3D printing, 3D animation rendering software, industrial CAD studio tools and thermoforming machines. With access to 3D printing, students create concept models and functional prototypes for applied research and design projects. 3D printing is also used for presenting designs in international exhibitions, design competitions and seminars. “Local businesses are looking for smarter, more economic product designs and manufacturing since the government announced the Make in India and Skill India initiatives. It is important we equip students with knowledge and hands-on experience in the latest technologies that correspond with the industry standard,” said Rattan Gangadhar, head of the digital design department. Abstract Ideas Brought to Life Hands-on 3D printing helps students better understand complicated design theories. What used to be abstract ideas can now be demonstrated with 3D printed components customized for tailored training. 3D printing also unleashes

us™ thermoplastic, so students could perform functional tests while the vehicle was moving. The team 3D printed a functional, concept model with little lead time. After rounds of test prints and iterations, the vehicle design was finalized, detailed with laser-cut accessories and painted with a canvaslike texture. “The 3D Printer enabled us to build strong and durable parts in an efficient manner, saving us time and resources to focus on improving the design of the Gecko,” said Gangadhar, project leader of the Gecko.

students’ creativity in their research projects and in international competitions, including the SIAM Automotive Challenge in India, the 1-Design Award and Red Dot Award in Germany. For the Red Dot Design competition, students had to build a two-in-one vehicle. A team of DSKIC students created the Gecko: a tent on wheels that doubles as a portage to provide shelter and carry goods for rock climbers on difficult climbs. The team was inspired by a gecko’s feet that use tiny hairs and intermolecular forces to stick to surfaces. Students used this same technology on the Gecko, a complex design with irregular geometry. Rather than use traditional methods like CNC machining, the team used CAD and 3D printing to prototype multiple designs. All of the parts, including the headlights and taillights, were printed with Stratasys production-grade ABSp/

Investing in Innovative Designing The 3D printer at DSKIC is also useful for teachers and students building models with unique shapes and innovative designs, such as an X-car with rotating wheels. “It would have been very difficult to produce the X-car because of the delicate frame and wheels. But 3D printing made it easy for us as we split the model in two halves and printed them with high accuracy so that they can be snapped together,” said Gangadhar. DSKIC’s visionary move to implement 3D printing into its coursework has opened the eyes of its students to innovative designs in transportation, manufacturing and digital design as prototyping becomes more cost-effective and efficient. Today, students from various departments regularly use the 30 printer to fine tune their designs and compete in some of the most prestigious design challenges in the world. “3D printing has motivated students to be as creative as they can be and given them a great tool to visualize their designs without much hassle. Seeing them keep experimenting is perhaps the most rewarding for instructors,” said Gangadhar.

JANUARY 2017

MACHINE TOOLS WORLD

METROLOGY

TECH TRENDS

Applaudable Service Support given by Speroni India Precision Machining & Auto Components PMAC Mr. Karthik, Director, PMAC

recision Machine & Auto Components (P) Ltd (PMAC) specializes in manufacturing of Precision Machined Components to Industrial Valves, Earthmoving, Agriculture, Building & Construction Equipment, Locomotive and various other Industries in India. We have the capability of supplying fully finished components as per customer’s drawings and specifications out of cast, and forged materials. Director PMAC, Mr. Karthik says, “Many of the manufacturing companies consider tool presetter as merely a cost to the company because of wrong selection in tool presetter machines. There is still a lack of awareness on how a good tool presetter can be more beneficial that can

Before

MACHINE TOOLS WORLD JANUARY 2017

improvise the productivity. “We are using Tool Presetter past more than 10 years and we know the value of Preset Tools. The fundamental criteria for selecting any Tool Presetter, the machine should be rigid and sturdy enough to deliver repetitive and higher accuracy results. We found Speroni machines with these expected capabilities. With all our Group of Companies we have more than 6 machines.” He says, “Apart from the various features and advantages of having Speroni machine, we appreciate the efforts that Speroni India puts in to deliver the best service support for us. During 2015 flood, all our machines were under water for around 3days. When the water settled

After

down and when we entered our plant we realized that all our machines were badly rusted and most of the electronics had got totally damaged. Among them, Speroni Esperia, being 7 feet under water, was assumed to be scrapped like other machines; however we still took a chance & called Speroni India team to support us. Mr. Santosh Shinde, Application Head Speroni India, examined the machine and was positive for fixing it by replacing few of the electronics and some mechanical rusted parts. His team worked harder for one month and got the machine back to its original condition with similar accuracy as before. I feel enthusiastic to share this incidence where we can give full credit to the design of the machine made by Speroni Italy team that justified the investment made by us for the most crucial situation for us. It truly goes well as – Built for Last” Speroni India Mr. Shinde says, “Although it was a difficult task, I thank my team who kept no stone unturned to achieve the customer’s satisfactory result. Customers invest on Speroni because they trust us and we consider it as our responsibility to stand strong with them even during their odd times.

For more information Web: www.speronispa.com

METROLOGY

TECH TRENDS

Renishaw to debut new metal additive manufacturing system at IMTEX 2017 Renishaw, a world leader in precision engineering technologies, will be exhibiting its extensive range of metrology and additive manufacturing equipment at IMTEX 2017 which takes place at the Bangalore International Exhibition Centre, Bangalore, India, from 26th January to 1st February

enishaw will be exhibiting on stand B123, Hall 3A, showing its new RenAM 500M additive manufacturing system, its new high productivity machining cell concept, as well as its new non-contact vision measurement probe system (RVP) for co-ordinate measuring machines (CMMs). Also demonstrated will be the new MODUS 2™ metrology software suite which simplifies the programming of CMMs, plus Renishaw’s full suite of machine tool probes, calibration products, metrology fixtures, styli and position encoders, including the Queen’s Award winning RESOLUTE™ absolute encoder. RenAM 500M additive manufacturing system Making its India trade show debut will be the RenAM 500M. Fully designed and engineered in-house to be used for serialised production, the RenAM 500M builds complex metal components directly from CAD using metal powder fusion technology. Highlights of the system include a Renishaw designed and engineered optical system with dynamic

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focussing, automated powder sieving and recirculation, a 500 W ytterbium fibre laser and patented high capacity dual filter SafeChange™ system. High productivity machining cell showcases process control Renishaw will demonstrate how the ability to monitor key process inputs, analyse data and continuously improve manufacturing processes facilitates increased productivity and higher accuracy. Simply measuring the output of a manufacturing process using ‘tailgate’ inspection is not enough and, more often, too late to control all the variability in a manufacturing process. It is critical that checks and measurements are also made before, during and immediately after machining to control both common-cause and special-cause variation. Automation, measurement and feedback can deliver process control throughout the stages of manufacturing. Optimised processes monitor not only the condition of parts, but also the performance of machines, process trends, interventions and environmental effects. Renishaw’s high productivity machining cell will use the machining of an enclosure housing to show how measurement data and connectivity can enable highly

automated accurate manufacturing with low overall labour costs to be realised. The cell will demonstrate the effects of machine tool performance on the quality of parts produced, and show how manufacturers can monitor and control their machines to ensure they are capable of producing good parts. Renishaw will also demonstrate rapid automated setting of tools and workpiece location using standard user-programmable cycles. SPRINT™ high-speed contact scanning system Renishaw will also be exhibiting its game changing SPRINT system which brings exceptional, high-speed, high-accuracy scanning to CNC machine tools. SPRINT records a constant stream of accurate 3D points across the part surface, and analyses this data in real time on the CNC machine tool controller, to provide gamechanging opportunities for automated in-process control on high-value CNC machines. The SPRINT™ system incorporates a new generation of on-machine scanning technology that will deliver a step-change in the benefits of process control, enabling fast and accurate form and profile data capture from both prismatic and complex 3D components.

METROLOGY

TECH TRENDS For blade manufacture, the SPRINT system provides unprecedented capability for blade tip refurbishment and root blending applications. For multi-task machining applications, the SPRINT system offers users completely new process control capabilities, including exceptionally repeatable diameter measurement cycles. Additional functionality offered by the SPRINT system provides a rapid healthcheck of a CNC machine tool’s linear and rotary axes in seconds, making it possible to implement a daily machine monitoring regime with little or no operator involvement. Non-contact vision probe for the REVO® multi-sensor system IMTEX also sees the India launch of Renishaw’s new vision measurement probe (RVP) for use with the REVO-2 5-axis measurement system on CMMs. RVP increases the multi-sensor capability of REVO-2 by adding non-contact inspection to the existing touch-trigger, high-speed tactile scanning and surface finish measurement capability of the system. For certain applications, non-contact inspection provides clear advantages over traditional tactile probing techniques. Thin sheet metal parts, components with large numbers of holes (as small as 0.5 mm), and parts which are not suited to tactile measurement can now be fully inspected with the RVP system. This new innovation also gives exceptional improvements in throughput and CMM capability by utilising the 5-axis motion

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and infinite positioning provided by the REVO head. MODUS 2™ metrology software suite Users of co-ordinate measuring machines visiting IMTEX 2017 will also be interested to see how the MODUS 2 metrology software suite brings new levels of clarity and efficiency to the programming and operation of CMMs. Based on the established and highly capable MODUS platform, and supporting Renishaw’s range of three and five-axis CMM sensor technologies, MODUS 2 has been designed with usability in mind, including an innovative, easy-to-learn interface and faster programming, resulting in unprecedented levels of productivity with or without a CAD model. The user experience for MODUS 2 is also designed to be identical whether the software is connected to a ‘live’ CMM or working in an offline environment where

full simulation with speed control allows measurement sequence development and visualisation. Further innovations include ‘Off Surface’ motion technology, intelligent measurement strategies, automatic reporting and an interactive virtual CMM environment. From simple manual machine operation through to complex part measurement on multi-axis systems, MODUS 2 adapts automatically and only offers functionality relevant to the current task. Next generation of digital encoder Also on display will be the VIONiC digital encoder range which has been designed to reduce overall system size to the minimum achievable for a highperformance system, whilst delivering class-leading performance in terms of cyclic error, jitter and accuracy. Customers can choose between two VIONiCreadhead variants. The standard VIONiCreadhead features a SubDivisional Error (SDE) of <±30 nm, a range of available resolutions from 5 µm to 20 nm, and speeds beyond 12 m/s. Alternatively for the most demanding performance requirements, customers can select VIONiCplus™ with best-inclass SDE down to <±10 nm, low jitter to 1.6 nm RMS and resolutions from 100 nm down to 2.5 nm. Low SDE encoders are essential to minimise velocity ripple, which is important in constant-velocity applications such as laser scanning.

Visit us at :

MARPOSS 4.0 T H E S M A R T FA C T O RY T O G E T H E R

TOOL & PROCESS MONITORING Genior Modular can monitor real time and track quality from row to ďŹ nish part providing and using various sensors and control information. This solution allows machines and components to communicate and optimizes the manufacturing process. Marposs is the partner you need to make Industry 4.0 a working reality.

26th Jan to 1st Feb 2017

Hall 3B / Stand A112

METROLOGY

TECH TRENDS

Smart Industry – The future of manufacturing

hen most people think of Industry they probably they imagine a big, noisy place where everything runs at the steady pace dictated by giant machines. Raw materials are transformed into finished goods, unvaryingly and at a predictable rate, while people working there adapt to the processes and needs of the machines. While this is still true in many cases, the Industrial world is changing in a trend that goes under a variety of names including Industry 4.0, the 4th industrial revolution, Industrial Internet of Thing (IIoT) and smart manufacturing. Often revolutions looks like evolutions to those who are involved at the time. Only with the perspective of history is it clear that a “revolution” happened. At ST we believe that “Smart Industry” is an (r)evolution that builds on the many different technology advances over the past decades (evolution) but which will fundamentally changes the way factories and workplaces function (revolution). For us “Smart” means doing things more efficiently, more flexibly and in a more environmentally friendly manner. It also means the manufacturing will be safer for people working there. To achieve this we see industrial

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infrastructure evolving in three directions: More Efficient • With Industry consuming 50% of the energy in the world and factories accounting for 80% of that, reducing their energy use will play a major role in putting the planet on a more sustainable course. • Higher efficiency can be improved at all points in power usage with a particular focus on power conversion & energy harvesting, power management, power storage and motor control (since 50% of the energy in a factory is consumed by electric motors) More intelligent and aware • Machines are aware of the humans around them and provide new interfaces such as smart tools, augmented reality and touchless interfaces for easier and safer interactions. • Sensors collect information about every machine all the time. Then safe & secure distributed local processing allows data to be turned into information, allowing realtime monitoring and predictive maintenance and repair.

• Products contain the instructions for their manufacturing and carry that information with them throughout their lifecycle. More Connected • Machines are connected inside the factory to the larger supply chain and to the cloud. When orders can be customized in real time and only what is needed is actually made, this enables optimal planning and flexibility in manufacturing. • Real-time communication down to the lowest level of sensors and actuators, ensuring optimal reactivity and realtime analysis processes • And of course all of these communications are secure. Semiconductors are a key enabler behind this new Smart Industry, pervasive through the industrial infrastructure and behind the digital intelligence that it makes possible throughout the entire supply chain. As a supplier with over 30 years’ experience in developing products for factory automation and industrial applications, ST is playing a leadership role with its catalog of products that help make smart industry a reality, today.

EDM

COMPANY SPOTLIGHT www.mtwmag.com

Sparkonix to launch new generation EDMs & Industry 4.0 solution at IMTEX 2017 Meet Better results at affordable price

Founded in 1968, Sparkonix is a leading machine tools manufacturer in the EDM Sparking technology in India. The first to launch the EDM Spark Erosion technology in the Indian market, Sparkonix has served over 1,000 unique applications across 15 diverse industries. At IMTEX 2017, Sparkonix is launching CNC EDM Drill, a first by any Indian machine tool manufacturer.

New Launch: CNC EDM Drill

Meet the Future of Shop-floor productivity

In yet another first, Sparkonix is also launching its industry 4.0 solutions through its strategic partnership with System Insights, USA. The Vimana - a predictive analytics platform by System Insights for manufacturing intelligence is used by some of the world’s largest and most respected companies. Vimana unfolds a new dimension in productivity by providing previously unavailable insights from the shop-floor in real time.

Meet ‘India’s EDM”

IMTEX 2017 will also feature flagship models from Sparkonix’s highly popular range of over 25 variants of EDM Sparking machines. With over 5,500 installations across 150 cities and towns in India, Sparkonix’s EDMs are the most preferred choice in Spark Erosion technology across industries, regions and applications.

“The CNC EDM Drill is a indigenous product, developed in-house by Sparkonix’s R&D team. With the launch of CNC EDM Drill, Customers will benefit immensely from our application engineering expertise and advanced technology, made available at affordable price.” Shailesh Patwardhan, Director - Marketing, Sparkonix (India) Pvt. Ltd.

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MACHINE TOOLS WORLD

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COMPANY SPOTLIGHT

Ratnaparkhi Electronics Industries: The game changer

Mr. R R Ratnaparkhi, Managing Director, Ratnaparkhi Electronics Industries Pvt Ltd

stablished in the year 1989, we, “Ratnaparkhi Electronics Industries Private Limited ”, are proficient manufacturing and supplying of technologically advanced CNC Wire Cut EDM and EDM’s. With over 27 years of operation REIPL has achieved a consistent growth and received accolades from customers and various organizations,which includes the best innovative product award by RMTS organized KMG group in the year 2016 for the latest product “SMARTCUT”. REIPL manufactures and supplies wide range of EDM products viz:-

1. EDM SPARK EROSION MACHINE (ENC MODEL-Programmable Z axis) 2. EDM SPARK EROSION MACHINE (ALTRA ZNC MODEL-With Fuzzy logic ) 3. CNC WIRECUT MACHINE (EZEECUT- Reusable type) 4. CNC WIRECUT MACHINE (SMART CUT-Single Wire type) 5. EDM DRILL MACHINE 6. PEDM- PORTABLE DRILL CUM TAP REMOVER MACHINE. REIPL is based in Nasik,Maharashtra. With manufacturing unit in nasik,REIPL has got Sales and Service network in Pune, Mumbai, Baroda, Ahmadabad, Ludhiana, Noida, Faridabad, Chennai, Bangalore, Kolkata and Coimbatore. All our sales and service engineers are factory

MACHINE TOOLS WORLD JANUARY 2017

trained to support the customers with technical and application information. Under the leadership of the Managing Director ‘Mr. R R Ratnaparkhi’, with over 27 years of EDM experience and over a 100 members strong team and growing..... REIPL is no doubt; a leading manufacturer in EDM machine and a One Stop Solution to all the customers for the same. REIPL, started off with a role changing product for the market in the year 2000 with the first Made In India reusable CNC Wirecut machine.Challenging the exponentially growing Chinese machine manufacturing industry at that time and standing tall in the vicinity of competitive rates against Chinese machine, REIPL has poised to take EDM technology in INDIA to Subliminal heights. One of the most successful product of REIPL is “EZEECUT”,with its low maintenance cost, rapid cutting speed, uptop highlighted feature’s, EZEECUT has become a integral part of die mould industry today.With over 1800 + installations for EDM and WIRECUT machine REIPL has come up with yet another state of art wirecut machine”SMARTCUT”. Again giving importance to low maintenance cost and rigid structure.SMARTCUT is another milestone by company. This is in accordance with the “MAKE IN INDIA”initiative launched by Government Of India and is the latest contribution to for the Machine Tool Industry. We are happy to inform you that we are launching this new CNC Wirecut machine and Altra 5530 with Orbital at IMTEX 2017 show at Bangalore. About REIPL

Strength - We have strong team of more than 11 sales and support professionals handling all the products of EDM. And more than 20 trained service and application engineers to take care of installation and commissioning, warranty

and post warranty services. Network - We believe in being close to the customer and serve the customer through our 9 branch offices covering all major industry locations and through our Head Office at Nasik. R & D - A very competent and Hi Tech R &D team comprising of senior team members with cumulative collective experience in EDM /WEDM technology of more than 2000 man years . Manufacturing - A State of Art manufacturing facility in Nasik. REIPL THROUGH YEARS:-

• 1989 : Company established for manufacturing EDM control panel. • 2000 : India’s first reusable wirecut EDM “EZEECUT”. • 2004 : CNC reusable wirecut EDM ,”EZEECUT PLUS”. • 2010 : High end CNC reusable wirecut EDM ,”EZEECUT NXG”. • 2012: High Speed EDM Drill , “EZEE DRILL”. • 2015 : High speed ,auto wire tension reusable wirecut EDM, “EZEECUT HSAT”. • 2015: CNC wirecut EDM ,”SMARTCUT” (continues wire ). • 2015: Electric discharge machine “ALTRA ZNC”. An Industry leader for over 27 years,REIPL prides itself on meeting the demanding needs of the customer by providing excellent products at affordable prices.This strategy of combining superior and rigid electronic support with heavy duty machine tool is why industry professional alike choose REIPL.Through their dedication of providing Superior customer service and product expertise is why they have remained forefront of the EDM industry.

VOLLMER at IMTEX 2017 Hall 2B D102 26 January – 1 February 2017 Bangalore, India

EFFICIENCY SQUARED THE NEW VOLLMER VGRIND

Discover the VOLLMER tool grinding machine now, for the production of solid carbide tools. With innovative multi-level machining for even more productivity and precision. Other highlights: New machine frame concept, optimum accessibility and overview, flexible workpiece automation solutions

Scan code. Start film.

and well known operating software. Ready for precision at its best?

www.vollmer-group.com/vgrind VOLLMER TECHNOLOGIES INDIA PVT LTD. // Spl Plot No. 9, 3rd Main, 10th Cross // 1st Stage, Peenya Industrial Area // Bangalore – 560 058 // India info-india@vollmer-group.com // Phone: +91 80 28394477 // Phone: +91 80 41711155

EDM

IN FOCUS

NICKUNJ : The synergy of perfection with precision

Mr. Nickunj Shah, Chairman & Managing Director Nickunj Eximp Entp P Ltd Q. Nickunj has gained substantial market share in Indian market, please brief its journey from the inception & share some its milestones?

Our journey commenced four decades ago as a product and service provider with one product: crucibles for melting non-ferrous metals. This was followed by graphite to be used in high temp applications and super alloys (nickel based) for the aerospace industry. Our customer base expanded in concurrence with the first wave of industrial

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reforms in the 90â&#x20AC;&#x2122;s. In timely fashion, pneumatic & electric tools, machine tools accessories, and high temperature insulations were introduced. The Piezometer System was introduced thereafter and has proved to be a stellar product, much in demand even today. Carbon Fiber, Fabric, Carbon Carbon Composites (CCC) and Graphite Paper for Fuel Cell Applications were added to the product portfolio. We set up our own machine shop to manufacture machined graphite components, thus

strengthening our commitment to customers. In the early 2000â&#x20AC;&#x2122;s, we ventured into a totally unrelated product basket with machines and consumables used in the manufacture of gold, silver and imitation jewellery were offered under the JMMC Division. Refractory products were added and we were pioneers in introducing the neutral ramming mass for Coreless Induction Furnaces (CIF) in Indian foundries. We set up a facility for manufacturing EDM Wires, which was

EDM

IN FOCUS a milestone achievement. Emboldened by the stupendous success of the JMMC, we were inspired to offer the most technologically advanced products 3D Printers, laser marking & welding machines, titanium sheets, and nickel based super alloys amongst others. These products were offered under 15 various divisions, created by bunching products specific to an application or industry. About seven years ago, however, we underwent a restructuring and consolidation process and all the divisions were reorganized under 5 business verticals: Advance Engineering Solutions; EDM Solutions; High Temperature Solutions; Jewellery Manufacturing Solutions and Metal Cutting Solutions. From a single office in 1987, we have grown to a head office in Mumbai, 10 branch office locations, 6 retail outlets, and 3 job shops. Further, we employ 380 agile and competent individuals catering to a customer base in the excess of 25K. Q. Please brief us about company’s global reach & what are the global alliances that has been made in order to out-front the competition?

One of our key strengths is our 60 global

partners, who are renowned leaders in their own specific fields. Some of these partnerships are more than 25 years old. All our partners have grown their business in India, emboldened by Nickunj’s partnership and support. Some have even established their operations after years of hard work put in by the Nickunj team to establish the brand in the country. Our core competency has always been in sourcing technologically-driven cost-effective products and services for our customers in India. To achieve this objective, we have committed to extensive overseas visits; to interactions at various levels with manufacturers; and to trials and evaluation at the customer end. The marketing initiatives were complemented by an efficient aftersales-service. This service was manned by extremely competent staff, who have been trained at our overseas principal’s facilities. Lastly, transformation from simply a company offering products, into an End to End Solution Provider is our methodology to out-front the competition.

Q. What are the market prospects for the Nickunj products in India and How do you plan to position these products?

Industrial demand has been fluctuating with positive bias on a long term basis in India. The prospects are infinite and the potential huge. The Prime Minister’s ambitious “Make in India” campaign, coupled with the advent of foreign investment in manufacturing facilities in India, will have an exponential effect on demand. Indian customers are very cost conscious and are open to trying new products and solutions. We have products and solutions suited to specific applications. Additionally, our wide product spectrum finds applications in most of industries, offering us an inroad to more opportunities. Our experience, expertise, product knowledge and close collaboration with customers enables us to position our products/solutions strategically. Q. Can you brief us about the marketing strategies that were applied in order to stand out in the competition?

Our approach has been “Glocal”. We meet the needs of local customers with global solutions, providing maximum cost efficiency and minimum

Nickunj - Head Office Overview

MACHINE TOOLS WORLD JANUARY 2017

EDM

IN FOCUS risk for customer. One of our offerings is sourcing and supplying difficult to procure materials. We go one step further to combine our products with cost-effective solutions packages, thus providing all necessary technical inputs and administrative assistance for setting up Greenfield projects. This has helped create a niche for ourselves in a fairly saturated market with fierce competition. Another Nickunj strategy is our Productivity Improvement Program. We use our customers facilities, and deploy our personnel and products to substantially increase productivity and ensure steady & regular consumption of our products. The customers benefit from increased productivity, while we gain from a regular flow of captive business.

Q. In your opinion how can the Indian manufacturing industry become globally competitive?

Mission We at NICKUNJ, aim to emerge as an end-to-end manufacturing solutions provider, drawing inspiration and guidance from our overseas Principals and

• Mass Production / Economies of scale • Focus on Productivity • Continuous Product Development through own R &D efforts. • Stringent Quality Control & Assurance Systems • Automation, wherever possible • On time delivery. • Skill Development

from the active support of Team NICKUNJ, comprising of 380 talented professionals. We take challenges in our stride and endeavour to create benchmarks in providing, ‘bestfit’ solutions to our clients’ needs of ‘efficient manufacturing’. We remain committed to

Q. What are the key technological

meeting the complex demands

Q. Brief us about the R&D and Quality

trends that are driving your industry?

of our valued customers

policy for your business?

• Automation in manufacturing. • Use of laser. • Combination of software with equipments to enhance efficiency. • Environment friendly materials in industrial /construction industry.

by stretching our core

All our overseas principals have very stringent and efficient quality assurance controls in place. They have strong R&D facilities to keep the products in tune with the latest technologies. The products we offer are subject to stringent quality controls. In our graphite machine shop, with continuous R&D efforts, we were able to machine components of acceptable quality on conventional machines (normally machined only on CNC’s or VMC’s). This was done with reduced machining time and minimum wastage. In fact, offcuts generated were used for machining other components thereby making the component competitive. Our stated Policy on Quality is enumerated below: We at Nickunj Eximp Entp P Ltd are committed to offer quality products & services to all our customers by providing a superior technological edge, innovative hi-tech industrial products and services backed by trained, agile & competent staff. By deploying the synergy in SOURCING quality products, offering

sound SOLUTIONS, responsive & prompt SERVICE and unmatched SUPPORT, we are committed to continual improvement leading to total customer SATISFACTION, which is synonymous with the name ‘NICKUNJ’.

MACHINE TOOLS WORLD JANUARY 2017

Q. How do your perceive the future of the Indian manufacturing industry?

We are indeed catering to the manufacturing industry, and therefore, my reply to question 3 above partially answers this question. Whilst there could be setbacks in the short term, the long term forecasts are intact and with the slew of measures including the tax reforms adopted by the government, the future seems to be bright for the manufacturing industry. Further, demographic advantage with focus on digitization will play out to increase demand and that bodes well for manufacturing Q. What is your vision for your company?

Make NICKUNJ Numero Uno in each field of operation. Play a CATALYTIC ROLE to make India technologically competent and self reliant.

competencies, viz. “Innovative Product Sourcing”, “Customized Solutions” and “Impeccable Customer Service”, beyond conventional standards. We strive to maintain a focussed approach and ensure the expansion of our scope, far beyond the realms of basic trading activities – delivering only the highest quality products, complete manufacturing solutions, productivity improvement projects and various other services through our in-depth industry knowledge. We aim to “Catalyse & Transform” every step of the manufacturing processes of our customers, enabling us to proudly proclaim that NICKUNJ is truly: “Catalysing Transformation”.

Nickglo

+ TM

EDM

IN FOCUS

MAKINO: Global Leadership in EDM Technology Arena Q. Please brief us about recent initiatives undertaken in EDM space? Which are your focus areas?

Electric Discharge Machining technology is undergoing a sea change in terms of process capabilities and productivity levels. Several developments in Power Electronics, Adaptive control technologies and innovative process techniques have pushed the limits of EDM capabilities in terms of machining speed, accuracies and achievable surface finishes. EDM Controllers are getting more intelligent and are able to adapt and optimize machining conditions according to machining requirements and reduce human intervention to a great extent.Automation solutions are also becoming more practical and have a dramatic impact on productivity. Makino has been focusing on integrating these new technologies into practical features in its new generation machines and making it work for real life challenges. Q. What are the market opportunities for your products in India? How do you plan to position these products?

The Indian Die Mold tool rooms cater to the Automotive Industry predominantly and to some extent the FMCG Industry. In the last few years, requirements in terms of Quality/Cost/Delivery are driven by globally competitive market forces. Hence the Indian tool rooms have an immediate need to upgrade their infrastructure to meet such global levels of productivity and quality. The requirement is not just high quality machines but also a knowledgeable workforce. This is a huge opportunity for Makino, where we focus more on a holistic technology transfer to our customers rather than just supply machines. In the last two decades, many tool rooms have invested on our High Speed Milling machines but the EDM area has always been lagging behind with low cost machines. With growing de-

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mand for high quality molds and dies, at greatly reduced manufacturing lead times, tool rooms can no longer survive with age old, low cost/low end EDM machines. We are now seeing a huge opportunity for highly efficient EDM machines whose higher cost are justified by their capability to meet current demands for high quality and productivity.

Mr. Sadananda Koppalkar Head Business Development - EDM, Die & Mold, Makino India Pvt Ltd

Q. According you what are the factors affecting to your business?

• Our market is predominantly dependent on the Indian Automotive industry. Both domestic and export trends in the automotive industry have a direct impact on our growth • The quality and complexity levels of the molds and dies manufactured in India is getting more closer to the global levels and coupled with a demand for short lead times, there is a huge opportunity and demand for highly efficient machining technologies. • Demand for short lead times and cost pressures are resulting in long term efforts to establish local infrastructure for producing high quality molds Q. What are the key technological trends that are driving EDM industry?

• The most important trend that is driving CNC EDM business is the usage of Graphite as electrodes. Most of the shops are in rapid conversion mode from Copper electrodes to Graphite electrodes and this switch over demands a good CNC EDM as the technologies in conventional machines are limited to certain quality and speeds and this creates the demand to go for better machines. • Recently many Japanese and European companies have entered India directly and also procuring the Tools and Molds from local commercial tool rooms which demand high accuracy

and faster lead time. This is forcing the customers to go for a high end CNC Machines to meet the commitments of both quality and delivery. • In order to reduce the dependency on skilled manpower, today’s tool rooms demand an easy operator interface modules and easy programming methods to have smoother transitions. The newest controllers focus more on integrating efficient Adaptive Control and intelligent Programming Features which makes EDM operations simple and less dependent on operator skills. Q. What is your vision for your company?

We would like to be a one stop machining solutions provider to Tool rooms by contributing latest technologies, process and manufacturing practices so that the quality and delivery demands by OEMs can be met by our customers. Keeping in mind the requirement of right manpower for the industry, we have established a Technical Training Center, a first of its own kind that provides a 1 year comprehensive training covering the topics of machining, CAD/ CAM, quality and best manufacturing practices. These students, upon successful completion of the course, are offered to our customers across the country.

GRINDING & CUTTING

TECH TRENDS www.mtwmag.com

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

ith the Vgrind 160, we have established ourselves in the international tool grinding market for the first time, says Dr Stefan Brand, Managing Director of the Vollmer Group. “For us, this is a logical and consistent step in order to develop our core competency in sharpening, and to further strengthen Vollmer’s international position as a comprehensive solutions provider for tool production.” The response since Vollmer has launched its Vgrind 160 on the tool-grinding market has been incredibly positive, leading the company to invest in the machine. Vollmer places considerable emphasis on continuing development of the technology influenced by their own experiences and those of their customers. Machining solid carbide milling cutters and drills With the Vgrind 160 grinding machine, five CNC-controlled axes ensure precise machining of workpieces. Using

the Vgrind 160, tool manufacturers can produce solid carbide drills and milling cutters with a diameter up to 50 millimetres. The core of the Vgrind is the new kinematics system, which is controlled by two vertical spindles. This is because, unlike with a single spindle or horizontal double spindle, multi-level machining can be carried out thanks to the vertical arrangement. In addition, the spindle arrangement solves the common problems related to fixed and floating bearings, which leads to more precise results when machining workpieces. Speeding up production around the clock Thanks to short linear axis travel distances and swivel ranges, the Vgrind enables you to reduce machining times for machining workpieces. Nonproductive times are shortened because tool manufacturers can load the two grinding spindles with different tools. An optional tool magazine

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MACHINE TOOLS WORLD

GRINDING & CUTTING

TECH TRENDS with eight grinding wheel packages enables tools on the vertical spindles to be changed over automatically. The pallet magazine HP 160 enables up to 272 workpieces to be supplied. The HPR 250 free-arm robot is also a new addition which increases autonomy and efficiency during tool manufacturing – the HPR 250 makes it possible for the previous capacity to be tripled. The automation solutions ensure optimal utilisation of the machine, around the clock. Achieve precision across several levels The Vollmer grinding machine achieves more precise results thanks to multilevel machining, as a workpiece is only ever machined on the fixed bearing side of a grinding wheel set. In addition, the grinding wheel set is always located at the C-axis pivot point, which allows an accurate sharpening process. A further guarantee for precision and accuracy is the polymer concrete design of the

machine, as this solid foundation provides improved damping and vibration behaviour. The design and the wall concept of the Vgrind 160 lead to a compact and stiff construction with low space requirements. Intuitive operation with established software Operation of the Vgrind 160 can be easily and individually adjusted thanks to a height-adjustable, pivoting control panel. The display can be positioned so that not only does the operator have an optimal view of the graphic interface, but the work area also remains visible. To control the grinding machine, Vollmer uses the software NUMROTOplus, which offers comprehensive applications for the production and resharpening of various tools. The software of the Swiss market leader, NUM, is used for around 40 different types of machine from 15 wellknown manufacturers in 50

Visit us at Imtex 2017 @ Hall 2B D102 26 Jan to 1 Feb 2017, BIEC Bengaluru

Using the two vertical spindles of the Vgrind 160 grinding machine, tool manufacturers can machine their solid carbide tools on two levels.

With the Vgrind 160 grinding machine for solid carbide tools, Vollmer entered the tool grinding business field. 90

MACHINE TOOLS WORLD JANUARY 2017

countries. “We developed the Vgrind as an innovative platform, with which tool manufacturers can produce their products for their market precisely and efficiently,” adds Dr Stefan Brand. “A close dialogue with our customers and the changes in the market motivates us to continuously develop and improve our portfolio.”

INTEGRATED SINGLE SOURCE PRODUCTION SOLUTIONS TURNING

SURFACE GRINDING

GEAR HONING

FLEXIBLE SHAFT MACHINING

POWER SKIVING

I.D. & O.D. GRINDING

THREAD GRINDING

GRINDING TOOLS

HONING TOOLS

SERVICE & RETROFIT

VISIT US AT

HALL 4 / STALL C117 www.dvs-technology.com www.nemade.in

GRINDING & CUTTING

COMPANY SPOTLIGHT

Solitaire with New Dressing Attachments to Centerless Grinders namely Diamond Roll dressing and Diamond Disk dressing. They are sparingly used around the country. However with higher volumes for exports, many organizations would benefit from this new concept. We are also displaying a Gantry Automation for loading, unloading and indexing of components and operated by CNC controls. Star attraction in the stall:

Mr. Ashok Sheth, Chairman, Solitaire Machine Tools Ltd

The new dressing attachments and the feasibility to use them in Centerless grinders as well as other grinding applications would be of interest to prospective users. Also with rising shortage of skilled personnel on shop floor, automation would be of great interest to visitors. Drivers and stimulants:

Expectations from IMTEX 2017:

IMTEX 2017 is an event where technologies of most countries merge and we get a chance to learn of the new technological trends as well as cost effective solutions. We get an opportunity to meet with all our customers with whom we have worked over the last 27 years and get feedback on how their machines are working and how we can make it more productivity oriented. For us, customer is our Guru and we learn a lot from them. We also find new and prospective customers, where the orders can be expected over the next one year. As an effective promotional tool:

We are a solution oriented organization

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and our efforts are to introduce new ideas to our existing and prospective customers to improve their productivity, quality and meet demands of international markets. The new developments introduced by us in the last two years are exhibited and explained, so that more users can benefit by the new features added to our grinders. Innovative products on display:

We would display our Precision Centerless grinders, which are popular and widely used around the country and many industrialized countries. We are also displaying two new grinding wheel dressing attachments,

The economy may be showing slow growth, but there is potential to boost the growth through exports and manufacturing auto components for new variant of vehicles being introduced in domestic market. With decline in China growth and possible restrictions on imports from Mexico, USA can be a major growth market for India. The Machine Tool Manufacturers have to Target the market with potential for major export to USA in next 1 to 3 years. Our observation has been that the stigma of Indian Product being inferior no longer exists and is well accepted around the world. It is also observed by visitors that Indian machines are more sturdier and have a long useful life compared to some of the other Asian machines.

Visit us at :

26th Jan to 1st Feb 2017

Hall 1A, Stall A-111

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

GRINDING & CUTTING

IN FOCUS

EMAG : Global leadership through cognizance & excellence Mr. Andreas Zieger, Director, EMAG India Pvt. Ltd. Q. EMAG has gained substantial market share in machine tool industry worldwide , please elucidate the success story of the company? The machine tool (MT) market is a cyclical market and to stay on top one has to face the daily challenges and reinvent oneself again and again. EMAG has been in MT business for more than 150 years. Our important milestone was the invention of vertical turning principle in the 90â&#x20AC;&#x2122;s. Where lot of established manufactures had only a smile, but the vertical pick up machines are now a major concept with a lot of advantages and EMAG is market leader. Beside that core strength in turning we learned that in modern production the classical dividing lines between turning, milling and grinding will soon disappear. Our R&D started to integrate more and more technologies in our machines, even literately in one machine, we offer grinding and turning or hobbing and deburring. Now a days success factors to

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increase the machines performance are the automation and the flexibility of the machines to adapt the processes. Here we developed a modular machine concept in which we can integrate more and more of our technologies, like turning, grinding, hobbing, hardening and also integrate them with full automation.

And like all international companies we use the various local benefits for the product optimization. Here we have production plants in Germany, France, Italy as well as in US and China. Sales and Service team are in more than 20 countries and the technology centers in 6 location around our HQ in Stuttgart.

Q. Please brief us about the exports and overseas operations & what are the global alliances that has been made in order to out-front the competition?

Q. What are the market prospects for the EMAG products and How do you plan to position these products?

EMAG is worldwide operative, coming from Germany, Europe is still the core market and important because of the partnership with the European car OEMs, who develop parts with us together. But with our international network in sales and production, we cover all major production hubs in the world, can support our international customers with proven service solution anywhere in the world.

In general I would say that the MT market is not growing significant. Additional demand is partly compensated be increase in efficiency of the machines and longer life time of the machines. EMAG is well positioned with sturdy, high tech machines and with the combination of our various technologies plus the modular machine concept the machines are ready for the future. Also in India we realize a change in the manufacturing industry from a cheap job chopper to an

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Hobbing and Deburring Solutions

Shaving Technology

Gear Metrology

Cutting Tool Solutions

Workholding Solutions

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www.gleason.com

IN FOCUS international oriented quality partner. And here we can provide proven solution or can develop new lines and concepts. To achieve it we need a close partnership with our customers over a well-trained sales organization as a bridge between the task of the customer and the expertise of our worldwide technology organization. Thus we develop new solutions together with our customers, like PCL for build cam shafts or Graziano for laser welded differential casings or HAL for jet engine blades. In all our projects we target to get the extra benefit for our customers, not simple the cheapest my too product.

Q. Can you brief us about the marketing strategies that were applied in order to stand out in the competition of machine tool industry? Because we are seeing ourselves as technology leaders our major task is to share the knowledge, technologies and solutions with our customers to allow them to start challenging there thinking and to initiate a spark of a new concept. This is classical situation for a direct sales approach supported by informative marketing over web page, specialized magazines, Emailers. Of course we do use also the new media to share information, like success stories over Facebook or videos over YouTube. But the classical discussion between an experienced sales engineer and the responsible teams in a production plant is the most fruitful base to create an improved solution.

Q. Please elucidate in brief about the companyâ&#x20AC;&#x2122;s infrastructure & What are the measure that are being taken from the product manufacturing to distribution? In principle, we have worldwide three major machine production plants to produce the base machines. In our 6 technology plants we customize and tool up that machines or create complete lines, which we pretest with the customer before dispatch and finally with our worldwide service team we install and prove the machines at the customer place. The integration of various technologies

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GRINDING & CUTTING

to lines in combinations with additional equipment we do in our HQ. Beside turning, hobbing, grinding or laser welding we also add robot cells or central chip management systems to create complete production lines. All that requires beside a strong own production, a well-organized supply chain management and project execution management.

Q. Brief us about the R&D and Quality policy for your business? Quality management is the backbone for our daily improvement process and allows us to get stable results and learn each day. And our centralized R&D is driven by the international driven innovation process, where we collect the needs from the market, work with institutes about future processes and material together and finally the vision of the owner family to pushing us forward. And the world is changing faster and faster, e-mobility, new materials, additive production, â&#x20AC;Ś.

Q. What are the key technological trends that are driving machine tool industry? Trends from the market are the mass production to reduce costs, individualization of products with more product variances and faster life cycle time of product, fortunately the sustainability gets more importance and reduction on used resources. This requires high accurate and high efficient machines, with higher flexibility. Automation becomes a more integral part, because here the quality and efficiency can be improved. Industry 4.0 is a big word, which in my eyes will bring machine technology and IT together, here

sensor technology and big data can be added. All that is to optimize the process and use underutilized capacity. Recourse saving like electricity, material, coolant in the production as well as during the machine manufacturing is gaining importance too.

Q. How do your perceive the future of the machine tool industry? In future we will see more automated plants, where machines are linked, less manpower for stupid jobs. Technologies will come up new, like tool less electro chemical processes or additive productions. Sustainability I hope will play a more important role for the products as well as for the machines. And maybe my kids will commute in driverless cars to worldwide connected offices to plan and control the production.

Q. What is your vision for your company? At the moment our vision is to make manufacturing systems for precision metal components, this will still stand valid for the next years and behind the curtains we look into the future and work out our part of contribution and how we need to reinvent our machines.

GRINDING & CUTTING

IN FOCUS

United Grinding: Precision with Perfection 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. 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

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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. 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.

Mr. Sudheendra C. R. President - India Operations, United Grinding GmbH 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 in-house 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.

IN FOCUS

GRINDING & CUTTING

SBS Precision : The dynamic balancing & process control expert Q. Please elucidate in brief about the SBS Precision infrastructure & What are the measure that are being taken from the product manufacturing to distribution? SBS Precision sees India as one market instead of breaking it up into regions like East, West, North Our quick and effective customer support is biggest strength. We provide single window solutions to all customers for any issue instead of creating separate departments for sales, service, administration etc.

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

Mr. Rajesh Parsramka, Director SBS Precision Systems (India) Pvt Ltd

B.E. Electronics & Communications Engineering B.I.T. Mesra Post Graduate Diploma In Business Management I.I.M. Calcutta

Q. How do your perceive the future of the Indian machine tool industry?

Q. SBS Precision being in the industry for longtime & has gained bounteous market share in Indian machine tool industry, please brief SBS Precision’s journey from the beginning & share some its achievements?

Future is very bright and there are immense opportunities for growth

From a few handful customers a decade ago to hundreds of satisfied customers all over India today the journey has been full of challenges and success stories. We are now an important player in Dynamic Balancing & Process control business in India.

To continue to be the best choice for customers for dynamic balancing and process control equipment and always try to improve our services through innovation and hard work

Q. What are the market prospects for the SBS Precision products in India and How do you plan to position these products? Unlike our competition SBS is highly focused and specializes in providing solutions for complex applications for dynamic balancing and process control with the widest range of products available to meet customer’s technical specifications as well as budget constraints

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Manufacturing tolerances are becoming tighter with every passing day, product life cycles are becoming smaller, Manufacturing process have become highly flexible to adapt to any sudden changes in the business environment. All this provides high incentive to manufacturers to go for dynamic balancing and process control equipment.

MACHINE TOOLS WORLD JANUARY 2017

Q. What is your vision for SBS Precision?

Q. Please address the issues that are affecting the machine tool industry? Scarcity of working capital has been a serious concern with machine Tool OEM’s coupled with very high uncertainty about deliveries creating a long chain of blocked & un productive working capital. Lack of trained professionals in machine Tools industry is another big issue. The next generation of professionals are not yet ready to take over from the present generation who have rich knowledge and experience.

METAL WORKING FLUIDS

COMPANY SPOTLIGHT www.mtwmag.com

Hangsterfer fluids : The safe & green choice of every metalworking process

magine a factory free of noxious odors and dangerous chemicals. Imagine a factory full of safe and happy workers. Imagine increased productivity. All of this is possible with Hangsterfer’s metalworking lubricants. Since its incorporation in 1937, Hangsterfer’s Laboratories has been committed to making the highest quality metalworking lubricants. As a fourth generation family business we value the health and safety of the people we work with and this concern extends to our customers and their families. We only sell products we would want our family and friends to use. That is why all of our products adhere to the highest environmental, health and safety standards. The manufacturing industry has increasingly come under scrutiny by various regulatory agencies for the use of hazardous chemicals. Strict bans and regulations will continue to rise for many raw materials including formaldehyde condensates, boric acid, secondary amines, and short and medium chain chlorinated paraffins. Many metalworking fluids currently on the market face drastic formula changes if not total elimination. We at Hangstefer’s have always used the safest, highest quality ingredients in our products. Our customers can feel secure using our products because they do not contain any of these increasingly regulated raw materials. We have biorenewable, synthetic and highly refined products, and all are REACh, RoHS, and VOC compliant. Our products are GHS compliant and are free of hazardous pictograms including the

increase productivity, extend tool life, and improve surface finish. Our customers can feel confident using us for all of their metal cutting and metal forming needs because of our advanced performance-enhancing technology. Our products can eliminate common lubricant problems such as corrosion, dermatitis, and foam. This adds up to higher efficiency and cost savings over time. The use of our products ensures long useful life, low consumption, and the capability to machine in multi-metal applications. We have several technologies  that are especially good for Aluminum, Composites, Nickel, Stainless Steel, Titanium, Molybdenum, Tungsten, Zirconium and their alloys. We also have many aerospace, medical, and electronics approved products. Hangsterfer’s metalworking fluids allow you to machine better and safer with their unparalleled green technology. Keep your factories safe, efficient, and environmentally friendly by using Hangsterfer’s. All of our products are made in the USA, ensuring strict adherence to quality and consistency.

Mr. Edward Jones, COO & Technical Director, Hangsterfer’s dead tree and fish environmental hazard, the health hazard pictogram depicted by an exploding body, and the exclamation mark. The lack of harsh chemicals does not mean we compromise on performance. Our technologies are proven to

For more information, Website: www.hangsterfers.com

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COMPANY SPOTLIGHT

METAL WORKING FLUIDS

NYNAS : Global leadership in Metal Working Fluids arena Nynas is a different kind of oil company – we want to use oil, not burn it.

With around 1000 employees, production facilities in Europe and South America as well as offices in over 30 countries, Nynas is dedicated to researching, producing and supplying specialty naphthenic oils and bitumen for a growing global market. Together with our customers, we have the knowhow to find new applications and meet new challenges that can help shape society. We take oil further to bring value to customers and the world we live in. Nynas is a key global supplier of highly refined, hydrotreated naphthenic base oils. These Naphthenic Specialty Products (NSP) are applied as base oils for lubricants and lubricating greases, or as process oils for rubber and plastics (and many other uses). The naphthenic base oils have many attractive properties for the formulation of industrial lubricants, and have found widespread application due to the following properties: • Wide viscosity range, 3 to 700 cSt (at 40 °C) • Higher solvency power than paraffinic base oils of the same viscosity • Low PAH aromatic content • Low toxicity and IP 346 label free • Very good low temperature properties • Very high emulsion stability • Good heat transfer capacity • effective convective cooling • efficiency • Globally available base oil supply Nynas has a strong international position as a supplier of base oils for MWFs. This is because of stable, high quality thanks to in-house production capacity, but also because

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the knowledge base built up over the years helps customers to find the right product for various applications. The challenge is to find the right product for various applications in order to minimise wear on tools and machines, and to avoid unplanned operational shutdowns. In machine shops and manufacturing industry Nynas’ naphthenic base oils find use in industrial lubricants such as hydraulic fluids, gear oils, sideway oils, and in metalworking fluid formulations (MWF) for metal cutting and metal forming. The greater emulsion stability achievable in MWF emulsions based on naphthenic oils is the most important benefit brought to our end customer’s formulations. High solvency also facilitates the

creation of stable formulation also of complex formulation, containing high concentrations of additives. MWF emulsions based on naphthenic oils are used for metal cutting and also for hot rolling. The high solvency and very good solution stability properties are important advantages also when formulation neat MWF:s applies for metal cutting or metal forming. The increase in industrial production in countries such as India and China is also increasing demand for metalworking fluids (MWFs). The total global production of MWFs increased from 1.85 million tonnes at the turn of the millennium to the current level of almost 2.4 million tonnes. This increase can be linked almost exclusively to developments in Asia, which now accounts for more than 40% of consumption, compared with 30% in the year 2000. On average, MWFs account for 6% of the global lubricants market. Total global consumption is expected to reach around 2.8 million tonnes by 2020, with Naphthenic oils increasing their market share in this application. Growth will be enhanced by the increased use of MWFs in many industries, including the transport industry. Another driving force is the increased use of special alloys and demand for more high-performance fluids. This is to some extent counteracted by the increase in demand for metal replacement and alternative metalworking technologies and regulations. Ultimately, it’s important to remember that technological advancements also bring the need for improved MWF performance with respect to longevity and stability, and improved tool life.

W: http://www.losma.in | E: info@losma.in | T: +91- 9226107775

Plot no. 7A, Gat. No. 63, Shindewadi, Tal: Bhor, Dist: Pune - 412 205, India

Losma India Pvt. Ltd.

GLOBAL LEADER IN ‘OIL MIST FILTRATION & FUME EXTRACTION SYSTEMS’ FOR MACHINE TOOLS Since 1974

TECH TRENDS

METAL WORKING FLUIDS

Go GREEN ! Vegetable Oil based Cutting Fluids for Boosting Manufacturing Performance - Vrushal Phadnis, TAURLUBE Petrochemicals

t present nearly all metal cutting machines in the industry working with cutting fluids use products containing Mineral Oil. The recent years have seen a dramatic increase in prices of petroleum products, owing to the weakening of the Rupee and the demand - supply situation. Metal working fluids (MWF), the raw materials of which are majorly dependent on petroleum derivates have taken a direct hit, forcing suppliers to increase their prices over 15-20% in a short span of time. Considering the uncertainty of petroleum product prices and supply

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side constraints, MWF manufacturers now a days are constantly on a lookout to reduce dependency on petroleum. This has led to various developments in Synthetic products that fulfil the requirements of lubrication, corrosion prevention and dissipation of heat from the tool and work piece. However, a parallel line of development is in the field of renewable & bio-based products that are reasonably stable in product costing & supply, i.e. products derived from Vegetable oils. Vegetable oils, owing to their high polar properties adhere better to metal surfaces thereby creating a more durable

lubricating film than conventionally used mineral oil based products. The basis for the high lubricity lies in the very structure of the molecules of vegetable oils. Molecules of the vegetable oils are heavy, long and have dual polarity, which implies that each molecule of oil has opposite electrical charge at its ends. These bi-polar molecules have great affinity towards metal surfaces, which have a natural & inherent ionic charge on their surfaces. This results in the formation of a strong, durable and homogeneous layer of oil over the metal surface that is able to withstand high cutting forces without rupturing, thus enhancing the insert life during metal cutting operations. Mineral oils on the other hand, do not have polar properties. They form a film of layer on the metal surface which is weaker in nature, and that can rupture easily. Thus, in order to make mineral oil based film exert higher forces, it is required to induce strength to the film using Extreme Pressure (EP) additives. A comparative study conducted at a manufacturer of Aluminium & Steel parts revealed an increase in the life of carbide inserts by over 35% [350

Specialty oils for maximum emulsion stability and high solvency

The superiority of metalworking fluids made with Nynas base oils is just one example of how a daily chore can turn into a regular delight with the right naphthenic solution. The same goes for greases and lubricants, where Nynas base oils offer high solvency and excellent low temperature properties. www.nynas.com/base-oils

Nynas Naphthenics Pvt. Ltd. #2203 - 2205, Kesar Solitaire, Plot No.5, Sector 19, Palm Beach Road, Navi Mumbai 400 705, Maharashtra, INDIA Tel. : +91-22-6793 3800 | Fax : +91-22-6793 3900 | manoj.singh@nynas.com | http://www.nynas.com

TECH TRENDS

The basis for the high lubricity lies in the very structure of the molecules of vegetable oils. Molecules of the vegetable oils are heavy, long and have dual polarity, which implies that each molecule of oil has opposite electrical charge at its ends.

METAL WORKING FLUIDS components / insert edge ] using Vegetable oil based fluids, compared to a good quality mineral oil based fluid [260 components / insert edge] used in the same machining conditions. Hard to cut metals such as Stainless Steel and Titanium used in Aerospace and Dental industry which require higher cutting forces and speeds often face the issue of overheating & inadequate insert life, putting a limitation of machine speed - feeds. Vegetable oils maintaining a more durable film are able to withstand high cutting speeds, without overheating of the component or tool, thereby facilitating faster machining of these metals and improving

production numbers. A very useful feature of vegetable oils is their flash point. Vegetable oils have a significantly higher flash point which leads to lower evaporation losses and lower oxidation, leading to less smoke formation during metal cutting operations. Typically a mineral oil based neat cutting fluid having viscosity 22 cSt has a flash point of 170 - 180 deg C. A vegetable oil based neat cutting fluid having the same viscosity will exhibit a flash point of over 240 deg C. This ensures higher fire safety, lower oil consumption and cleaner working environment. Toxicity levels of vegetable oil based products are low, thus increasing the operator health and skin compatibility. The heavy molecular structure of vegetable oils also results in lower mist formation during machining, leading to a safe and cleaner working environment. Common sources for extraction of vegetable oil for use in cutting fluids include Sunflower, Rapeseed, Soya bean, etc. Life Cycle Analysis (LCA) of vegetable oil based cutting fluids shows that the environmental impact of the production, use and disposal of these products is far less than that of mineral oil based products. Vegetable oils have higher organic content and are easy to treat for disposal and lead to lesser Chemical Oxygen Demand (COD) and Biological Oxygen Demand (BOD) in Effluent Treatment Plants (ETPs). Use of vegetable oils and latest renewable resource additives in combination with effective microbial control chemistry have led to the development of highly performance driven, effective and environmentally responsible fluids. For more information, Losma India Pvt. Ltd. Plot no. 7A, Gat. No. 63, Shindewadi, Tal: Bhor, Dist: Pune - 412 205, India T: +91- 9226107775 W: www.losma.in E: info@losma.in

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Turning workplaces into safer places

www.schmersal.in

Programmable modular safety control PROTECT PSC1 ■ Connection for all standard safety switches up to PL e and SIL 3 ■ Safe axis monitoring according to EN 61800-5-2 ■ for up to 12 axes ■ Universal communication module: supports the standard field bus systems including the safety protocols

TECH TRENDS

Schmersal Group : Powerful Safety Systems for Machine Tools range of products for various requirements - ranging from a compact solenoid interlock for small safety guards to a three-point interlock for very large safety guards and a modular system for protection walkable hazardous areas. Safety in any operating mode Studies demonstrate that an excessive amount of accidents on machinery and plants occurs during set-up and maintenance. This can be prevented by implementing special safety measures for these tasks. For instance by special operating modes such as set-up mode and process observation, which are described in the new Machinery Directive (2006/42/ EC). The Schmersal programme includes for instance enabling switches to put these operating modes into practice.

afety in system: Protection for man and machine - under this motto, the Schmersal Group develops and produces safety switching appliances and systems for the entire machinery and plant construction for decennia already. In some industries, special and additional requirements are applicable. As customer-focused company, who intensively deals with the wishes of the manufacturers and users of machines, Schmersal has ta-ken up these challenges from the start. As a result, specific products and solutions were developed for many industries, amongst which the machine tool industry. This provides safety to your industry! High productivity Machine tools accomplish diverse processes in the metal working industry, e.g. turning, milling, grinding, and punching. Every second counts, especially in large batch production: the productivity is a highly crucial factor to determine the competitive advantages of a machine tool. As machinery safety is regarded, this means that the safety guards must not

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affect or interfere with the productivity. The Schmersal Group develops powerful safety systems for the machine tool construction in accordance with this principle for many decennia already. Interruptions unwanted Interruptions of the production process are unwanted, and not just because of productivity reasons. When the operator opens the safety guard of a boring mill, thus interrupting the process, both the drill bit and the workpiece can be damaged. This explains the above-average use of solenoid interlocks in machine tools. These devices keep the safety guard closed as long as the process is running. For these applications, the Schmersal Group offers an extremely comprehensive

Core target: avoid tampering According to studies, the tampering of the safety devices installed on machinery however is unfortunately standard practice in one-third of the metal-working companies. This risk can be minimized in a simple manner by means of coded safety switches and safety sensors as well as hinge safety switches. Fast diagnosis minimizes downtime It is recommended to use the â&#x20AC;&#x153;AS Interface Safety at Workâ&#x20AC;? standard for the transmission of safety-related signals. In this case, the user benefits from considerably reduced installation efforts and overheads as well as enhanced diagnostic possibilities - features, which minise possible downtimes. The Schmersal Group offers a comprehensive programme of safety switchgear with integrated ASi Safety interface. For more information, Website: www.schmersal.in

AUTOMATION & ROBOTICS

INNOVATOR www.mtwmag.com

Bettinelli’s Solutions for Motion Control & Automation “Our presence in India means quite something in fostering a symbiotic relationship with our customers,” says Mr. Rupesh Paparaju, Director, Bettinelli Automation Components, India

ettinelli S.p.A, established in 1953, specializes in the development and manufacturing of precision motion control components and systems. In 1996 a separate division named CDS Cam Driven Systems was created for engineering solutions in automation and motion technology. CDS produces the widest range of mechanical Cam Driven Units, commonly known as rotary / indexing tables for precision motion control applications, requiring rotary or linear transfer, positioning and handling. The products range includes, cam indexing and servodriven tables, ring positioning drives, intermittent and oscillating drives with parallel or right angle configuration, rotary & linear part handlers, precision link transfer systems, and epicycloidal servo reducers.

Wide ranging products

The broad product spectrum covers IP parallel shaft indexers, IT roller dial indexing tables, TR roller dial indexing tables, HP roller dial indexing tables, IG/ IGA roller gear indexer, TL precision link conveyors, MHP/LHP part handlers, FTHT open center ring tables and packages of rotary indexing tables. Bettinelli has a wide range of standard products. These are delivered in 3 weeks. When it comes to customized products, these are

designed, manufactured and shipped in 6-8 weeks. The manufacturing takes place centrally in Italy. The regimen starts with design & engineering, CNC induction hardening, CNC milling, grinding, quality check and then assembly, painting and shipment. In order to ensure quality, all components are machined internally, including the cam hardening by a proprietary CNC controlled induction hardening equipment. For better finish, the products are also subjected to chemical nickel plating, blasting and painting. The manufacturing process is constantly controlled to conform to international standards. The company’s quality systems are ISO-9001-2008 certified. The company has its own subsidiaries to look after sales and service in Germany, France, United States, India, and China and representative companies in other countries such as Spain, Denmark and the Netherlands.

Strategic advantages

Over the years, Bettinelli Group and CDS Indexers have become synonymous with high quality automation products and technologies. “Our design and manufacturing systems have furnished competitive and strategic advantages to numerous industries in pharmaceutical, automobile, manufacturing, packaging and a plethora of other sectors. And for automation functions, our solutions are invariably preferred by companies,” says Rupesh Paparaju, Director, Bettinelli

High Precision Fast Link Conveyor, TL Series

Parallel Shaft Indexer

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INNOVATOR Automation Components, India. The Indian subsidiary, headquartered in Pune, serves its customers in India by providing installation, commissioning, and after-sales support. It also offers technical consultation. In the pharmaceutical industry cam driven systems are used in filling, blister pack, tablet making and packaging machines. In automobile industry, they are used in pallet transfer tables, assembly machines, painting applications and test rigs, just to mention a few. In machining industry, they are used with advantage in deburring, lapping and pressing machines and in transfer lines. In SPM & robotics, they find applications in transfer lines, station loading, sequential operations and so on. Inwelding, these indexers are inevitable in positioners, synchronous welding, robotic welding and component transfer. Packaging too is a major application area. Cam systems are used in box filling machines, wrapping machines, cartoning and capping machines. Indexers are also used in casting, printing and cosmetics industries.

microns), these systems also feature zero backlash. CDS Indexers are known for durability. Thanks to the friction followers, they do not break or need to be replaced. They can bear higher loads compared to needle-based followers. Compact cast aluminium alloy housing, double extended cam-shaft, CNC case hardened cam-profiles, etc. are the salient features lending to high productivity. CDS underlines precision in operations. Repeatability of +/- 0.02 mm at cam follower, Airtight special aluminium alloy housing, Flanged through-hole input and out-put shafts supported by large preloaded tapered roller bearings, and Oscillating and customized cam motion are some of the

Features galore

The Bettinelli products are easy to install, they can run at a speed of 800 cycles per minute; there is no wear & tear and hence they entail zero maintenance. Designed to give high accuracy (+-20

Part Handlers – Linear & Rotary

elements facilitating this. CDS customization leads to adaptability. Customized size, stops, input shaft, threads & tooling on output flange, bores on the housing and a number of other features like prearrangement for gearbox connection, etc. contribute to this attribute. Proximity to the customer

The Indian arm of Bettinelli, based in Pune, Bettinelli Automation Components Pvt. Ltd., is highly customer-centric. “Our presence in India means quite something in fostering a symbiotic relationship with our customers. It helps us to match our world-class products with our eminent customer support,” underlines Paparaju, Director, who has built up a team to improve Bettinelli’s response time. “CDS are high-tech products which lend themselves to enhance the operational efficiency and productivity at the customer’s end. We stay close to the customer to understand his needs and offer customized solutions within the shortest possible time to ensure peak uptime of his equipment and operations”, he adds. Bettinelli is participating in INTEC-2017 in Coimbatore to put up an impressive show of its capabilities and offerings to the automation industry. - P.K. Balasubbramaniian

Roller Gear Indexers

Rotary Indexing Tables, TR Series

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MACHINE TOOLS WORLD JANUARY 2017

TECH TRENDS

AUTOMATION & ROBOTICS

Application of Linear Encoders on Machine Tools By Abhilash Tripathi Associate Director (Sales & Service) Heidenhain Optics & Electronics India Private Limited

he requirements facing industrial production of mechanical parts are steadily growing. Rising cost pressure is driving a trend toward dynamic machine tools that produce parts economically with very high accuracy even in small batches. The use of linear encoders to ascertain the slide position— also called “closed-loop control”—permits accuracy from the first to the last part. The effects of the feed mechanism, such as a difference weight of workpiece or the expansion of the recirculating ball screw, have no influence on the machining result and therefore on the accuracy of the machine. If the machine operates in a so-called “semiclosed loop,” the table position is measured through the pitch of the recirculating ball screw and the angular position of the motor encoder. Changes in the feed mechanism, such as thermal expansion, cannot be detected in the closed loop. At higher traversing speeds, however, the ball screw becomes significantly warmer. Figure 1 illustrates such heating with a thermal camera. The

Figure 1: Thermal behavior of a recirculating ball screw 114

MACHINE TOOLS WORLD JANUARY 2017

Figure 2: Effect of drive accuracy on series production inhomogeneous temperature distribution with temperature peaks of up to 50.5°C is clearly visible. Positioning error up to 200 µm within a short time is unavoidable and cannot be compensated because of the unknown distribution curve. The test setup shown in Fig. 2 illustrates the effects on the accuracy in the production of 300 parts. One workpiece with three holes, 2 mm deep, and the corresponding outside contour was machined. After 30 more workpieces were “machined” without tool contact, machining was repeated with 2 mm further infeed in the Z direction. This machining sequence was repeated to simulate the production of 300 individual parts. The workpieces show a considerable difference in the machining result of semiclosed loop control in comparison with that of a closed loop control. The deviations from the desired position are up to 200 µm. In contrast, the workpieces from machines with linear encoders provide the correct contour to within a few micrometers. (Fig. 3) The use of linear

Figure 3: Deviation between hole patterns in series production encoders therefore permits accuracy from the very first part without protracted run-in cycles. Of course, this also applies for mold making. If, for example, two mold halves are machined, then form deviations due to machine error normally require extensive rework. This basic consideration applies both for linear and rotary axes. Here, too, positions can be measured with a

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TNC 640 â&#x20AC;&#x201C; The new High-End Control for Milling and Turning Operations The new TNC 640: for the first time, milling and turning are combined in one TNC. Now users can switch as desired between milling and turningâ&#x20AC;&#x201D;within the same NC program. Switchover is independent of the machine kinematics. It automatically takes the respective operating mode into account and without any additional action.This new simplicity is complemented by dialog-guided plain language programming, the optimized user interface, powerful programming aids as well as comprehensive cycle packets taken from amply field-proven HEIDENHAIN controls into the new TNC 640.

HEIDENHAIN OPTICS & ELECTRONICS INDIA PRIVATE LIMITED

Angle Encoders

Linear Encoders

Chennai 600031, India

Contouring Controls

phone +91 44 3023 4000

Position Displays

Length Gauges

www.heidenhain.in

Rotary Encoders

TECH TRENDS speed-reduction mechanism connected to a rotary encoder on the motor, or with a highly accurate angle encoder on the machine axis, whereby angle encoders achieve significantly higher accuracy grades and reproducibility. Linear encoders in various mechanical designs Machine tools are usually equipped with sealed linear encoders, which are available in two designs. The 100 series (with large cross section) is available up to a measuring length of 4240 mm. By fastening it every 200 mm with the machine base, a very high reliability is achieved against vibration conducted from outside. The 400 series (with small cross section) permits measuring lengths up to 2040 mm and is used primarily where installation space is limited.The fundamental design of the encoders is identical for both series. A light source transmits light through the glass scale. The high-accuracy DIADUR graduation on the glass produces a precise pattern on the detector (photoelements), which is converted by the integrated electronics into electrical signals. With linear encoders for machine tools, the detectors function exclusively according to what is known as the single-field principle. These detectors, opto-ASICs developed by HEIDENHAIN, are optimized for application in machine tools. They are characterized by high tolerance to contamination and EMC interference. This modern sensor technology is the basic prerequisite for very high reliability together with consistent signal stability. The housing protects the optics from heavy contamination and allows itself

Figure 4: Full-size and slimline linear encoders

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AUTOMATION & ROBOTICS Figure 5 : Principle of design

to be fastened to the machine base. The elastic sealing lips close the slot required for movement almost completely. In many cases, these measures do not suffice to ensure reliable operation. Under extreme exposure to liquid or condensation, the use of clean compressed air has proven to ensure reliability for many years of operation. A coupling between scanning carriage and mounting base permit the +/- 0.3 mm mounting tolerance to the machine components without impairing the accuracy of the encoder. In the machine tool sector, too, the share of linear axes with direct drive is steadily increasing. This has been driving the continuously increasing demands on measuring technology with regard to signal quality and neutrality in the control loop. Besides small signal periods, a low position error within the period is also required in order to attain the required bandwidth in the closed loop. The absolute LC linear encoders with single-field scanning attain a max. error within the signal period of +/- 20 nm and therefore place no limit for the control bandwidth. Absolute measuring technology significantly facilitates finding the commutation angle after the machine tool is switched on, and allows simple implementation of feed axes with direct drive. Mounting the encoders If the use of linear encoders is considered

early in the design phase, fast and reliable mounting in only a few minutes is possible. For example, it allows the required alignment of the encoder to the machine guideway through milled stop edges. Of course, pins can also be used to align the encoders. For the absolute linear encoders of the 400 series there are accessory â&#x20AC;&#x153;pins with clamping elementsâ&#x20AC;? that ensure a reliable connection of the scale with the machine base. They are recommended for measuring lengths of 640 mm and more. At 1240 mm measuring length or longer, the clamping elements or a mounting spar must be used in order to ensure the required stability of the encoder perpendicular to the measuring direction.The clamping elements have two advantages over the use of mounting spars. First, they can reduce cost, and second, they do not change the basic mounting conditions. It is therefore easy to implement a modular design with variable measuring length.

Figure 6: Installation via clamping elements for the 400 series Summary A decisive factor for the productivity of a machine tool, besides accuracy (can I use this equipment to manufacture this part in a reliable process), is the availability of the equipment. High productivity with consistently high part quality is most easily achieved with linear or angle encoders. Today, their application is considered standard, not only on universal machines, but also on production machines. They are supported with numerous aids, beginning with 3-D models for simpler machine design, to special mounting accessories, fast and reliable mounting, and electrical testing equipment for initial servicing.

AUTOMATION & ROBOTICS

TECH TRENDS

ROBOTICS: The flexibility factor Mr. Arjun Prakash, Managfing Director, Effica Automation Ltd. Q. Effica is a well-known name in Robotic automation. What are the automation solutions you offer for the manufacturing sector? We offer robot based component loading and unloading systems. The solutions are available for multiple CNCs, forging presses, sheet metal presses, plastic injection moulding and similar processes. Along with this we offer all the accessories required to complete the solution like conveyors â&#x20AC;&#x201C; roller, belt, and slat, the end effectors for gripping various types of components, the safety systems, infeed and outfeed component stacking magazines. We also offer gantry machine tending to replace articulated machine tending projects for payloads from 2 kg to 100 kg. This is an economical solution, and with this the existing plant layout need not be disturbed. We also do bag conveying & palletizing automation. This is a robotbased high speed palletizing system with a speed of 20 tonnes per hour. For the FMCG segments we offer pick and place solutions for the packing requirements. These are very high speed solutions for

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light weight products with a special emphasis on hygiene. We have made our systems modular and user-friendly so that in the event of a failure, the end-user can fix it themselves. This way we have removed the fear of breakdown and consequent downtime from the mind of the end-user. Q. Productivity enhancement is understandable. How do you increase efficiency and flexibility? Robots help enhance flexibility. Special purpose machines need retooling but robots need only reprogramming. The changeover is minimal and not timeconsuming. Practically we observe that our customers have seen an increase in machine utilization by up to 35% while using our solutions. This is because people are prone to fatigue and night shift efficiencies are very low. This is not there when robots are at work. Naturally efficiency levels are high. Q. Could you elaborate on the cost saving aspects? To begin with there is a form of instant savings from the increased machine

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

AUTOMATION & ROBOTICS

TECH TRENDS

Fourleaf : EGAmaster Non-Sparking Tools PROPERTIES AND FEATURES

GAMASTER, S.A. Non-Sparking Tools are the best alternative for non-sparking application purposes in potentially explosive environments. All tools are forged after casting to achieve the best quality in the market, both in mechanical properties and attractive finishing. We incorporate to our non-sparking tools all our knowledge of decades designing and manufacturing hand tools, making the most ergonomic, easy-to-be-used and nicest design for them. All EGA Master Tools are manufactured according to the strict Copper-Beryllium Alloy Composition

120

Be:

1.8%-2%

Ni + Co

0.2%-1.2%

Other:

<0.5%

Rest:

Hardness

35-40HRc (320-370 Brinell)

Tensile Strength

1250 N/mm 2

Property

Application or Benefits

Non-sparking

Appropriate for explosive potential environments.

Non-magnetic safety

Essential for equipmentâ&#x20AC;&#x2122;s that require complete non-magnetic safety

Corrosion resistant

Especially well-suited for applications in corrosive environments like encountered in marine works or fire-fighting applications.

Forged after casting

Provides higher mechanical properties and better finishing.

Ergonomic designs

The use of bi-material anti-slippery handles, dipping anti-slippery, totally ergonomic designs make operations easier, more comfortable and master.

control of ISO 9001-200, certified by the most prestigious institution for hand tool manufacturing, TĂ&#x153;V-Rheindland/ Germany. CAUTION: These tools are not classified as anti-static because they do conduct electricity. Do not use high copper content tools in direct contact with acetylene due to the possible formation of explosive acetylide, especially in presence of moisture. Tools made of Cu-Be alloy can be used in all groups (I, IIA, IIB, IIC) in a safe way, always respecting the maximun surface temperature allowed, except with acetylene that can create explosive acetylite gases. Tools made of Al-Bronze alloy can be used in a safe way, allways respecting the maximun surface temperature allowed, except for the IIC group (Hydrogen, gas of water, acetylene, bisulphide of carbon, Ethyl nitrate) .

Safe work in Acethylene Enviroments Items with copper compositions higher than 65% should not be used in acetylene enviroments. Both aluminium-bronze and copper-berylium allows do have higher copper compositions than 65%. Reason is not that copper-berylium can create a spark with the enough energy to create the ignition of acetylene, but that copper can react with acetylene creating highly explosive acetylates. For this reason, copper-beryllium or aluminium-bronze alloys should not be used in acetylene enviroments. EGMASTER, S.A is working in a newly developed non-sparking alloy that may be 100% safe to be employed in acetylene enviroments. If that is your situation, please contact us to be informed about the availability.

Website: www.fourleaf.co.in

DIFFERENCES AND HOW TO MAKE THE CORRECT CHOICE

Aluminium-Bronze Alloy

Concept

Cu-Be

Al- Br

Composition

Hardness

35-40HRc

25-30HRc

Magnetism

Non ferrous substance in the composition makes it safer when nonmagnetic applications are required.

Minimun ferrous components makes them not 100% non-magnetic, although its low magnetism make it appropiate for non critical non-magnetic applications.

Durability

Much higher due to the higher hardness and tensile strength. hogher efforts can be made.

Not as much as Cu-Be.

Price

Higher price due to the special raw material used

Around 30% lower price.

Al:

10%-12%

Ni:

4%-6%

Fe + Mn

<5.8%

Other:

<0.5%

Rest:

Hardness

25-30HRc (250-291 Brinell)

Tensile Strength

800 N/mm 2

MACHINE TOOLS WORLD JANUARY 2017

The new control system PNOZmulti 2 with up to 80% less energy consumption â&#x20AC;Ś

â&#x20AC;Ś than comparable products. The power consumption of the new base unit PNOZ m B0 is a minimal 0.8 W with 20 safe inputs and 4 safe semiconductor outputs (PL e, SIL CL 3) and a width of just 45 mm. Rely on 10 years of innovation from the market leader in safe control technology! Count on the configurable control systems, the worldwide safety standard for all machine types. The simple, graphics configuration tool saves engineering costs because you can create your safety circuit simply and intuitively on the PC. Visit us at the Hannover Messe, Hall 9, Stand D17.

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AD_PNOZmulti_2_222x285_EN_IND_2015_03.indd 1

23.03.15 11:14

TECH TRENDS

AUTOMATION & ROBOTICS

Rollon Linear Bearings for CNC Doors & auxiliary axes on machine tools need different linear motion components than spindles.

he makers of CNC machine tools are not known for skimping on their motion control components, especially those related to spindle movements. Yet not every motion on a CNC machine is mission critical. In fact, most machines have one or more axes that, unlike the spindle, do not require high degrees of accuracy and precision. These axes can include doors and other auxiliary systems not associated with cutting. By picking an appropriate motion solution for these auxiliary axes, machine builders can not only take some cost out of a CNC machine but also improve that machine’s reliability in the field. Doors, in particular, are an axis that are often designed with less-than-ideal motion components. From an accuracy standpoint, door motion may seem like an open and shut case, but they do present some challenging design issues of their own. They tend to be large sheet-metal structures that are subject to deflection

and alignment problems. They also have to work reliably in a contamination-prone environment filled with metal chips and cutting fluids. These size and contamination issues can be especially hard on linear bearings. Engineers who work in machine tools will sometimes reflexively specify recirculating ball linear bearings, in part because of familiarity. Yet this style of bearing is not the best choice when it comes to creating a dependable, costeffective door. Rollon has developed an alternative bearing solution for doors and related auxiliary applications. It’s based on Compact Rail bearings, which are both self-aligning and resistant to contamination.

Self-aligning. Aligning linear bearings is usually a difficult process that takes place during the machine building phase. Machine builders must first machine mounting surfaces to near perfect flatness. Then they’ll install bearings using fixtures to ensure that rails are aligned horizontally and vertically. Both of those steps can add significant time and cost to the machine. And in the case of machine tool doors, both of those steps may be both ineffective and unnecessary. They’re ineffective because the doors tend to be large sheet metal structures that will deflect in use, undoing even the most careful installation techniques. And they’re unnecessary because self-aligning bearings can accommodate deflection without the need

On CNC machines, not all motion axes are created equal. While spindle motions are all about accuracy and precision, doors and other auxiliary axes require a linear motion solution that’s easy to install and reliable.

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TECH TRENDS for the expensive machining or fussy installation procedures. Rollon’s Compact Rail system gets its self-alignment capability from the way that its large roller bearings interact with a set of rail profiles. The profiles are designed to allow the rollers an extra degree of freedom or two to offset misalignment between rails. In the case of machine tool doors, an emerging solution combines Compact Rail’s U and K rail profile to support the slider (See Figure 1). The U-style rail has a flat raceway that allows a roller freedom translate in an out relative to the axial direction of the rail. The K-style rail has a geometry that allows for limited angular rotation of the roller, while still offering precise linear guidance. Together, these rails can absorb significant alignment errors in two axes: Parallelism on the horizontal plane and height differences between rails in the vertical plane. How significant? It depends on the distance between rails. For example, at a two-meter span between rails, the system can absorb parallelism errors up to 4 mm in the horizontal plane and differences in rail height of +/- 50 mm. (See Table 1 for self-alignment capabilities at other rail distances). With the Compact Rail system, the source of the alignment errors is not important. Whether the errors are caused by the machine structure, installation or

AUTOMATION & ROBOTICS Rollon’s Compact Rail bearings are both self-aligning and resistant to contamination.

You can find Rollon India Pvt. Ltd. & its solutions for automation at: IMTEX 2017 – Bangalore, India January 26th - February 1st, 2017 Hall 7 - Stand B129 deflection in the field, the Compact Rail will adjust and do so without affecting the wear characteristics or lifespan of the bearing. Low Closing Force. Compact Rails additionally make the doors easy to open and close–and not just because design tolerates misalignment without impeding motion. Compact Rails also contribute to the smooth door motion because they have a low coefficient of friction (COF). The typical COF for a Compact Rail ranges from 0.003 and 0.006, depending on size. Contamination Resistant. Another important linear bearing attribute important in doors and other machine tool

auxiliary axes is contamination resistance. Recirculating ball linear bearings, which have little clearance between balls and raceways, have historically been susceptible to contamination-related failures and require elaborate protective measures. Making matters worse, metal chips are among the most damaging contaminants in the industrial world. Rollon’s Compact Rail keeps contamination at bay in a few ways. It has small features, like seals and wipers, that minimize contaminants on the rails. Installation tricks, such as installing rails upside down, can further reduce contamination levels. Mostly, though, Compact Rail’s contamination resistance rests on its overall design. Its small ball bearings are permanently sealed within larger rollers. And the rollers have a large size relative to typical contaminants. They can roll over many chips that would stop a recirculating ball bearing in its tracks.

For more information: Rollon India Pvt. Ltd. 1st floor, Regus Gem Business Centre 26/1 Hosur road, Bommanahalli Bangalore 560068, INDIA Tel: +91 80 67027066 Fax: +91 80 67027004 info@rollonindia.in www.rollonindia.in

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UNITY CONTROLS PVT. LTD

TECH TRENDS

AUTOMATION & ROBOTICS

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

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

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MACHINE TOOLS WORLD JANUARY 2017

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

TECH TRENDS

consider taking the pressure reduction in two steps, or stages. We typically use a two-stage regulator like the 44 – 3400 to do this. The 44 -3400 is composed of two 44 – 2200 regulators built into the same body and internally connected in series with one another. The decaying inlet characteristic of the 44 – 2200 is 1.5PSIG/100 PSIG. The first stage is preset at a nominal pressure of, say 500 PSIG. The second stage is adjusted to our original 200 PSIG set point. When the source pressure decays from 3500 to 500PSIG, the first stage sees a net decrease of 3000 PSIG on its inlet. The outlet pressure of the first stage will increase by 30PSIG, to 530PSIG. The second stage now sees a net increase of 30 PSIG on its inlet. The outlet of the second stage will go down by. 45PSIG (.3x1.5 decaying inlet characteristic =.45PSIG). To anyone reading a typical pressure gauge on the downstream side of the two-stage regulator, the decaying inlet characteristic is transparent. Controlling decaying inlet characteristic Two-stage pressure regulators are frequently employed as cylinder regulators for packaged specialty gases. The flows are typically lo, and the twostage 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

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MACHINE TOOLS WORLD JANUARY 2017

AUTOMATION & ROBOTICS 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

TECH TRENDS

Plasma & Automated

sheet metal cutting What is Plasma & Plasma Cutting? Plasma is a thermal, very hot, electrically conducting gas, from positive and negative ions, electrons and excited and neutral atoms and molecules. In physics, we often talk about the 4th state. As the plasma gas a monatomic argon or diatomic hydrogen, nitrogen, oxygen gases and air can be used. The plasma gas is ionized and dissociated by the energy of the plasma arc. By a recombination of atoms and molecules outside the plasma jet of the system, plasma rapidly releases the received energy and enhances the effect of thermal plasma beam on the machined object. For the cutting process, a pilot arc between the cathode and the nozzle is first ignited by means of high voltage. This weaker energy pilot arc prepares partially, by ionizing, the path between the plasma torch and the machined object. By touching of the pilot arc and

a complete understanding of how the part requirements would apply to automation—in terms of money. Highprecision dual-gas cutting systems cost many Lakhs of Rupees, often accompanied by an equally expensive controller. While these setups provide very high cutting speeds, it is difficult, if not impossible, for a small fabricator to justify such an investment.

the machined object (cursory incision and cursory piercing) the power of the main arc is automatically increased. All kinds of steels, brass, aluminium, copper, stainless steel and other metal alloys can be cut.

Automated plasma table: For cutting the same shape multiple times, using an automated plasma table saves hours of post-cut grinding, which enables Cornfield Customs to maintain price competitiveness. The move to an automated system increases productivity, and the machine produces good, clean cuts. Further, a dramatic reduction takes place in the amount of cut-edge finishing.

Road to Plasma-Cutting Automation Fabricators note several reasons for considering the move from manual plasma-arc cutting (PAC) to automated cutting. A basic reason to automate is simple: manufacturers need quality cut parts at a reasonable price and at high rates of productivity.

Quick Switch from Automated to Manual While most users largely dedicate their PAC system to automated cutting on its table, arrangement can be made to quickly switch to manual cutting, by a quickdisconnect torch feature. This allows the

Purchasing the Right System Facilitating the transition to automation requires a number of decisions. First, purchasing the right type of automated PAC setup needs

Comparison of Methods: Autogenous - Laser - Water Jet – Plasma POSSIBILITIES OF UTILIZATION OF THE CUTTING IN THE EVALUATION OF QUALITY, PRODUCTIVITY AND EFFICIENCY (1 = BEST WAY, 4 = INAPPROPRIATE WAY) REQUIREMENT

130

TOLERANCE

AUTOGENOUS

LASER

WATER JET

PLASMA

CONSTRUCTION STEEL< 5 MM

UP TO ± 0.5 MM

CONSTRUCTION STEEL< 5 MM

UP TO ± 0.1 MM

CONSTRUCTION STEEL 5 - 20 MM

UP TO ± 0.5 MM

CONSTRUCTION STEEL 5 - 15 MM

UP TO ± 0.2 MM

CONSTRUCTION STEEL1 5 - 25 MM

UP TO ± 0.5 MM

CONSTRUCTION STEEL 25 - 45 MM

1 (O 2 )

CONSTRUCTION STEEL> 45 MM

HIGH ALLOYED

Yes

ALUMINUM

(Yes)

Yes

PLASTICS

Yes

MACHINE TOOLS WORLD JANUARY 2017

TECH TRENDS user to efficiently switch from the setup’s 180-deg. mechanized cutting torch to a 70- or 90-deg. manual torch. Software automatically detects the selected torch to switch between automatic and manual modes. Technical Tips for Better Plasma Cutting Over the years, the air plasma arc process has been greatly refined so that plasma provides good quality cutting, gouging and piercing at very high speeds for a much lower cost. This cutting process is truly perfect for many industries. Plasma arc cutting is a process where an open arc can be constricted by passing through a small nozzle, or orifice, from the electrode to the workpiece. Although the technology behind the plasma arc may seem complicated, the process itself is very easy to learn and perform. Plasma - A Cut Above Oxyfuel 1. While oxy-fuel was the most common method of cutting carbon steel in the past, plasma cutting is gaining favour because it provides numerous advantages. Plasma cuts faster than oxyfuel; a pre-heat cycle is not required; the kerf width (the width of the cut) produced is small; and, it has a smaller heat-affected zone, which prevents the surrounding area from warping or damaging paint. 2. In addition, plasma cutting can be used on any type of electricity-conducting metal (the oxy-fuel process cannot cut stainless steel or aluminium). Moreover, plasma cutting is a cleaner, less expensive and more convenient method of metal cutting because clean, dry air is used for most plasma cutting applications. 3. A properly installed air plasma arc cutting setup is safer than oxy-fuel gas cutting. This is because there is a chance of flashbacks and the danger of flammable gases in exposed hoses with oxy-fuel torches. 4. Plasma cutting is easier for hole piercing due to the plasma jet. The plasma jet is the swirling force of air around the arc, in combination with the arc

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attachment, which focuses the heat into the metal. In addition, plasma arc piercing does not require the metal to be preheated, which saves production time. The plasma jet also makes for a better choice when cutting stacked materials. Plasma Cutting Applications The plasma process can be used to cut any material that is a good electrical conductor. Unlike chemical cutting, it can be used on any metal for applications such as stack cutting, bevelling, shape cutting, gouging and piercing. Plasma cutting can be successfully performed on a variety of material sizes as well. Plasma can be used to cut anything from thin gauge aluminium to stainless and carbon steel up to several inches, depending

upon the power of the cutting machine. Some Details of Plasma Torches There are three variables that determine torch performance. They are cut height, cut speed and voltage. These three variables are not independent, if the speed or height change, the voltage will change. In fact, if any of these three variables changes, the others will also change. This relationship is what allows the Torch Height Control to work. As the part is cut, the metal may warp and rise up off the table as it gets hot. When the metal warps up, it gets closer to the torch. This will result in a decrease in voltage. See the image below. When the system senses this decrease in voltage, it can raise the torch up to compensate for the warping metal. Automatic Torch Height Control When a cut is started, the torch is held at the cut height. (left) If the metal heats up and warps up, the distances from the torch tip to the metal decreases. (Right) This will result in a decrease in voltage.

When the system senses this decrease in voltage, it will lift the torch up to compensate for the difference in voltage. Summarizing about Precision Plasma Why Plasma? – a. Productivity, b. Versatility, c. Economy, d. Quality Is Plasma Productive? – a. PLASMA is for people who want to cut for production with simplicity! b. PLASMA provides an economical way for cutting Cu, CS, SS, AL and Alloys with very good results! c. PLASMA gives the most economical cutting results and best quality in the 3 to 45mm thickness range (for manual cutting)! Plasma Is A Faster Process – Cut speed on CS material @150A a. 5mm CS, 4000 mm/min. b. 6mm CS, 3500 mm/min. c. 10mmCS, 2250 mm/min. d. 12mm CS, 2000 mm/min. e. 20mmCS, 1000 mm/min. f. 25mm CS, 600 mm/min. Oxy-fuel cutting speed is just about 350 mm/min for all these thicknesses!! Precision Plasma a. Higher quality throughout the life of the consumables b. Precision cutting results in the ISO 9013 quality range 3 c. 2 degrees or less cut angle (“Q” mode) d. Sharp top & bottom edge e. Virtually no dross Plasma Process Automation a. No manual adjustments at flow control b. All inputs through CNC c. Fully automatic setup and switching.

TECH TRENDS Precision Plasma – Cut Finish with Laser –Like Quality

Process Automation - CNC Plasma a. Operator selects: Material Type, Thickness, and Quality Level b. CNC sets all process parameters c. CNC displays proper consumables CNC Plasma - Automatic Nesting a. Makes accurate parts: QUALITY b. Increases plate usage: PRODUCTIVITY c. Reduces scrap: COST Ador Welding has introduced a wide range of Poratble CNC Cutting & Large Gantry – Type CNC Cutting Systems for both Oxyfuel as well as Plasma Cutting A) KING CUT SMARTY – PORTABLE POWER

easy and simple to operate with CNC controller. 6. Easy to control Motorized Torch riser from controller. Salient Features of Kingcut Smarty • CNC Controller – Operated with Numerical control (NC) codes. • Unlimited shape cutting can be performed as Designed / Defined by computers as job require. • Able to cut Straight line, Straight Bevelling, Circle, Programmed shape and 45 stored patterns. • Motorized Torch, Electric Clutch X and Y axis helps for Fast, Easy and Precise operation. • Light Weight – Easy to transport, store safely and perform cutting in Site and fabrication workshops. • Oxy-Fuel Cutting – Oxy-fuel cutting Torch comes with long warranty. • Motorized Torch Raiser to operate torch easily from the controller. • Plasma Ready – Plasma system can be added to cut non-ferrous metals.

automatic Torch Ignition for Oxyfuel cutting. • The machine has both automatic and manual torch height control option. • Can be used with up to 2 torches as standard. (1 Plasma +1 Oxyfuel or 2 Oxyfuel) Plasma Machines used with King Cut EDGE

C) King Cut Pro –High Precision Cutting with High Definition Cutting Machine Salient Features of Kingcut Pro

PLASMA MACHINES USED WITH KING CUT SMARTY

KINGCUT SMARTY is a CNC cutting machine which is compact, lightweight and portable. It is supplied to users as ready to use at site. 1. Economical, easy to implement cutting High profile and Precision Jobs using Oxy-Fuel and Plasma Cutting technology. 2. This small machine comes with great features including Pre heat, Piercing mode, Array settings and Kerf compensation. 3. Easy to use and operate the CNC controller with 45 Built-in patterns. Simple to use interface. 4. Standard USB port is used to download codes for custom shape and design cutting. 5. Manual programming is also made

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B) KING CUT EDGE –GANTRY TYPE ECONOMIC CNC CUTTING Salient Features of Kingcut EDGE • The machine is an economic machine suitable for oxy-fuel cutting and Air Plasma. • Dual drive mechanism with linear guideways • The machine is ergonomically designed. • 15 inch high brightness LCD with all standard Menu. • The machine has the option of

• The machine is with very robust design for High Speed High Definition Plasma Cutting, Strip Cutting and Oxyfuel cutting. • Contour cutting in profile /holes with very high precision. • 15inch high brightness LCD with Touch Screen with all standard Menus for Cutting and Marking • The machine has the option of automatic Torch Ignition. • Can be used with up to 4 torches as standard. (2 Plasma /1Plasma +3 Oxyfuel / 4 Oxy-fuel ) Plasma Machines used with King Cut EDGE

Courtesy: Ador Welding Ltd.

TECH TRENDS

Safe, efficient test rigs Manipulation-proof safety gate system and configurable control system provide greater safety

ow well a vehicle handles on the road is not just a question of the spring system and vibration damping. Shock absorbers ensure travel comfort and also contribute tremendously to a brand’s image. Prior to series production, the vibration absorbers are subjected to a wide range of tests. SAR Gröpler GmbH specialises in the development and construction of high performance simulation and test rigs for shock absorbers. Shock absorbers, often also known as vibration absorbers, are used to collect the vibrational energy of moving masses and convert it into heat. Used in conjunction with the wheel suspension and spring system, they largely determine whether the driver of the vehicle finds the road handling comfortable and safe. Designing and manufacturing modern gas or oil pressure absorbers for the automotive industry are a science in their own right; today’s individual absorber types are completely custom-made for certain vehicle types or model series. Automotive manufacturers pursue completely different concepts when it comes to the detail, even establishing an individual brand or model image. Thanks to intelligent technology, drivers of higher-priced models can now

choose for themselves if they want their journey to be soft or hard-sprung. Test rig simulates reality Single or dual tube pistons essentially consist of the absorber tube, piston, piston rod, gaskets, valves and rubber-mounted fixing points and are true masters when it comes to converting vibration energy. Before they are manufactured in series and installed in vehicles in their thousands, the automotive manufacturer needs to be absolutely sure that the vibration absorber will satisfy the real-life demands over many years. That’s why new absorber models are comprehensively tested in advance on special simulation and test rigs. Almost all conceivable applications and loads that are likely to arise in rug-

At SAR Gröpler, the configurable control system PNOZmulti 2 from Pilz monitors the sensor technology and emergency stop pushbuttons.

Whether connected separately or in series, the safety gate system PSENslock from Pilz is suitable for safety gate monitoring up to PL e.

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ged, everyday use are simulated with regard to the respective vehicle model, its weight and special features. Various road surface conditions are included, as are temperature fluctuations and use in different climate zones. Compact test rigs include process control technology “It’s our job to develop and construct a rig in such a way that the performance requirements specified by the vehicle manufacturer can be simulated efficiently and reliably”, says Günter Gröpler, the company’s founder, summarising the task. SAR Gröpler GmbH is based in the Swabian town of Dettingen/Erms and specialises in this type of test rig. Just two years ago the expanding company relocated to the new industrial estate on the outskirts. His sons are also involved in running this innovative family business, which is a complete solution supplier for test rigs including process control technology and measurement data acquisition. But that’s not all. With over 40 years’ experience in the industry, alongside mobile test rigs SAR Gröpler GmbH also manufactures machinery for the production and filling of shock absorbers. Other focus areas include the development and production of hydroelectric power plants and the retrofit of old plants. “Thanks to our test rigs, customers can be certain that the type of shock absorber subsequently installed in the vehicle satisfies everyday demands”, says Jan Gröpler, the company’s Junior Manager. Test rig requires efficient safety technology The test rig that stands just before the final inspection area at a well-known German car manufacturer measures around two by two metres at ground level and is around three metres high. The vibration absorber to be tested is initially clamped

TECH TRENDS one device; thanks to IP56 protection it is also suitable for rugged environments.

The standard-compliant emergency stop pushbutton PITestop from Pilz ensures that the machine tool is shut down safely in hazardous situations. vertically on to the upper and lower lug between two retaining pins. Once the safety gates are closed, a multi-stage test and simulation program begins, based exactly on the customer’s requirements. Two motor-driven spindles contract the shock absorber; the massive eccentric on the lower part of the rig is set in motion. Controlled by proprietary software, the rig now simulates on-road use with a variety of speeds, hubs, gas pressures, vibration forces and frequencies. This is where it gets hard and fast: forces of up to 40 KN are exerted; sensors regularly measure the absorber’s reaction, the gas pressure and other relevant parameters. The item under test must meet the stipulated performance features even under extreme conditions; obviously it must neither squeak nor creak. The software displays progress clearly on the central operator panel; at the end of the test series, all measured data such as speed, load, friction and absorption are also displayed. “Based on these results the manufacturer makes corrections and fine adjustments to the valves, for example, or changes the oil pressure”, Jan Gröpler explains. Manipulation-proof safety gate system Automation and safety technology

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The configurable control system PNOZmulti 2 from Pilz controls the stroke movements of the machine tool from Pilz, the complete safe automation supplier, is used to ensure that set-up, operation and maintenance of the test rig at SAR Gröpler is simple, efficient and above all safe. “The risk assessment in accordance with EN ISO 12100 showed that risks emanate in particular from the eccentric and that a risk of crushing and injury in the event of a power failure cannot be ruled out, so that safety functions up to PL e of EN ISO 13849-1 are required”, says Timo Lurf, head of Pilz’s technical office in Reutlingen. The focus was therefore on finding reliable, safety-related solutions for the two safety gates in the upper area and for the safety gate in the eccentric area. That’s why the safety gate system PSENslock from Pilz is used on all three gates. The non-contact, low-wearing and fully coded system with an electromagnetic holding force of up to 1000 N offers maximum manipulation protection thanks to RFID transponder technology. Whether connected separately or in series, PSENslock is suitable for safety gate monitoring up to PL e. Thanks to flexible connection options (M12 connector, 5-pin or 8-pin), wiring is simple and can be achieved quickly, without great effort. The safety gate system combines safety, automation and diagnostic functions in

Flexible control The flexible and configurable control system PNOZmulti 2 fulfils its role as the central safety component in the test rigs from SAR Gröpler GmbH: it monitors all the sensor technology and the installed emergency stop pushbuttons, as well as controlling the stroke movements. The housing width of the base unit is only 45 mm. On the left-hand side it is possible to connect communication modules with serial or ETH interface, or fieldbus systems such as PROFIBUS-DP, CANopen, EtherCAT or Powerlink. There are still 20 safe inputs available, up to eight of which can be configured as non-safety-related outputs, plus 4 safe semiconductor outputs (each with PL e). With the new illuminated display you can save time and costs during configuration and diagnostics and reduce the engineering work significantly. With the PNOZmulti Configurator, configuration is simple and intuitive via drag & drop. What’s more, in conjunction with PNOZmulti 2 as a contact expansion module, the safety relay PNOZsigma provides multiple shutdown paths. Finally, Pilz emergency stop pushbuttons are fitted to all relevant parts of the rig, the control cabinet and the operator terminal. As a result, the rig can be brought to a safe standstill within fractions of a second. One-stop automation technology and safety SAR Gröpler GmbH offers its customers the security of knowing that the shock absorbers tested on its rigs meet the required quality features. With wide-ranging industry expertise, competence in the field of risk analysis and CE certification as well as an extensive portfolio of sensor and control technology, as a complete safe automation supplier Pilz offers customers like SAR Gröpler one-stop, economical and tailor-made solutions for automation & safety tasks. Courtesy- Pilz India Pvt. Ltd.

Linear solutions global provider.

ROLLON India Pvt. Ltd. - INDIA 1st ďŹ&#x201A;oor Regus Gem Business Centre 26/1 Hosur road, Bommanahalli Bangalore 560068, INDIA www.rollonindia.in - info@rollonindia.in

Rollon is a global provider of linear motion solutions for several industrial sectors, such as: industrial machines, railway, automation, packaging and logistics, aerospace. Bangalore (INDIA) January 26th - February 1st, 2017 Hall 7 - Stand B129

IN FOCUS

Machine Tools to Drive the Manufacturing Sector of India

echnavioâ&#x20AC;&#x2122;s recent market research report forecasts the production of machine tools in India to grow at a CAGR of 13% during the forecast period 2016-2020. This growth in the overall consumption is attributed to the increasing import of advanced product lines from countries like Japan, Germany, and Italy. The growth of automotive industry in India is the primary growth driver for this market. The automotive and auto components industry has accounted for about 40% of machine tools consumption in India. India is the automotive export hub in the South Asian market for some of the major auto OEMs like Ford, Isuzu, Suzuki, Honda, BMW, Mercedes-Benz, and Fiat. There has been a growing need to adopt CNC-based machine tools in the end-user segments to achieve precision and accuracy in the production process. This demand for CNC-based machines is expected to aid the growth of the machine tools market in India over the next four years.

History

Machine tool is any stationary powerdriven machine that is used to shape or form parts made of metal or other materials. The shaping is accomplished in four general ways: (1) by cutting excess material in the form of chips from the part; (2) by shearing the material; (3) by squeezing metallic parts to the desired shape; and (4) by applying electricity, ultrasound, or corrosive chemicals to the material. Before the industrial revolution of the 18th century, hand tools were used to cut and shape materials for the production of goods such as cooking utensils, wagons, ships, furniture, and other products. After the advent of the steam engine, material goods were produced by power-driven machines that could only be manufactured by machine

140

MACHINE TOOLS WORLD JANUARY 2017

tools. Machine tools (capable of producing dimensionally accurate parts in large quantities) and jigs and fixtures (for holding the work and guiding the tool) were the indispensable innovations that made mass production and interchangeable parts realities in the 19th century. Within 50 years of the first steam engines, the basic machine tools, with all the fundamental features required for machining heavy metal parts, were designed and developed. Some of them were adaptations of earlier woodworking machines; the metal lathe derived from woodcutting lathes used in France as early as the 16th century. By the end of the 19th century a complete revolution had taken place in the working and shaping of metals that created the basis for mass production and an industrialized society. The 20th century witnessed the introduction of numerous refinements of machine tools, such as multiple-point cutters for milling machines, the development of automated operations governed by electronic and fluid-control systems, and non-conventional techniques, such as electrochemical and ultrasonic machining. Yet even today, the basic machine tools remain largely the legacy of the 19th century.

Mr. Marc Jarrault, MD, Lapp India Pvt. Ltd.

1. Customers demanding for innovative, faster and high-precision machine tools that can handle the production of increasingly complex parts. At the same time, systems need to be compact, flexible and safe and ensure reliable communication. 2. Increasing globalization and mounting competitive pressures mean that machine tool manufacturers need to increase productivity, standardize the product portfolio, shorten development cycles and comply with a constantly growing number of standards and guidelines. 3. Optimizing the design and engineering and improving cooperation with other departments. Interdisciplinary approaches replacing traditional processes, changing engineering methods and offering considerable potential for optimization.

Challenges

Machine tool industry is inherently complex. The main objective of this industry is to build machines which will work towards reducing operational downtime for its customers. Cable requirements of this industry vary from machine to machine depending on the type of equipment their clients need. Yet there are challenges that the industry experiences from time to time which is a clear indication of the evolution of the industry. For e.g.

Bridging the Gap

The wire and cable market in India has come a long way, from being a small industry to a substantial one, over a decade. And though most part of the industry continues to be unorganized holding a major chunk of the market, there is a need for consolidation to achieve economies of scale, and bring in technology and quality improvements to the industry. Lapp India believes there is great potential for their products in the Indian

IN FOCUS market that will help bridge the gap in the cable & wire industry. It is a one stop shop with a wide range of connectivity and plug & play solutions for the growing automated industry in India. Currently, Lapp provides superior quality and highly flexible cables, industrial connectors, glands, conduits, marking systems, tools & accessories, customized system and robotics solutions for the intelligent factory of the future. Some of the products developed and introduced by Lapp are: ÖLFLEX® ROBOT F1 is designed to transmit control and monitoring signals as well as power supply in environments where combined twisting and bending stresses occur. It allows for • Faster speed and accelerations which increases the economic efficiency of the machines • Multi-standard certification to reduce variety in parts varieties and save costs • Increased durability under harsh conditions provided by robust PUR outer sheath • Resistance to contact with many mineral and oil-based lubricants, diluted acids, aqueous alkaline solutions and other chemical media • Wide temperature range for applications in harsh climatic environments It is widely applicable in multi-axis articulated robots, automated handling equipment, industrial machinery and machine tools in power chains or moving machine parts and plant engineering. ÖLFLEX® SERVO FD 7DSL is a hybrid cable for permanently moving power chain applications. It allows for • Faster speed and accelerations which increases the economic efficiency of the machines • Only one connection line between drive and motor-feedback system. Instead of the encoder cable an integrated DSL pair takes over the signaling • Less cables and reduced connection costs • Space and weight savings attributed to hybrid cable design

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• Increased durability under harsh conditions because of robust PUR outer sheath • Resistance to contact with many mineral oil-based lubricants, diluted acids, aqueous alkaline solutions and other chemical media ÖLFLEX® SERVO FD 7DSL is best used in power drive systems in automation engineering, connecting cable between servo controller and motor, power chains or moving machine parts, for use in assembling & pick-and-place machinery particularly in wet areas of machine tools and transfer lines. ÖLFLEX® SERVO FD 798 CP is screened encoder cable for high dynamic power chain application in harsh conditions. It is widely used in similar areas of application as ÖLFLEX® SERVO FD 7DSL. ÖLFLEX® CHAIN 808 CP is highly flexible, screened control cable with PVC core insulation and abrasion and oil resistant PUR outer sheath. Benefits include: • Good combination of quality and price • Compact design - thin and light, without inner sheath • Increased durability under harsh conditions because of robust PUR outer sheath • Resistant to contact with many mineral oil-based lubricants, diluted acids, aqueous alkaline solutions and other chemical media • Reduced electromagnetic interference because of copper braiding screens It is applicable in power chains or moving machine parts, in EMC-sensitive environments particularly in wet areas of machine tools and transfer lines. It is also suitable for use in measuring, control and regulating circuits in dry, damp or wet interiors. ÖLFLEX® ROBUST 215 C is screened control cable, weather, bio-oil, detergent and hot water resistant for use in food & beverage industry and composting plants. Its benefits include: • Weather, ozone and UV resistance

together with the wide temperature range that enable versatile use for indoor and outdoor applications • Resistance to contact with plant, animal or synthetic-based organic oils, greases, waxes and the related emulsions • Good resistance to ammonia compounds and bio-gases • Good resistance to cold and hot water as well as water-soluble cleaning agents well-suited for frequent steam cleaning It is widely used in machine tool building, medical technology, laundries, car washing equipment, chemical industry, composting plants, sewage works, food and beverage industry, especially for production and processing equipment of milk and meat products, agricultural equipment, for indoor and outdoor use in EMC-sensitive environments. With ÖLFLEX® CONNECT, Lapp offers customized cabling solutions assembled exactly to the customers requirement from cable assemblies to industry standard servo connections right up to sophisticated high speed drag-chain systems. With three distinctive offers, customers get madeto-measure solutions, covering all their connectivity needs: • ÖLFLEX®CONNECT CABLES – classic cable assembly. This refers to all cables for which Lapp assumes control of cutting to length, marking, stripping and connecting cables to connectors – in standardised designs or according to individual customer requirements. • ÖLFLEX®CONNECT SERVO – assembly of servo cables. They are available from the cost effective basic line servo solution for applications free of aggressive environmental influences, to the core line, specially designed for dynamic applications, right up to the highly dynamic extended line performance class. Lapp offers the right solution for every requirements profile. Our servo cables can be built as per the standards of Siemens, Rockwell, FANUC, BOSCH. • ÖLFLEX® CONNECT CHAIN for highly efficient power chain solutions from Lapp

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IN FOCUS UNITRONIC® ROBUST C (TP) is screened low-frequency data cable twisted pairs for bio petroleum/ cleaner/ hot water/ hydraulic fluid resistance and outdoor food beverage composting. Its benefits and areas of application are similar to that of ÖLFLEX® ROBUST 215 C. ETHERLINE® TORSION Cat. 5 is industrial ethernet cable for torsion stress applications. It can be used in dry or damp rooms screened against interference and can be used for industrial ethernet in harsh industrial environments. HITRONIC® HDH Mini-Breakout Cable for fixed installation in cable ducts. Its benefits include: • Easy to install due to small dimensions, high flexibility, & small bending radius • Suitable for field assembly Universal cable for cabling of buildings • Zero electromagnetic interference as

the cable contains no mured cabling - backbone Methods of Deployment: laying in trunking, ducts, trays, empty plastic pipes, building riser, raised floors and plenums The Road Ahead

Technological expansion and manufacturing development, is here to stay and grow. Henceforth smart cabling solutions (slim and light design) with greater intelligence have to be manufactured, as they are the prime facilitators in achieving the objective of interconnecting intelligent devices with low loss. Broadly, the cables and wires used in these automated equipment / devices have to be flexible, temperature resistant, chemical & mechanical resistant, weather resistant, flame retardant, halogen free, fire survival etc. Further, automated systems in machine tool industry are capable of working more tirelessly, faster, and more exactly

Industrial Vending System using Robocrib & Scalemate

he RoboCrib® VX1000 has been designed to provide secure access for up to 1048 SKUs (unique items). Imagine this incredible capacity in a system that has only a 34” (86cm) x 39” (99cm) footprint. The variety of available bin sizes makes managing both small and large items a reality (carbide inserts, drill bits, spray cans, tape, safety glasses, air tools, welding tips, solder, welding tanks and more!). RoboCrib® can control access to products by item, employee or job. Further, the system has the capability to track “Lot Control” numbers, and serialized items. Calibration control insures that no serialized item will be issued if it has fallen out of its authorized calibration cycle. AutoCrib® software also provides for FOD (Foreign Object Debris) control. Unlike other systems,

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RoboCrib® is physically mobile and can be mounted on optional wheels, making it perfectly suited to manage maintenance and repair parts throughout large areas like airline hangers, shipyards and large manufacturing plants. ScaleMate® for RoboCrib® provides for a significant increase in security over drawer based dispensing systems. In the typical drawer based system the user is asked to tell the With a ScaleMate® the system does not rely on the user to give a count of what was taken. Further, if the user attempts to put a foreign object into the bin in an effort to change the issue quantity, the system checks to make sure the new weight is divisible by the per piece weight. If not, Scale Mate® will report bin contamination to the system administrator

than humans. Robot technology hence is becoming one of the most dynamic areas for development. They are now used in almost all the industries since they have become a crucial component for complex production process due to its superiority. Lapp has substantial expertise at its disposal, as well as more than 25 years’ experience in working with customers to develop and bring to fruition solutions in the field of robot applications. Machine tool `is the backbone of the manufacturing industry in India. It is an integral part of the manufacturing sector that directly affects the economy of the nation. Therefore there is a constant need for innovation in the industry that will in turn enhance the ability of the industry to develop new products and solutions. The machine tool industry is also key to the Government’s ‘Make in India’ initiative with a direction for companies to invest for India to become a manufacturing hub.

FEATURES

• 24-7 Availability - With security and accountability • No Repackaging Required - Save time and money with every re-stock • Fastest Retrieval Time: Access any item in under 10 seconds! • Automates Purchase Orders - It even calculates the lead times • Variable Bin Size - Customized to your exact needs • Vend almost any item, type, or size!Issue large, small, or delicate items without item dropping! • Control Reconditioned Items - Force the use of reconditioned items first • Gage Management - Deny access to a serialized gage that has fallen out of its calibration cycle • Full User Access Support Supports proximity cards, key fobs, mag-stripe cards, barcodes, keypad/ PINs • Weight Capacity: 1000 lbs (453kg) • Configurations: Up to 1048 Bins SKUs (Unique Products) • Power: 100-240VAC– 50/60HZ, 5A/2.5A MAX . Operates in UPS.

The Lifeline of DELHI Indian Machine Tools Industry

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TECHNOLOGY @ work

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

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

26 Jan - 01 Feb 2017, Bangalore Venue

Organiser

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

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

www.imtex.in

INDUSTRY SPEAK

Product Innovations & Metal Cutting / Joining Mr. Satish Bhat, Managing Director, Ador Welding Ltd.

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Ador’s niche in Welding Technology:

Standing as a technology leader:

ADOR Welding Limited has always been the pioneer in India in terms of development of Welding Consumables and Equipment comparable to the bestin-class products, and tailor-made for the Indian customer requirements in terms of performance, competitive price, unwavering quality and delivery. Niche products have been developed for special applications like Sugar Mills and other arduous applications, and many other areas. ADOR Welding Limited is the only Indian company to have developed the full range of most advanced energyefficient Inverter based Welding equipment, suitable for all types of welding – SMAW, GMAW, FCAW, GTAW, SAW and Plasma Cutting. These are designed keeping in mind the power supply situation in India, scarcity in the availability of Mains Power in remote site locations (generator compatible equipment), arduous site conditions and the necessity of ruggedness and durability.

ADOR Welding Limited is the Leader in India, in developing and supplying completely digital AC / DC Inverter based TIG Welding equipment, Inverter based SAW Equipment with capability of submerged arc welding in both Constant current as well as Constant Voltage modes.

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Innovations showcased recently: • WELD TRACKER : This is an in house innovation for seamlessly monitoring welding data through wireless communication link. This can be used as a productivity and quality control tool as well as automatic tracking of job as per WPS. In spite of all advancements there are a few concerns in a fabrication process which may result into degradation of the weld process or affect the productivity e.g. operator efficiency or capability to weld, ability of the machine to provide precise voltage or current to maintain the quality of the weld, alarm system to indicate if the current and voltages

go beyond pre-set limits which results into weld defects. Also one should be concerned about Idle time and ON time of the machine in order to achieve the maximum productivity. By developing this system, the user industry has got the solution to the above issues. • SYNERGIC PULSED TIG: This is an in-house innovation for building in intelligence in TIG Welding applications. The welder needs to set material type, type of welding joint and material thickness as inputs. The software automatically fine tunes the welding parameters to obtain the best possible TIG welding. The conventional method would involve pre-setting of multiple parameters like AC / DC mode, Pulse / No Pulse mode, initial current, slope in time, Pulse Current, Background Current, Pulse frequency, Pulse duty cycle, Slop out time, crater current, etc. All these settings are eliminated in this innovative Equipment.

IN FOCUS www.mtwmag.com

Our focus: Strategic business relating to defence, aerospace, missiles & gearboxes

Mr. G.K. Pillai, Managing Director & CEO, Walchandnagar Industries Ltd. Niche in Engineering:

WIL has actually been involved in the area of high-tech engineering & manufacturing for over three decades now. There are five distinct areas where we have been doing work in this niche domain: • Nuclear Power Plant Equipment – Manufacture of critical and core components like Calandria, End Shields and Heat Exchangers. Supply of such components to various nuclear power plants in India including 220 MWe Reactor, 500 MWe PHWR Reactor, 500 MWe PFBR and 700 MWe Reactor. • Missiles components – Manufacture and assembly of Motor Casings for Missile programs – both strategic and tactical i.e. AGNI, AKASH, ASTRA. Bharat Dynamics Ltd (BDL) is our major customer in this arena. • Defence equipment– WIL has been closely involved with the ATV (Advanced Tactical Vessel) program to manufacture equipment like Weapon Containers and Launchers. On board integration work at Ship Building Centre, Vizag is also one of our ongoing activities. We have also manufactured and supplied equipment like Mobile Bridges and Launcher Assemblies (both wagon mounted and

truck mounted) in the past. • Components for Launch Vehicles – WIL has been a strategic partner for the Indian Space Research Organization (ISRO). Various core components of launch vehicles – for both PSLV and GSLV programs like motor casings, strap-on motors and various segments have been manufactured by WIL and have successfully performed during launches. • Gearboxes – Our offerings in this area are quite diverse ranging from high speed, low speed, planetary and marine gearboxes. These are designed for various applications/industries including Sugar, Cement, Steel, Paper, Hydel, Fertilizer, and Petrochemical. Our marquee offerings are the heavy duty gearboxes designed specifically for the Indian Navy (Frigates, Corvettes and Submarines).

exotic materials for niche applications like nuclear reactor components, missile / launch vehicle motor-casings, etc. Innovations showcased recently:

• Development of tooling (indexing and welding fixtures) and fabrication processes for missile components • Innovation in design and manufacturing of sugar centrifugal machines w.r.t. machines basket design and machining process • Welding development processes for various exotic materials (e.g. Incoloy) in the manufacture of nuclear reactor components • Demonstration of success of “CentralDrive” gearboxes for cement mills • Successful finishing (grinding) on Hofler gear grinding machine to achieve DIN 1 quality standard for marine gearbox components

Standing as a technology leader:

Roadmap for the company yearning for

WIL has been a pioneer in the application of technology (both engineering and production process) towards manufacturing heavy engineering jobs. WIL has an engineering & technology vertical called as Walchand Technology Group (WTG) which caters to development and absorption of engineering & design skills in both current business areas as well as upcoming target businesses. Also WIL deploys state–of-the-art technology in the manufacturing process – e.g. 5-Axis CNC milling machines for missiles components, automated welding centres for aerospace applications, Hofler Rapid 2200 gear grinding machine (for DIN 1 standards for marine applications), etc. Also WIL has proprietary technology especially in the areas of welding procedures involving

excellence and growth:

Amongst its various business lines, WIL would like to focus in a big way on growing its strategic businesses viz. Defence, Aerospace, Missiles and Gearboxes. We are also looking at Centrifugal Machines (applications in both sugar-making and other industries as a product platform for rapid growth). The government’s focus on ‘Make in India’ and ‘Self Sufficiency in defence’ gives us enough confidence to be able to respond positively to likely opportunities. WIL would also be actively pursuing technology tie-ups / joint-ventures for the purpose of technology acquisition. While the domestic market is where our main thrust is, we would be actively seeking opportunities to expand our footprint in exports markets as well.

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COMPANY SPOTLIGHT

A Welding Fume Extraction System at work

How Cleantek serves machine tool industry

he industry is slowly becoming conscious of health and safety of its people. And this had a telling effect on enhancing productivity,” observes Mr. A. Krishnamoorthy, Director, Cleantek. The company based in Coimbatore has been providing the technology solutions for creating a conducive work atmosphere since 2006. Cleantek manufactures a wide array of equipment and systems for vacuum cleaning of shop floors - both dry and wet. It offers several job-rated models.

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Industrial vacuum cleaner was the first product it launched in 2006. “Since then we have installed over a five hundred units which continue to give peak performance in the industry,” says Mr. Krishnamoorthy. “Seventy per cent of these equipment are custombuilt. We study the requirements of the customer and then design a system to suit his exacting needs,” he elucidates. Clean air solutions for safety and productivity in the industry

Cleantek offers wide range of dust

Mr. A. Krishnamoorthy, Director, Cleantek, Coimbatore

COMPANY SPOTLIGHT www.mtwmag.com

collectors. It uses micro filters / electrostatic precipitators, achieving a particle size of 0.3 microns. It also designs and supplies wood dust collectors, SAW flux recovery systems, powder / granules / food particle conveying systems which are made of SS-304 or SS-314 for better hygiene.

Dust mixed with oil in engineering units is a health hazard. It can cause respiratory problems to the operators and shop floor personnel. Cleantek has devised CNC oil mist collectors to help shop floor personnel breathe easy. Welding fumes are also a major health deterrent. They have a mixture of harmful gases which when in held can fuse breathing problems. One can get burning sensation in the eyes and even get headache. In order to address this problem, Cleantek has come up with welding fume extractors. These are both unitary and centralised to suck the fumes from the welding stations and throw out. Fume extractors are a boon to electronics and medical equipment manufacturers. Soldering fumes are far more harmful for health. Clean environment

Cleantek’s Oil Mist Collector

Another range of innovative products from Cleantek are oil sump cleaner. These systems collect the coolants mixed with metal chips, filter them unto 10 microns and feed them back to the sumps. This way the costly coolants can be recycled after filtering the sludge. Cleantek has supplied capacities

varying from 200 to 500 litres to diverse industries including automobile. For sewage treatment plants, Cleantek offers customised high pressure blowers and regenerative blowers to agitate water and separate the impurities. The company has supplied over 1000 blowers for specialised applications. Cleantek has an ISO-9001-2008 certified manufacturing facility equipped with the best of fabrication / production equipment. “We need hardly 2-3 weeks to design and executive an order for any customised equipment,” says Mr. Krishnamoorthy who has a mechanical background and a rich hands-on experience in the industry. Cleantek has an impressive list of clientele for its varied products and systems. This includes L & T, Ewac Alloys, Brakes India, Wheels India, TVS Rubber, Pricol, Tata Motors, Hyundai, Toyota Kirloskar, Bharati Shipyard, Areva, Parryware, Lakshmi Machine Works, Flowserve India, Michlen Tyres, Compton Greaves, IITs and so on. ‘Staying ahead’:

Cleantek, registering a growth rate of 50% year on year, is all set to make it big in this niche business. The company is envisaging expansion by moving to a sprawling manufacturing facility in Coimbatore itself. It will be opening branches in strategic locations to stay closer to the customer and serve him better. Mr. Krishnamoorthy opines that greenfield facilities must provide for proper ventilation and fresh air flow in the plant at the layout stage itself. They must also make provision for sewage / effluent treatment plants to curb pollution and create an eco-friendly work atmosphere. - P.K. Balasubbramaniian.

Cleantek’s Industrial Vacuum Cleaning System in use.

For more information, Website: www.cleanvacindia.com

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COMPANY SPOTLIGHT

Electrotherm (India) Ltd. E&P Division The Engineering & Projects (E&P) division of Electrotherm is a leading designer and manufacturer of Induction Melting Furnaces and has exported over 550 furnaces to 42 countries around the world

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.

A visionary leader

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 for

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Heat Treatment. 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. Global presence

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

COMPANY SPOTLIGHT www.mtwmag.com

“Technology Provider with High Productivity”

Mr. A. V. Srinivasan, Chief Executive Officer Meiban Engineering Technologies Pvt. Ltd.

eiban Engineering Technologies Pvt. Ltd. An associate company of, M/s. Murata Machinery Limited., Japan a leading manufacturer of CNC machines with high end technology was started in 2004 by A.V.Srinivasan along with Murata Machinery Limited., Japan. Meiban Engg has just completed 10 years of operation and has achieved a consistent growth and received accolades from customers, which includes a best supplier award from a multi-national company. Meiban Engineering Technologies Pvt. Ltd. is a solution provider in the field of automation and turn key projects for manufacturing Automobile and Sheet metal components. Meiban Engg serves with Muratec high end automated twin spindle chucker’s for manufacturing automotive components, hydraulic components and

bearing components. Meiban Engg supplies and services sheet metal machines which include CNC Servo Turret Punch presses of various capacities, punching and shearing machines, and panel benders. Meiban Engg has customers from various application industries and we have over 300 satisfied customers in a wide spectrum of both SHEET METAL AND AUTOMOTIVE industries. Meiban Engineering Technologies Pvt. Ltd. is based in Bangalore, with a Sales & Service branch office in Chennai, Delhi and Sales and Service representatives in Mumbai. All our sales & service engineers are factory trained to support the customer with technical and application information. Consists of a 30 -member strong team and growing... This includes 10 factory trained Engineers for pre-sales application and after sales service support along with Specialist exclusively to support CAD/CAM for sheet metal application. Factory trained agent’s engineers are available with our partner to serve our customers better. Muratec Technical Center - Bangalore & Local Turnkey center

With the addition of technical center in Bangalore, we are now able to do trials and demos on our machines for our potential customers. We have started

Meiban Towers & Muratec Technical Center at Bangalore, Inaugurated by Mr. Yosuke Murata – Executive Vice President. Murata Machinery Limited, Japan on June 22, 2011 undertaking local Turnkey in India. Total solution is Turning machine with loader plus peripherals and options to achieve full automation for unmanned operations on 24X7 basis. M-2048TE and MW 100, MW120 & MW180 have been installed in 2 separate show room spaces. With this new facility, Muratec has launched its five-year plan implementation of supporting Indian customers for greater satisfaction. State-of-the-art built-in solar panels for common area lighting and rain water harvesting systems installed enhance our contribution to the ecology. For more information, Web: www.meibanengg.com

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COMPANY SPOTLIGHT

Nikopas Engineering : Benchmarking the standards

e are Manufacturers and Exporters of ‘nkp’ BRAND THREAD CUTTING DIES AND DIE-NUTS made of CS or HSS Material. We produce and supply Cut Thread Split Dies. However, ground threads Dies (lapped finish). Gun Nose Dies can also be supplied. Generally HSS Dies are manufactured out of M2 grade material; however, dies in 5% Co. (M35) and TIN Coated can also be supplied. We produce vide range of Thread forms standard as well as non-standard RH as well as LH sizes from 1/8”(3mm) to 4” (100 mm) in COARSE as well as FINE pitches. We produce different Thread Forms, such as, BSW, BSF, UNF, UNC, UNEF, UN, NS, WHITHWORTH

FINE, METRIC(FINE, COARSE), BSP BSC, BSCON, BSCY, ME, Pg, NPT, BSPT, ACME, BUTTRESS, ETC. Generally, Dies & Die Nuts supplied by us are cut threads, split and thread produced is to medium/6g/2A tolerance. However, Company is specialized in manufacturing Dies & Die Nuts to various thread tolerance such as 2A, 3A, 6g, 8g. We also manufacture as per requirements – may be on specific Drawings from buyers, we request you to please indicate your choice of requirement from our large Range of Products (More than 2000 different designs) indicated in our Website referred above. We have our Authorized Stockiest in Christchurch, NEW ZELAND. We are at

Technical Details : Threading Dies and Hex Die-nuts

• As a rule dies are manufactured solid, pre slotted (Form B). The dies produce male threads within the tolerance zone 6g or medium fit. The narrow web (Slot) on Die can be easily cut off with cut off wheel, when special tolerances are required. The Die will then be adjustable (form A). • Generally two types of dies are in common use , Cut Thread Dies and Ground Thread Dies. Ground Thread Dies have thread lapped and produce good quality threads. They are more accurate and generally used on machines. Cut Thread Dies are used by hand . • Round Dies are used to produce threads where as Hexagonal Die-nuts or Rethreading Hex Die-nuts are used for repairing of damaged or worn out threads. A simple spanner is used to drive the Hex Die-nuts. • nkp (LAPPED) Dies are ground after hardening in exact concentricity to their threads in both the perpendicular and horizontal planes. In good working conditions the Dies will always run true on the work piece. • nkp (LAPPED) Dies produce exceptionally good finish. • The design and heat treatment of dies give a high efficiency in steel up to 750 N/mm2. For steel with tensile strength >750 N/ mm2 and shot chipping brass special types Dies are available. • The number of flutes in the Dies depends on the nominal size of the thread and on the application. • The High Speed Steels and special Carbon Steels used for manufacturing of Dies are subject to a strict quality inspection.

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Mr. Dilip B. Sawant, Managing Director Nikopas Engineering Pvt. Ltd. present manufacturing and exporting to UK, TURKEY, MIDDLE EAST, SOUTH AFRICA and NEW ZEALAND on monthly basis large quantities as per their requirements. For more information, Email: nkpmktg@gmail.com Mobile - 9765560428 Web - www.nikopas.com

• The carefully supervised heat treatment produces quality and highly efficient tool life. • The quality and accuracy In size of the thread produced depends essentially on many factors such as machine should be in Al condition preferably with positive feed and chuck having axial and radial compensation. They prevent defective threads. Special attention must be paid to perfect alignment of the work pieces. • True alignment of work piece and Die are of prime importance. • Dies must be sharpened correctly and in due time. Blunt or faulty re-sharpened tools produce defective threads and increase torque up to 100 %, causes excessive wear and breakage. • While producing male threads with Dies it should be noted that the diameter of the bolts / component must always be a little smaller than the nominal size of the thread. While producing ISO male threads within the tolerance position 6g or medium, the negative allowance for the major diameter must be considered (major diameter of bolt = NOMINAL SIZE MINUS ALLOWNCE) • In principle diameter of bolt should be as low as tolerance will allow. • In order to facilitate start of threading, the bolt should be provided with bevel / chamfer. • A perfect alignment of the tools axis to the work piece is very important to produce male threads and good Die life.

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PRODUCT SHOWCASE TAKEZAWA SEIKI Honing Machines

For Product Enquiry Contact Arhan Technologies Pvt. Ltd. Plot No.18, Final Plot No.106 Ramtekadi Industrial Area, Hadapsar - 411 013, Pune, India Telephone : 020 65603200 / 01 / 02 / 03 E-mail: contact@arhan.co.in Website: www.arhan.co.in

Japanâ&#x20AC;&#x2122;s Takezawa Seiki is pioneer in Single Pass Honing machines and Honing Reamers is going to start its Fully Servo Controlled and ECO Models Honing machines production in India jointly with Arhan Technology/ Miyakawa Kogyo India Pvt. Ltd. This will enable Indian customers to get Japanese machines at economical pricing than import from Japan with total local support. Takezawa Seiki machines allow honing process in just a single pass and at the same time increase tool life four times that of ordinary metal working tools. These machines allow profitable parts production to customers. Fully Servo controlled machines has all Servo axis and complete control over the process for highest accuracy. Takezawa has unique patented micro-oscillations honing technology. This technology gives superior finish for both ferrous and non-ferrous materials. Standard honing machines have tool reciprocating cycles. Other honing machine manufacturers use multi-station index system and claim for single pass honing. While Takezawa Seiki offer true Single Pass honing in single station with single tool process for material removal up to 30 microns. Machine models with maximum honing capacity of Dia. 20, 30, 60 mm will be manufactured in India. These machines will enable mass production with improved productivity, superior part quality and reduction in Cost/piece. These machines are capable of processing Cast Steel, Cast Iron, Stainless Steel, Carbon Steel and also Aluminium, Aluminium Alloy material. These aluminium and copper honing applications are new in Indian industries. Takezawa machines with Takezawa Reamers are capable of entire honing process in just a single pass with a roundness of 0.5 micron and surface finish of 0.5S. Part Cylindricity is also improved. Takezawa will be able to offer complete solution of Machine + Tool + Fixture. Takezawa makes various types of reamers, Expansion Type, Head Expansion, Spiral Groove, Non-Expansion, Expansion with separate reamer external body type (Only abrasive part replacement). The Takezawa Seikiâ&#x20AC;&#x2122;s knowhow in diamond and borazon CBN has enabled long life with more abrasion resistance. In expansion type reamers Takezawa Seiki will use high precision parts from Japan and original Japanese precision parts, drives, controls and motors in these machines. Non precision parts will be manufactured in India and total assembly, testing will be conducted with Japanese manufacturing system to have Japanese Quality. Takezawa Seiki will give Japanese expert solutions to Indian customers. Takezawa Seiki has arranged demo of these machines for customers in January, February 2017 at its Indian facilities.

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PRODUCTS

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

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.

Hangsterfer’s CC 10 - 22 Straight Cutting Oils For Deep Hole Drilling • • • • • • • • • •

CC 10 & CC22 oils are Chlorine-Free Non-Staining Can be used safely on all materials Non-Toxic Non-Irritating Non-Corrosive Easy to recycle and waste treat Lower misting Fewer residues

Hangsterfer’s neat cutting oil CC10 is recommended for Deep Hole Drilling /Gun Drilling application. CC10 (Viscosity 10) has all the capability to outperform. Hangsterfer’s neat cutting oils are recognized by various machine manufacturers around the world. These oil improves tool life and surface qualities to the large extent. In addition to the lubricity provided at the cutting zone, Hangsterfer’s cutting oils provide excellent lubrication for the machine’s slides, guide bushings, bearings, and spindles. For Product Enquiry Contact Hangsterfer’s Laboratories, Inc. USA Sanjay Tools & Adhesives Mobile : +91 9822028518, +91 9892516810 E-mail: hangsterfers@sanjaytoolsnsk.com Web : www.hangsterfers.com

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

PRODUCTS www.mtwmag.com

Mitutoyo 2D Color Vision Measuring system: Quick Image series The ultimate vision measuring machine with simple operation using oneclick instant measurement.

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

The new Quick Image series provides further ease of use and improved operability with no compromise in the measurement accuracy of ± (3.5+0.02L) μm. It proves to be efficient for shop-floor use without the necessity of highly skilled operators. The one-click measurement function enables measurement and tolerance judgment with a single mouse click, regardless of workpiece orientation within the field of view. Measurement results displayed on the screen provide a quick GO/NG judgment promoting the efficiency of your quality control system. An illustrated guidance tool provides instructions for carrying out measurement, making a manual unnecessary. The telecentric optical system with its high depth of Focus needs no focusing even on a stepped workpiece. High-resolution digital colour camera of 3 mega pixels is provided for precision dimensional measurements. The Quick Image series is ideal for applications requiring distortion-free imaging with accurate measurement capability.

Tool Holders with full Functionality The Toolflex System is a range of simple, flexible tool holders for easy storage of handled tools and other items in most settings. Toolflex is the obvious solution when you need to store a large number of items in a small space. Suitable for indoor and outdoor use. The holders are made of durable plastic with a flexible TPE gripping surface that can grab the tool easily with just the slightest push of the hand.

User Friendly and Flexible

For Product Enquiry Contact Fourleaf 203, Malwa, Patanwala Estate, LBS Marg, Ghatkopar (W), Mumbai-400086, Maharashtra, India. Tel: +91-22-41202082 Email: hello@fourleaf.co.in

The Toolflex tool holder only requires a simple, one-handed action to hang up or take down the tool and the ingenious design of the holder also ensures that heavy tools are kept firmly in place. • Strong, recyclable materials (ABS, PP and TPE) • Numerous uses, both indoors and outdoors • Ideal for handles/tools 15-40 mm in diameter • A complete product range • Swedish manufacturing and quality standards The Holder can grip virtually all shapes – rectangular, round, square, triangle. Toolflex System is very simple to mount and use!

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PRODUCTS

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

Following are some of its unique features:

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

• • • • • • •

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

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

Spindles with Back Tapers Birla Precision Technologies Limited offers a wide range of Taps quick change for Transfer machines and machining centers.

Our production develops adaptors with the following categories: • Tapping to Double Compensation • Rigid tapping • Tapping with Axial displacement. Our company offers spindles with back tapers such as BT-MAS403, ISO 30/40/50 (DIN 69871) HSK (DIN 69893), the tap adaptors formers are available in sizes 0 - 1 - 2 - 3 - 4- 7.

All items are also available with the following attachments:

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

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• Chuck Weldon according to DIN 1835, mainly used for control machines and transfer machines • Chuck Morse taper, according to DIN 228A and 228B, mainly used for machining centres and boring • Spindle Keystone, according to DIN 6327, mainly used for transfer machines and threading • Cylindrical and chuck VDI, DIN 69880, mainly used for control machines • Spindle with conical “B” according to DIN 238, mainly used for traditional machines such as drill presses or threading With the aim to provide better quality and longer life, the we use the best grades of steels and subject all products to rigorous quality assurance during each stages of manufacturing , assembly and testing.

ADVERTISERS INDEX COMPANY NAME

PG. NO.

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PG. NO.

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FOURLEAF

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RENISHAW INDIA (PUNE)

ROLLON INDIA PVT. LTD.

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ACCUSHARP CUTTING TOOLS PVT. LTD.

ACE MANUFACTURING SYSTEMS LTD.

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GLEASON WORKS (INDIA) PRIVATE LIMITED

ACTCAD ENGINEERING SOLUTIONS PVT. LTD.

143

GROB MACHINE TOOLS INDIA PVT. LTD.

ADOR WELDING LIMITED

131

AMTEX - 2017

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HEIDENHAIN OPTICS & ELECTRONICS INDIA PRAIVATE LIMITED

115

ANCA MACHINE TOOLS PRIVATE LTD

HYUNDAI WIA INDIA PVT. LTD.

APEX PRECISION MECHATRONIX PVT. LTD.

135

ARHAN TECHNOLOGIES PVT. LTD.

123

IMTEX - 2017

151

AUTODESK

IMTOS - 2017

146

BETTINELLI AUTOMATION COMPONENTS PVT. LTD.

113

BHARAT FRITZ WERNER LTD.

BIRLA PRECISION TECHNOLOGIES LIMITED

C CAPITAL FIRST

143

CLEANTEK

127

CNC SOFTWARE, INC.

JYOTI CNC AUTOMATION LTD.

S SAMKRISH MACHINE TOOLS

SANJAY TOOLS & ADHESIVES

107

SBS PRECISION SYSTEMS (INDIA) PVT. LTD.

SCHMERSAL INDIA PVT LTD

108-109

SHAVO TECHNOLOGIES PVT. LTD.

119

SMC PNEUMATICS (INDIA) PVT. LTD.

SOLITAIRE MACHINE TOOLS LTD.

SPARKONIX (INDIA) PVT LTD

SPERONI INDIA PVT LTD

SPRAYMET SURFACE TECHNOLOGIES PVT. LTD.

147 39

LAPP INDIA PVT. LTD.

STARRAG GROUP

LOSMA INDIA PVT. LTD.

103

TRUCUT PRECISION TOOLS PVT. LTD.

MACHAUTO EXPO - 2017

149

MACHINE TOOL TECHNOLOGY INDONESIA - 2017

150

UCAM PRIVATE LIMITED

MAPAL INDIA PRIVATE LIMITED

UNITED GRINDING GMBH

MARPOSS INDIA PVT. LTD.

UNITY CONTROLS PVT. LTD.

125 65

DELTA ELECTRONICS INDIA PVT. LTD.

DIJET INDUSTRIAL CO. LTD.

MITUTOYO SOUTH ASIA PVT. LTD.

INSIDE BACK COVER

U-TECH ASSOCIATES

DMG MORI INDIA

MMC HARDMETAL INDIA PVT. LTD.

INSIDE FRONT COVER

DOWEL ENGINEERING WORKS

137

DVS TECHNOLOGY GROUP

NARITAA TOOLING PVT. LTD.

NICKUNJ EDM WIRES & CONSUMABLES P LTD

WALCHANDNAGAR INDUSTRIES LTD.

VOLLMER TECHNOLOGIES INDIA PVT. LTD.

EFFICA AUTOMATION LIMITED

117

NICOLAS CORREA, S. A.

ELECTROTHERM (INDIA) LTD.

NYNAS NAPHTHENICS PVT. LTD.

105

EMAG INDIA PVT. LTD.

ENGIMACH - 2017

PANSWORLD TELEVISION (INDIA) PVT. LTD.

141

PHILLIPS MACHINE TOOLS INDIA PVT. LTD.

PILZ INDIA PVT. LTD.

121

F FARO BUSINESS TECHNOLOGIES INDIA (P) LTD.

FATTY TUNA INDIA PVT. LTD.

FIBRO INDIA PRECISION PRODUCTS PVT. LTD.

129

FALSE COVER

133

Y YAMAZAKI MAZAK INDIA

32-33

YG CUTTING TOOLS CORPORATION PVT. LTD.

FRONT GATEFOLD

R RATNAPARKHI ELECTRONICS IND. PVT. LTD.

RENISHAW INDIA

Inside Story

Mr.

Prashant

Sardeshmukh Director, MMC Hardmetal India Pvt Ltd

My Life’s Goals

Aim & Ambition: My ambition in life to be a self-driven, motivated & successful professional taking great care of core values. I would like to work with sincerity & honesty and aspire to be a role model for someone who would like to follow my footsteps. I would like to continue to keep learning and starve for perfection. I would like to learn from everyone to constantly improve my knowledge base. I would like to tap the peak of my abilities with a perfect work life balance. Vision: To deliver my best in the interest of my company and build a team of professionals who will leave no stone unturned to achieve the common goal of the company. Be a strong leader together with a respectable mentor to build a team which will not only be appreciated by our customers but also by competitors. Social Goal: Hand in hand with Mitsubishi’s philosophy “For People, Society & the Earth”, would like to give back the society its dues in a graceful manner. Would like to empower women and underprivileged children through our CSR practises indirectly contributing in building a strong nation. Business Goal: To be the most preferred tooling solution provider by keeping customer’s business goals ahead of our own business goals and winning customer’s confidence. Create a world class manufacturing set up in India to provide state of the art technological products at a reasonable price. To create a working environment with strong culture where employees can develop both professionally and personally.

My Leisure Choices Favourite Tourist Spot: Goa in India and Zermatt in Switzerland. I love the Glacier Express ride which is one of the most spectacular train route in the world. Music I Like: I like all types of Indian Classical music. It depends on my mood and situation. Sports I Love : Cricket & Tennis.

Ask my Taste Buds Favorite food: Japanese and Italian. Unagi Don is my most preferred Japanese food. Gnocchi, Mushroom Risotto & lamb chops are my favourite Italian food Favourite Drink: Japanese Sake with Unagi. And Italian white & red wines with Italian cuisine.

In Awe of I Admire: Mr Fumio Tsurumaki, President - Advanced Materials & Tools Company MITSUBISHI MATERIALS CORPORATION.

164

MACHINE TOOLS WORLD JANUARY 2017

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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