NO 1 END MILLS MAKER
*
*
END MILLS • DRILLS • TAPS • INSERTS • TOOL HOLDERS
MORE THAN 30 MILLION PIECES PER YEAR. NO.1 ENDMILLS MAKER IN ROUND TOOLS.
IN THE WORLD
www.yg1.kr
Worldwide YG-1
Being the Best through Innovation
The X5070 SPECIALLY DESIGNED AND MADE WITH NEW GENERATION NANO GRAIN MATERIAL FOR MACHINING HIGH HARDENED STEELS (50 TO 70 HRc).
• High abrasion resistance • High feed rate • Excellent surface finish • Special coating for machining high hardened steels
IT OFFERS: Reliability & safety • Increased tool life • High productivity
Range
0.1 to 25.0 mm
Flutes
2,3,4 & 6 Flutes
Availability
Ball nose, Corner radius & Flat end mills
Coating
Special blue
Application
High hardened materials (Dry cutting)
BEST QUALITY & ONTIME DELIVERY WORLDWIDE
YG Cutting Tools Corporation Pvt. Ltd.
Plot No. 2C, Obadenahalli Industrial Area, Phase 3, Dodaballapura Village, Dodaballapura, Bangalore – 561203
Tel: +91 80 2204 4621, Fax: +91 80 2204 4645, Email: marketing@yg1india.com
Volume 02 No. 10 | March 2017 | ` 150
Pages 98 | RNI No. MAHENG/2015/64267
www.mtwmag.com
Publisher & Printer Shirish Dongre
CEO
Contents
Vol 2 Issue 10 | MARCH 2017
COVER STORY
Shekhar D.
Editor Shilpa Dongre
Marketing Team Ladoji Pendurkar, Amol Powle, Bhavin Shah, Bharat Shah, Vinod Surve, Kamlesh Balkrishna, Kavita Chaudhari
Designer & Layout Arun P. Shinde, Nandan S. Moghe, Dinesh S. Gawade
Online Division Ganesh Mahale, Pradeep M. Pillalamarri
Circulation Executive Satish Kadam, Amol Ranshur Branch Offices (Zonal)
NORTH (Delhi & NCR regions) Sandesh Jain : 09810837877 / 09871602777
SOUTH (Chennai & Coimbatore) Y. V. Raghu : 09566141224 Bangalore Vaman : 09686721340
EAST (Kolkata & Other regions) S. Roy - 09433097806
Competence in advanced technology worldwide Mr. L. J. Naidu, Managing Director, GROB Machine Tools India Pvt. Ltd.
38 PORTFOLIO
18
WEST (Maharashtra & Gujarat) Pune Shilpa K. - 09833373371
Dormer Pramet launches new data calculator app
Gujarat Dinesh Shah - 09327344559
20
Rajkot (Saurashtra) Swapnil Bhatia: 09227909005
IMTEX 2017 – A Huge Success
34 Head Office : Divya Media Publications Pvt. Ltd., 3rd Floor, Harmony Tower, N.S. Road, Thane-400 602. Maharashtra Tel: +91 22-25380574/75, Telefax: +91-22-25418254 E-mail: shekhar@divyamediaonline.com Website: www.mtwmag.com Printed & Published by Shirish Dongre on behalf of DIVYA MEDIA PUBLICATIONS PVT LTD., Printed at Anitha Art Printers 29/30, Oasis, Next to Vakola Market, Santacruz(E), Mumbai-400055, published from 303/304, Harmony Tower, N.S.Road, Court Naka, Thane West, Thane-400601. Editor : Shilpa Dongre
6
MACHINE TOOLS WORLD MARCH 2017
BUSINESS NEWS
Bettinelli’s Solutions for Motion Control & Automation
PROJECTS
22
Marshall Aerospace & Defence Group enters into multi million dollar life of programme contract with Maini Precision Products Ltd.
24
87
British Deputy High Commissioner launches Renishaw’s products at IMTEX 2017
26
LAPP India launches EPIC SMART Industrial Connectors at IMTEX 2017
26
DMG MORI showcases wide range of innovations
28
Mastercam at TECMA 2017
30
DesignTech Systems launches 3D printers in partnership with Solidscape
26
FARO names Katrona Tyrrell Chief People Officer
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 CASE STUDY
Vol 2 Issue 10 | MARCH 2017
PRODUCT SHOWCASE
90
84
KING CUT PRO – The Large Gantry Type CNC Cutting Machine
Bettinelli’s Solutions for Motion Control & Automation
TECH TRENDS
91
Avantin Metal Cutting Fluids
42
66
LC 485 up to 2040 mm
64
Higher Precision for Machining Centers in Automated Large-Batch Production
LC 185 up to 4240 mm
Family Fluids Business Changes with Times
LB 201 up to 28 040 mm
60
92
80
70
Linear Encoders for machine tools
Authorisation concepts in machine automation
82 8
MACHINE TOOLS WORLD MARCH 2017
94
Roundtest RA- 2200
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
Editorial Board
Editorial Index A Accusharp 58 Ador Welding 52, 90 ANCA Machine Tools 82
Bettinelli Birla Precision Heidenhain Optics & Electronics India Pvt. Ltd
Mr. GK Pillai Managing Director & CEO Walchandnagar Industries Ltd.
Mr. Rupesh Paparaju Director, Bettinelli Automation Components Pvt. Ltd.
42, 92
L
Lakshmi Machine Works 91 LAPP India
B
Mr. A.P. Jayanthram Managing Director
Heidenhain India
34 93
M
Maini Precision Products 22 Mastercam
C
26
Carl Bechem Lubricants 91
Mitutoyo South Asia
D
N
DesignTech Systems 30 DMG MORI 26, 28 Dormer Pramet 18
Nickunj Eximp Entp
28, 64 94
93
P
Pilz India
72
E
EOS Mr. Arjun Prakash Managing Director Effica Automation Ltd.
Ms.Samina Khalid Marketing Manager
Renishaw Metrology Systems Ltd.
Mr. MIHIR Baxi President – Global Sales Jyoti CNC Automation LTD
30
R
Ratnaparkhi Electronics 94
F
FARO Technologies
32
Renishaw
24, 84
S
G
GROB Machine Tools
96
Sparkonix U
H
Hangsterfer’s
66
Unity Controls
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
10
Mr. B.P. Poddar Vice President - Sales & Marketing FEMCO Fatty Tuna India Pvt. Ltd.
MACHINE TOOLS WORLD MARCH 2017
Mr. Jayant Vaidyanathan VP - Sales & Application Tsugami Precision Engineering India Pvt. Ltd.
80
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
92
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
CEO CORNER Technology Adoption - The key to success Machine tools are the main driving force of industrialization of a country or a region. They are the corner stone of economic development and sustained growth of manufacturing sector. The objective is to ensure sustained growth of 15-20% which will not be feasible unless proper thrust is given to Machine tools manufacturing sector. The need of the hour is to strengthen and realise the critical role of Machine tools industry to cater to the rising expectations and requirement of automobile, Railways, Defence, Aerospace and other engineering industries to give required boost to manufacturing sector. Hence technology adoption will play crucial role for machine tools manufacturers to produce fast & precise products which will be in line with latest industry standards. The machine tool industry is key to the government’s flagship ‘Make in India’ and ‘Skill India’ initiatives, given that it makes the machines required for the manufacturing sector. There is a positive sentiment in almost all manufacturing segments, with a direction for people to invest and an opportunity for India to become a manufacturing hub. India has made significant progress in various spheres of science and technology over the years and can now take pride in having a strong network of S&T institutions, trained manpower and an innovative knowledge base. Given the rapid pace of globalisation, fast-depleting material resources, increasing competition among nations and the growing need to protect intellectual property, strengthening the knowledge base is an important issue. As India has potential & inherent excellence, there is great scope for Indian Machine Tools industry to rise with recent technology transformation, we sure that soon Indian Machine tools industry becomes the superpower on the horizon.
CEO
12
MACHINE TOOLS WORLD MARCH 2017
MODULAR GEAR CUTTING MACHINE FOR GEAR PRODUCTION PRODUCTIVE
FAST
USER FRIENDLY
HIGHLIGHTS
+
High speed pick-up gear hobbing machine for milling chucked parts with a tailstock
+
xcellent chip flow – ideal for highperformance dry gear E hobbing
+
robe to measure gears and sensor system for aligning P with boreholes or grooves
+ + +
Easily integrated into manufacturing systems Integrated automation: no additional costs Time-tested KOEPFER gear hobbing technology
EMAG India Private Limited “Technology Centre” I No. 17/G/46-3 · Industrial Suburb I 2nd Stage · Yeshwanthpur I Bangalore · 560022 I Karnataka · India Phone: +91-80-42544400 I Fax: +91-80-42544440 I E-mail: sales.India@emag.com I Website: www.emag.com
COMPACT
BUSINESS NEWS
IMTEX’ 17 throws new light on manufacturing sector Indian Machine Tool Manufacturers’ Association’s (IMTMA) flagship exhibition “IMTEX 2017 & Tooltech 2017” held at the Bangalore International Exhibition Centre (BIEC) in Bengaluru concluded on 1 February 2017. The exhibition attracted a footfall of 75,440 visitors. Orders worth Rs. 1,670 Cr and enquiries to the value of Rs. 18,989 Cr were generated during the exhibition. Compared to IMTEX 2015 & Tooltech 2015 the booked orders have shown an increase of 16%, whereas the generated enquiries increased by 21%. The exhibition held at BIEC from 26 January to 1 February 2017 was inaugurated by Shri Siddaramaiah, Hon’ble Chief Minister of Karnataka. Mr. Girish Shankar, Secretary (HI), Department of Heavy Industry, Ministry of Heavy Industries & Public Enterprises, Government of India; D.V. Prasad, I.A.S., Additional Chief Secretary, Commerce & Industries Department, Government of Karnataka; and Dr. Naushad Forbes, President, Confederation of Indian Industry (CII). Speaking about the advancements in
technology demonstrated at IMTEX 2017, IMTMA President, P. G. Jadeja reflected, “IMTEX 2017 once again provided a platform for launch of new machines with latest technologies related to the machine tool industry. Technologies such as Internet of Things, Industry 4.0, 3D printing, etc. attracted large number of visitors mostly technology professionals including 158 trade delegations from public and private sectors such as automobiles, auto components, defence, aerospace, railways, power and energy, pharmaceuticals, etc.” IMTMA Director General, V. Anbu stated: “With the addition of a newly constructed state-of-theart hall measuring 17,500 square metres IMTMA was able to provide more space for exhibitors
STATEMENT ABOUT OWNERSHIP AND OTHER PARTICULARS OF MACHINE TOOLS WORLD MAGAZINE, THANE, AS REQUIRED UNDER RULE 8 OF THE REGISTRATION OF NEWSPAPERS, (CENTRAL) RULES 1956
1. Place of publication
FORM - IV SEE RULE 8 : 303/304, Harmony Tower, N.S.Road, Court Naka, Thane West, Thane -400601
2. Periodicity of its publication
:
Monthly
3. Printer's Name Whether citizen of India Address
: : :
Shirish Sunderrao Dongre Yes A3/604, Chavandal Tower, Parsik Nagar, Kalwa West Thane - 400605
4. Publisher's Name Whether citizen of India Address
: : :
Shirish Sunderrao Dongre Yes A3/604, Chavandal Tower, Parsik Nagar, Kalwa West Thane -400605
5. Editor's Name Whether citizen of India Address
: : :
Shilpa Shekhar Dongre Yes A2/603, Chavandal Tower, Parsik Nagar, Kalwa West Thane -400605
6. Name and Address of individual who own the
:
Divya Media Publications Pvt. Ltd. 303/304, Harmony Tower, N. S. Road,Court Naka, Thane (W) 400601
I, Shirish Sunderrao Dongre, hereby declare that the particulars given above are true to the best of my knowledge and belief. Date: 1-03-2017
18
MACHINE TOOLS WORLD MARCH 2017
Sd / Shirish Dongre Publisher
to showcase machines which in turn translated into more orders and enquiries than ever before.” For the first time an International Buyer Seller Meet was organized by IMTMA and EEPC (Engineering Export Promotion Council) which saw participation of 57 international buyers from 19 countries. The show also hosted student centric programmes such as i2 Academia Pavilion (a special pavilion representing academic and research institutions) Jagruti (a programme to orient engineering students with emerging technologies), and Connect (an awareness programme for young engineers visiting IMTEX) which evoked good response from both students and colleges from across India.
Dormer Pramet launches new data calculator app International cutting tool supplier Dormer Pramet has launched a new machining data calculator app. Designed primarily for smartphones, the “calculators’ app” will help determine a variety of data on popular operations including milling, turning, drilling, threading and boring. By entering different job settings including tool diameter and material type the user can quickly and easily establish the optimum conditions for an efficient machining process. A wide range of parameters can be navigated by simply swiping the screen, including power demand, torque and cutting time. Available in 18 languages, ad-
ditional user preferences provided include metric and inch options. A valuable tool for engineers and machine operations across a wide range of industries, the app is available to download now, free of charge, from iTunes and Google Play.
A member of the UNITED GRINDING Group
KRONOS Centerless external cylindrical grinding
Are you looking for the most efficient way to grind your high-volume, high-precision workpieces? Then you have found the KRONOS series by MIKROSA! These compact and versatile centerless grinding machines with an infeed length of 120 mm up to 655 mm combine maximum speed with the highest quality requirements. Its broad technology spectrum extends from infeed grinding in single or multiple production to throughfeed grinding and oscillation grinding. www.mikrosa.com
United Grinding GmbH, India Branch Office · No. 487 - D1 & D2A · 4th Phase, KIADB Main Road · Peenya Industrial Area · Bangalore 560058, India · Phone +91 80 30257 612 · Fax +91 80 30257 603 · info.in@grinding.ch
BUSINESS NEWS
IMTEX 2017 – A Huge Success IMTMA’s flagship event and South East Asia’s largest exhibition on metal cutting techncologies, IMTEX-2017 combined with TOOLTECH 2017 held at the Bangalore International Exhibition Centre from 26th Jan - 1st Feb 17 was a runaway success. The event was inaugurated by the Chief Minister of Karnataka, Siddaramaiah on 26th Jan 17. Secretary, Dept. of Heavy Industry, Ministry of Heavy Industries & Public Enterprises, Govt. of India, Girish Shankar; Addl. Chief Secretary, Commerce & Industries Dept., Govt. of Karnataka, DV Prasad; and President, Confederation of Indian Industries (CII), Dr. Naushad Forbes were the chief guests at the event. In addition, Chairman-Exhibitions, IMTMA, Jamshyd N. Godrej; President, IMTMA, PG Jadeja; Vice President, IMTMA, P. Ramadas, and Director General, IMTMA, V. Anbu were also present at the inaugural.
Truly global The exhibition occupied a total area of 60,000 sq. mt. This comprised the addition of a new hall admeasuring 17,500 sq. mt. added this time in the form of Hall 4 which again was inaugurated by Chief Minister Siddaramaiah. Over 1000 exhibitors showcased the innovations in 6 halls. Twentytwo
countries including India participated in the show with 7 group participations from China, Czech Republic, Germany, Italy, Spain, Taiwan and United States. Numerous technologies such as Hybrid machines, 3D printing, Industry 4.0, and many more innovative technologies were launched and displayed at this edition of IMTEX which attracted nearly a lakh visitors comprising decision makers and business heads, R & D, Design and Engineering from across the spectrum of the Indian metalworking industry.
A world–class hub for capital goods Inaugurating the exhibition, Chief Minister Siddaramaiah said, “It is well-known that machine tools are the backbone of manufacturing, and a strong machine tool industry propels strong manufacturing which in turn spurs the economy. Karnataka was the cradle for the machine tool industry which has now grown to produce over 50% of the Indian machine tool output. Keeping this in view, the government along with the industry charted out a plan for developing a machine tool park in the state. This park at Vasantha Narsapur in Tumkur district is a joint venture between the
Mazak India’s stall at IMTEX-17. The company put up an impressive show displaying their sophisticated Vertical Machining Centers, CNC Turning Centers & Multi-Tasking Machines
20
MACHINE TOOLS WORLD MARCH 2017
Government of India and the Government of Karnataka and will come up in a land of 500 acres. Once functional, the park is expected to boost the domestic turnover of machine tools while saving foreign exchange and reducing imports. Furthermore, the park will also create over 4000 jobs in manufacturing and administrative fields.” Speaking on Indian Capital Goods Policy and its impact on the ‘Make in India’ initiative, DHI Secretary Girish Shankar said, “India’s Capital Goods Policy envisages the capital goods to grow from Rs.2.3 lakh crore to Rs.7.5 lakh crore in 2025. The policy has been formulated with a vision to increase the share of capital goods contribution to the GDP from 12 per cent to 20 per cent of total manufacturing activity by 2025. Our endeavor is to drive growth for capital goods sector and build India as a world-class hub for capital goods. This covers critical areas such as increasing the total production, employment, domestic market share, exports, skill availability, technology depth, and SMEs. I am sure these initiatives will lead to strengthening the machine tool industry and capital goods industry. “Further he added: “I am glad that
IMTMA’s flagship event IMTEX 2017 supports demonstration of India’s capability in the machine tools segment on a massive scale and is a strong enabler of ‘Make in India’.”
A boon to the manufacturing industry “IMTEX is not just for the machine tool manufacturers, but for the entire manufacturing industry of India. The exhibition has a potential to attract investment and provide growth opportunity for the industry in Karnataka. This can happen only when we promote our industries,” said Additional Chief Secretary, Govt. of Karnataka, DV Prasad. “The Karnataka Government is working on enhancing industrial connectivity in the Chennai-Bengaluru and Bengaluru-Mumbai corridors. The State is supporting the National Investment Manufacturing Zones at key locations which is expected to give added impetus to the manufacturing sector. Encouraged by State’s efforts many auto and auto ancillary units have made their base in Karnataka,” he added. Speaking on IMTEX’s formidable stature in the Indian machine tools sector, Chairman-ExhibitionsIMTMA, Jamshyd N. Godrej said, “Two years from now, we will be celebrating the 50th year of IMTEX.
Linear Encoders, Angle Encoders and TNC Controls were some of the products showcased by Heidenhain India
Group GROB based y o n a rer f rm ufactu , offering The Ge g man es in d in a h is a le al mac epts univers g conc in in h 5-axis c a e and m v e ti v o ti innova Mold, Autom & for Die ustries. d allied in
G-Series
Horizontal 5 axis machining centers
Precision at the highest level
Contact: GROB-WERKE GmbH & Co. KG Mindelheim, GERMANY Phone: +49 8261 996-0 E-Mail: info@de.grobgroup.com GROB Machine Tools India Pvt. Ltd. Hyderabad, INDIA Phone: +91 40 4202-3336 E-Mail: info@in.grobgroup.com
GROB_Indien_Anzeige_Magazin_die_and_mould_April_2016_DINA4.indd 1
GROB 5-axis universal machining centers stand out due to their absolute precision and reliability in the automotive, medical and mechanical engineering industries, in tool and mold making as well as in the aviation industry. The proven 5-axis simultaneous technology with horizontal spindle position enables you to machine parts of various sizes and materials in a flexible and failure-free way while offering maximum stability of the machine. Fast chip-to-chip times and the innovative further development of our spindle technology guarantee a high economic efficiency and productivity. The GROB G-series – for the most versatile machining possibilities.
www.grobgroup.com
02.05.2016 08:11:57
BUSINESS NEWS The main objective of IMTEX is to demonstrate and showcase different manufacturing technologies and innovations to enable the manufacturing companies and industries to take decisions on what they need to meet their current and future requirements.” As technology becomes a formidable enabler in manufacturing, it is imminent to incorporate it in all aspects of manufacturing,” said President, CII, Dr. Naushad Forbes. “The machine tool sector has a huge responsibility and scope to make Indian manufacturing successful and therefore the industry needs to leverage not only
its design capabilities but also ICT, Automation, Industry 4.0, as well as innovations,” added Dr. Forbes. To further provide impetus to the machine tools industry, IMTMA is working closely with NITI Aayog and DHI in giving shape to the future technological initiatives and R & D efforts for the machine tool industry. Speaking on opportunities for machine tools sector, President IMTMA, PG Jadeja said, “The aero-defence sector presents an attractive growth opportunity. To tap this, IMTMA has launched an initiative and formed the Aero-Def Group to bring our members closer
to this important customer segment and work out development and marketing strategies.” Several programs were held in conjunction with IMTEX-17. IMTMA and EEPC India with support from the Government of India organized a Reverse BuyerSeller Meet. This presented an opportunity to connect with importers from 23 countries. The i2 Academia Pavilion, a special pavilion representing Academic and Research Institutions from around 40 institutions including six IITs from all over India was held concurrently. Connect, a special forum for imparting knowledge on
machine tool industry for young engineers visiting IMTEX was arranged from 27-31 Jan. Students and young engineers interested in building a career in manufacturing got a chance to know more about the machine tool industry. Earlier, the IMTMA-Premier Outstanding Entrepreneur Award in memory of Vinod Doshi was given in the inaugural function. Milind Kelkar and Mohini Kelkar the duo behind Grind Master won the Award in recognition of their visionary pursuit of entrepreneurial excellence. – P.K. Balasubbramaniian
Marshall Aerospace & Defence Group enters into multi million dollar life of programme contract with Maini Precision Products Ltd. Marshall Aerospace and Defence Group, Cambridge, UK and Maini Precision Products Ltd (MPP), entered into a multimillion dollar life of programme contract for structural machined parts and sub-assemblies for a major aircraft programme at Aero India 2017. With this contract, MPP is now positioned as the single source from India to support Marshall for their manufacturing requirements for the duration of this program. Marshall Aerospace and Defence Group was represented by Mr. Andrew Monk, Supplier Manager and Mr. Jeremy Rogerson, Supplier Quality Manager. Maini Group was represented by Mr. Gautam Maini, Executive Director, Maini Group and Mr. Naresh Palta, CEO, Aerospace & Defence, Maini Group. On this occasion, Marshall stated that MPP has been a key supplier to MARSHALL for complex structural parts and sub-assemblies and has achieved the status of top rated
22
MACHINE TOOLS WORLD MARCH 2017
L-R : Mr. Naresh Palta CEO(A&D) Maini Group, Mr. Gautam Maini MD Maini Precision Products, Mr. Andrew Monk Supplier Manager Marshall Aerospace and Jeremy Rogerson Supplier Quality Manager Marshall Aerospace signing the Multimillion dollar life of programme contract with Maini Precision Products Ltd on Day 2 of Aero India 2017
supplier during this period . The high level performance over the years has built the confidence at Marshall, resulting in the decision to extend this contract for the entire life of the programme. Mr. Gautam Maini said, “MARSHALL has been our strategic customer since 2010. With this agreement, we are poised for further growth in this relationship.” Mr. Naresh Palta further added,
“It is a vindication and recognition of our strong commitment to performance for meeting Marshall’s manufacturing requirements”
About Maini Group: Founded in 1973 by Dr. S. K. Maini, Maini group is a diversified group of three companies with a history of more than four decades of Innovation, technology and sustainability. The group caters to multiple seg-
ments like Automotive, Aerospace, Industrial, Material Handling and Warehousing Solutions. Maini Group designed and manufactured India’s First electric car: the Reva. Maini Precision Products Ltd (MPP) is the flagship company of Maini Group. Today, MPP is a One-StopShop with high-end machining and assembly facilities catering to a global clientele. Building up on the strong foundation of Automotive experience, in 2005, MPP made its first foray into aerospace. MPP Aerospace Division started exporting machined high precision fuel line components to Safran Aircraft Engines then known as Snecma, France for its commercial aircraft engines. Continuing the efforts over last 10 years, MPP Aerospace has developed strong buildto-print learning with global OEMs and Tier-1’s, like Safran Aircraft Engines, Eaton, Magellan, Marshall Aerospace, Dassault Aviation, Rockwell Collins, Woodward etc.
DIFFICULT MATERIALS MADE EASY
LESS CHATTER. SHORTER CYCLES. YOU CAN HEAR THE DIFFERENCE. Mastercam’s Dynamic Toolpaths deliver a consistent chip load, making difficult material easier to cut. That means longer tool life, reduced machine wear, and shortened run times. See and hear the difference at Mastercam.com/dynamic.
For more information, visit mastercam.com/dynamic
BUSINESS NEWS
British Deputy High Commissioner launches Renishaw’s products at IMTEX 2017 Renishaw, a world leader in precision engineering technologies, has revealed a range of new metrology and additive manufacturing equipment at IMTEX 2017, which is taking place at the Bangalore International Exhibition Centre from 26th January to 1st February. The new products were announced in a speech made yesterday at the company’s exhibition stand by Dominic McAllister, the British Deputy High Commissioner, Bengaluru. In his speech, McAllister praised Renishaw’s long term commitment to India. He said: “Renishaw has been trading in India since 1983 and it employs 350 highly skilled people across the country, including a wholly owned subsidiary here in Bangalore and a large facility in Pune. Many of its employees in India directly contribute to the R&D
and manufacture of its exciting measurement and metal 3D printing technologies which are being demonstrated at IMTEX.” The new products announced by Mr McAllister are designed to meet the requirements of the advanced manufacturing sector in India; from the need to produce parts with increasing complexity and tighter tolerances, to the drive to reduce costs, to increase speed of operation
and the requirement to improve the ease-of-use for new technology. In June 2016 Renishaw opened an Additive Manufacturing Solutions Centre at its Pune site, which aims to increase the adoption of metal 3D printing technologies by Indian manufacturers. At IMTEX the company introduced the RenAM 500M additive manufacturing system, which the Deputy High Commissioner said “has been fully
designed to be used for serialised production of complex metal components directly from CAD using metal powder fusion technology.” As demands on component tolerances increase, manufacturers are now required to consider all error sources from the machines producing parts; angular errors as well as linear and straightness errors. Therefore at IMTEX, the Deputy High Commissioner also announced Renishaw’s new XM-60 multi-axis calibrator which is capable of measuring all six degrees of freedom from a single set-up, in any orientation for linear axes. The Deputy High Commissioner also announced the India launch of Renishaw’s new vision measurement probe (RVP) for use with the REVO-2 5-axis measurement system on co-ordinate measuring machines.
IMTMA organizes second symposium on Smart Manufacturing Indian Machine Tool Manufacturers’ Association (IMTMA) is organizing the 2nd edition of ‘Symposium on Smart Manufacturing on 24-25 February 2017 in BIEC Conference Centre, Bangalore. This symposium is a combination of technical presentations, case studies by users, interactive sessions, panel discussion and brain storming with industry experts. The theme of the symposium is “Evolving the Factory of the Future”. Industry experts from renowned companies viz. ABB Global, Robert Bosch Engg., Beumer India, Schunk Intec, Universal Robots, Festo, AMIT, IFM Electronics, TAL Mnfg., Toyota Kirloskar Auto
24
MACHINE TOOLS WORLD MARCH 2017
Parts, Roland Berger, Ernst & Young amongst others will address various facets for successful adoption of Smart Manufacturing. ‘Automation Buzz’, a concurrent exhibition displaying a wide range of automation devices and systems, software and a host of automation solutions will be displayed simultaneously in BIEC. Sharing his views on the symposium IMTMA President P.G. Jadeja expresses that “Smart Manufacturing is an emerging industrial revolution which will integrate human intelligence with data and technology to effectively manage complex business requirements. The symposium will
address and understand the realtime application and benefits of Smart Manufacturing in the Indian context” The presentations will cover topics such as Overview of Smart Manufacturing in the Indian context, Manufacturing Plant Integration as a 1st step to Industry 4.0, IIoT of Robots, Smart & Cost Effective Automation, Big Data Analytics, Data Collection, Connected Factory, Pneumatics on the Network, Intelligent Clamping & Gripping - Industry 4.0 ready, Collaborative Robots, IO-link technology as a first step towards smart manufacturing, Smart Logistics, amongst others
The panel discussions will address various aspects of Industry 4.0 relevant to Indian context at the organizational level, infrastructure considerations, skills sets required, cost implications, etc., and draw up a roadmap for successful adoption of Smart Manufacturing. Symposium will be attended by CEOs, top management executives, senior executives, practicing engineers, industry consultants and R&D specialists from manufacturing industries such as automotive, auto components, consumer durables, machine tools, tool rooms, aerospace, defence and railway units, general engineering and other discrete manufacturing industries.
BUSINESS NEWS
LAPP India launches EPIC SMART Industrial Connectors at IMTEX 2017 Lapp India, a 100% subsidiary of the Lapp Group Germany and a leading supplier of integrated solutions and branded products in the field of cable and connection technology in India, launched EPIC SMART, the industrial rectangular connector at IMTEX 2017. EPIC SMART Industrial Connector is designed and manufactured in Asia for the Asian customers with the promise of high performance at a cost-effective price. These connectors are used for power and control application in all industries ranging from Machine Tool, Automotive and Material handling to Industrial Automation. They are suitable for rated current up to 16A & Voltage: 500 Volts tested as per DIN IEC 60512-5 & with UL approval. EPIC SMART is available in 6, 10, 16 and 24 contacts with screw type termination for easy assembly. These connectors can withstand temperature ranging from -40°C to +125°C making them very robust for industrial applications. “We are excited to announce the launch of EPIC SMART Industrial Connectors under EPIC®, our global and well-known brand of industrial connectors. This product has been designed keeping in mind the demands of the developing
countries especially India. This is just another move in our efforts to constantly innovate and contribute to meet customer requirements. We have chosen IMTEX 2017 to launch the product as this product is most relevant to the Machine Tool industry”, said Marc Jarrault, Managing Director - Lapp India. IMTEX is a flagship event for the Indian metal cutting industry. At the exhibition, Lapp India is display its standard product offering in cables,
connectors, glands and accessories with a focus on ÖLFLEX® CONNECT, their customized solution offering especially for Machine Tool segment. We are also displaying ÖLFLEX® ROBOT 900 P, ÖLFLEX® ROBOT F1 and ÖLFLEX® CHAIN 808 that have been designed keeping in mind the requirements and challenges faced by the Machine Tool segment with regard to flexibility, compact machine design and harsh environmental conditions during manufacturing.
DMG MORI showcases wide range of innovations At the traditional Open House at DECKEL MAHO in Pfronten DMG MORI shows a wide range of innovations. The 9,000 international trade visitors will be greeted by a display area of 8,500m2 featuring more than 80 high-tech exhibits – including 3 world premieres – and major sector highlights from the fields of automation, digitization, Additive Manufacturing and technology excellence. By a majority shareholding of 50.1% in REALIZER GmbH in Borchen, the group is strengthening its future technologies in Additive Manufacturing. With the founding of the start-up ISTOS, DMG MORI is expanding its digitization expertise. DMG MORI is focusing on strengthening its future technologies: With selective laser melting DMG MORI is bundling the most important
26
MACHINE TOOLS WORLD MARCH 2017
generative production processes for metallic materials under one roof. DMG MORI already has extensive know-how in the field of laser deposit welding with powder nozzles through SAUER GmbH. By integrating the REALIZER products, DMG MORI is gaining access to “Selective Laser Melting” (SLM). In this process, the material is applied in powder form in very thin layers and melted by laser. “This is the perfect complement to our high-tech machines in the field of Advanced Technologies. Selective laser melting in the powder bed opens up completely new areas of application for our customers,” says Christian Thönes, Chairman of the Executive Board of DMG MORI AKTIENGESELLSCHAFT.
As a pioneer of the powder bed process, REALIZER has consistently developed SLM technology, elevating it to the level of mass production and now has more than 20 years’ experience in its application. In future, development and assembly will take place in Borchen and at DMG MORI in Bielefeld. The two leading production technologies enable complex, metallic components to be produced from powder. For this purpose a wide variety of weldable materials up to and including multi-material applications can be made use of. With the founding of the start-up ISTOS, DMG MORI is expanding its digitization expertise. The new Düsseldorfbased company is developing digital production projects for DMG MORI and interested partners.
BUSINESS NEWS
Mastercam at TECMA 2017 CNC Software, Inc., is traveling to Mexico to support Mastercam Reseller Cad Avshmeip, S.A. at the TECMA 2017 Show. Attendees will get to see the most powerful Mastercam machining software yet. Stop by Booth # 642 at Expo Bancomer Santa Fe in Mexico City, Mexico, March 7-10 for a look at Mastercam 2017 which introduces a more efficient workflow, improved usability, Dynamic Motion improvements, and so much more. Mastercam 2017 features a new ribbon interface and makes it easier to find the functions you need to complete your tasks. “Many of our more powerful tools were underused because customers did not know where to find them,” says CNC Software President, Meghan West. “We spent a lot of time with users determining the best way to simplify this, and the response has been overwhelmingly positive.” The ribbon tabs group similar functions and displays them in order from simple to more complex. Each tab relates to a type of activity, from creating wireframe geometry to generating toolpaths. Editing functions are on the same tab as creation functions so you have all the tools you need, when you need them. Mastercam’s Dynamic Motion technology can slash machine time by as much as 75% or more. It maximizes material removal rates, extends tool life, reduces cycle
25.4%
time, saves wear and tear on machines, and cuts hard materials more easily. New to 2017, micro lifts now use a line-of-sight approach to move the tool where it needs to go through unobstructed areas. This results in reposition moves that are more efficient, less complex, and travel a shorter distance resulting in shorter cycle times. Mastercam 2017 introduces Maximum Stock Engagement for select 3D High Speed Finishing toolpaths, allowing you to limit how deeply the cutter engages uncut material and protect smaller tools from taking too heavy of a cut. Optimized Raster Motion improves toolpath efficiency by filling in steeper geometry with perpendicular raster motion to create a cleaner result. Mastercam Mill-Turn now supports multistation tool locators for turrets as well as half index positions and improvements to tool and job set-up to improve overall workflow.
DMG MORI sets course for the future DMG MORI held up well in financial year 2016 despite a difficult market environment: Order intake of € 2,369.9 million reached a new record high (previous year: € 2,282.8 million). Although the worldwide market for machine tools was in decline at -1.7%, DMG MORI rose order intake by 4%. By the concentration on the core business with machine tools and services, DMG MORI set the course for the future. This includes measures for a new sales and service structure worldwide, optimising production capacity and sale of companies that do not form part of the core business operations. All figures are provisional; they are subject to audit and the approval of the financial statements by the Supervisory Board. Order intake grew increasingly positive over the course of the year: After orders in the third quarter had already surpassed the level reached in the previous four quarters by 12%, order intake rose in the fourth quarter of 2016 to € 610.3 million – an increase of 13% (previ-
28
MACHINE TOOLS WORLD MARCH 2017
SNIPPETS
ous year’s quarter: € 540.8 million). Over the whole year order intake increased by 4% to € 2,369.9 million (previous year: € 2,282.8 million). In the reporting year DMG MORI thus achieved the highest order intake so far in the 146 years of company history. Sales revenues of € 2,265.7 million were slightly below the previous year (€ 2,304.7 million). In the fourth quarter sales revenues reached € 636.6 million (previous year: € 655.9 million). The export share remained as in the previous year at 67%. The results of operations in financial year 2016 developed as follows: EBITDA amounted to € 169.7 million (previous year: € 243.1 million), EBIT reached € 103.9 million (previous year: € 185.9 million) and EBT was € 94.1 million. The current forecast for machine tools assumes moderate growth in 2017 despite considerable uncertainties. The VDW (German Machine Tool Builders’ Association) and the British economic research institute, Oxford Economics, currently expect consumption worldwide to grow by 2.1%.
The industry welcomes the ministry’s move to step up allocation for capital expenditure by 25.4% as against the year before and control fiscal deficit at 3.2% of the GDP for FY18
25%
The reduction in income tax to 25% is a positive step towards development of the MSME sector and enhance their production capacities as Machine tool industry is the backbone of MSMEs.
7.5%
the customs duty reduction from 7.5% to 2.5% on three critical components (CNC systems, ball screws and linear motion guides) has been extended to all CNC machine tools under HSS code 8456 to 8463. This will have a direct bearing on the machine tool industry and enhance its development
2200 Cr
The setting up of the next phase of ‘Skill Strengthening for Industrial Value Enhancement’ (STRIVE) at a proposed budget of Rs.2,200 Cr in 2017-18 and 100 India International Skill Centres across the country will ensure availability of skilled manpower for the industry
BUSINESS NEWS
EOS makes Robotics meet additive manufacturing EOS, the global technology and quality leader for high-end Additive Manufacturing (AM) solutions, has announced its support of the Swiss society Devanthro and the Roboy project at the Technical University of Munich. The goal of the Roboy project is to advance humanoid robotics to the capability of human bodies. The vision is to iteratively improve Roboy models until the performance is comparable to humans in dexterity, robustness and flexibility. The first prototype – Roboy Junior – has muscles and tendons rather than motors in the joints. It has been developed under substantial usage of AM: The complete skeletal body structure of Roboy, which encases his bones
and muscles, has been built with EOS systems for Plastic Additive Manufacturing. The use of Industrial 3D Printing has several key advantages; among them is the possibility of building complex functional geometries as well as sustaining a fast and iterative
hardware development. Additive Manufacturing allows for highly complex structures which are also extremely light & stable. It provides a high degree of design freedom, optimization & integration of functional features, and the manufacture of small batch sizes at economical unit costs. The Roboy development benefits from all these advantages: Building complex functional geometries without classical fabrication constraints allows the Roboy team to implement functionality directly into the geometrical parts. Due to Roboy’s maximal mechatronic complexity on a minimal space, it is not possible to validate some project requirements in simulation. Therefore, the development team
needs to be able to test the robot itself. AM is key to this because it allows the fast manufacturing of individual components and the modularization and parameterization of the robot’s construction, enabling an iterative hardware development. Rafael Hostettler, Roboy project leader, comments: “In software development, rapid development cycles allow software improvement by testing it ‘in the wild’. Additive Manufacturing allows us to apply this approach to robotics, enabling a rapid development to find optimal functional parts in a fraction of the time.” He continues: “EOS’ AM technology is a key component for doing this as it enables the iterative hardware development that is crucial for our project.”
DesignTech Systems launches 3D printers in partnership with Solidscape DesignTech Systems Ltd., a leading name in CAD/ CAM/CAE, PLM and Additive Manufacturing technologies, has announced a strategic partnership with Solidscape, for the distribution of high precision 3D Printers for manufacturing of wax patterns in India, Nepal, Bangladesh, Maldives, Sri Lanka and Bhutan. DesignTech will develop the infrastructure to support the expansion and adoption of 3D printing custom manufacturing solutions. Solidscape 3D printers are known for their ability to produce ultra-fine feature details and are considered a premier technology for applications like custom jewelry manufacturing, high precision casting, and advanced biomedical research. “DesignTech Systems Ltd.’s strong business reputation and broad footprint throughout India is ideal to support Solidscape’s growth plan,” stated Fabio Esposito, President, Solidscape Inc. “Having a world-class partner that can
30
MACHINE TOOLS WORLD MARCH 2017
deliver top quality high precision 3D printing solutions for custom manufacturing, sales and service throughout India was our strategic goal. DesignTech Systems is the perfect partner to respond to customer demands for on time, on quality and cost value delivered.” Vikas Khanvelkar, Managing Director, DesignTech Systems said, “3D Printing has
revolutionized the way products are built. Having realised the competitive advantage and value that this technology can bring, manufacturing companies in India have shown enthusiastic adoption of 3D Printing technology, making it an integral part of their product design validation, visualisation and manufacturing processes. We have, ever since our inception in 1998, worked on helping engineering industry in India migrate and make a transition from using the conventional methodology, to adopting digitised, validated and process-oriented approach of building and developing products. DesignTech Systems in that sense can be considered a pioneer in promoting the CAD/CAM/CAE technology amongst the engineering industry and SMEs in India. Solidscape is a world leader in high precision 3D Printers for custom manufacturing. Their 3D Printing accuracy and precision is unmatched. And we are thrilled to forge an alliance with them.”
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
BUSINESS NEWS
FARO names Katrona Tyrrell Chief People Officer FARO has announced the appointment of Katrona Tyrrell as Chief People Officer (CPO). She will report directly to Simon Raab, Ph.D., FARO’s President and CEO. Ms. Tyrrell will advise the senior leadership team as it works to scale FARO’s vertical sales organization while maintaining and strengthening FARO’s entrepreneurial culture, employee engagement, and career development. As CPO, she will guide all aspects of human resources for the company, including Human Resources business partnering, talent management and Human Resources Information Systems. “Our culture is a fundamental component to what makes our company special and highperforming,” said Simon Raab, Ph.D., FARO’s President and CEO. “We created the CPO role specifically to bolster this important foundation. Strength in this area of our business allows us to succeed in everything else we do and is
32
MACHINE TOOLS WORLD MARCH 2017
ment, employee engagement, and organizational effectiveness. Prior to joining IDT in 2006, Ms. Tyrrell held leadership and management positions at Towergate Partnership, Ltd. and Roberts & Partners Managed Services in the U.K. Ms. Tyrrell holds a post-graduate diploma in strategic management from Crawley College in the U.K. essential to propel our growth. Katrona’s extensive background and experience building, maintaining and leading talent and corporate culture strategies will complement the founder-CEO mentality we have returned to the company. I’m excited for her partnership, perspective, and the contributions she’ll make.” Ms. Tyrrell joins FARO from IDT Corporation where she was the Global Senior Vice President – Human Resources, leading a team that was responsible for global succession planning, leadership development, performance manage-
About FARO 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 Cobalt 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.
PORTFOLIO
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
B
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
34
MACHINE TOOLS WORLD MARCH 2017
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
PORTFOLIO 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
36
MACHINE TOOLS WORLD MARCH 2017
COVER STORY
The fidelity for unprecedented service & Quality
Mr. L. J. Naidu, Managing Director, GROB Machine Tools India Pvt. Ltd.
Competence in advanced technology worldwide 38
MACHINE TOOLS WORLD MARCH 2017
COVER STORY www.mtwmag.com
Q. GROB has gained substantial market share in Indian machine tool industry, please elucidate the success story of the company? Since its entry in to Indian market in 2007, Grob gained substantial market share with proven strategies of the company in similar markets. We initially focused on automotive OEM’s, followed by their tier 1 vendors with our system machines and later with a big bang in die & mold and aerospace industry with our state of the art universal horizontal 5 axes machining centers. Continuous year on year increase in business and market share fuelled our thoughts for further expansion in Indian market. The key factor for success of Grob in India and worldwide is our highly reliable machines with most advanced technology and the best in the industry service support to customers.
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? At the moment we export our services to overseas projects as well, thanks to the high skill levels of our engineers. Future plans are already set in place to supply customer specific process related technology in the beginning followed by
machines from India to southeast Asian countries. GROB is a globally operating company with headquarters, main manufacturing plant in Germany with additional production plants in Brazil, USA, China and Italy supported by its own worldwide subsidiaries handling sales & service. Continuous development of new technologies for the future upcoming demand of world market, Our owner family support for sustained growth in the company by reinvesting the entire profit for up gradation of technology in production processes & expansion of production facilities and focus on continuous improvement in performance of our machines will always keep us as market leaders. We say “Other have it easy they just have to be better than the rest, But at GROB every day we have to be better than GROB”
from Indian market, GROB started huge investment in setting up its plant in India which will be 6th in the world.
Q. Can you brief us about the marketing strategies that were applied in order to stand out in the competition of machine tool industry? GROB marketing strategy is very simple “don’t look for a new customer everyday, instead build long term trustable partnership with existing customers and increase your business share with them”. Operating in highly competitive machine tool business, you have no chance to make mistakes and you should provide unprecedented service support to your customers, this is the main philosophy of GROB. At GROB customer success is our success and customer is first.
Q. What are the market prospects for the GROB products in India and How do you plan to position these products?
Q. Please elucidate in brief about the company’s infrastructure & What are the measure that are being taken from the product manufacturing to distribution?
GROB sees huge potential in Indian market for its products in the years to come, accordingly plans have already been worked out for implementation starting from 2017, to be always ready to serve the growing demands of the market. Eying at the forecasted future demand
Unlike its competitors, GROB produces everything in house maintaining highest level of quality standards. Starting from engineering, production, assembly, & testing of all its machine components, this helps GROB to deliver high quality & most reliable machines well within the
GROB 5 Axis Universal Machining Centers
MARCH 2017
MACHINE TOOLS WORLD
39
COVER STORY agreed delivery schedule. This philosophy of 100% in house production helped GROB to become worlds biggest supplier of turnkey projects.
Q. Brief us about the R&D and Quality policy for your business? One of the biggest department in GROB Group is its R&D and engineering with over 900 engineers working on continuous development of new technologies for tomorrows market need and at the same time focusing on reduction of number of parts in the machine which helps in increasing machine reliability and energy saving. GROB is the first machine tool company to sense the need of new technologies for the fast emerging electro mobility segment outfacing IC engines worldwide. GROB is proud say that it bagged huge business in this new segment and again retaining its market leadership in already delivering several turnkey projects for electro mobility.
Q. Please comment on the current machine tool scenario in India? Currently machine tool industry in India is in growth path, for companies coming out with innovative technologies and reliable machines there is always a scope to grow. Customers buying criteria is also slowly changing from low cost machines for short term to advanced technology long term reliable machines.
Q. Could you brief us on Indian & Global perspective of machine tool industry? What are the distinguishing factors? Machine tool is the core of mechanical manufacturing industry, traditionally
Grob Mindelheim plant
40
MACHINE TOOLS WORLD MARCH 2017
India always looked at short term where as the developed and developing nations looked at long term vision and perspective. We can clearly witness it today that there is a swift change in Indian vision and perspective inline with global markets towards machine tool industry.
Q. In your opinion how can the Indian machine tool industry become globally competitive? Invest on R&D, focus on new technologies and build reliable products, don’t keep only the cost in mind but to keep in mind the state of the art machines at competitive prices.
Q. What are the key technological trends that are driving machine tool industry? Industry 4.0 is one of the hottest topic, GROB to maintain its market leadership position launched its own in-house develop GROB net 4 industry. Highly reliable, accurate, energy efficient and low life cycle cost is need of the day, a lot needs to be done in this area with implementation of modern technologies in machine tool industry. Aim at dry machining & MQL to support swatch Bharat moment to make clean & green India.
Q. How do your perceive the future of the Indian machine tool industry? For sure it will be one of the key industry fuelling the growth of Indian economy. The initiative of make in India by Prime Minister Mody is already well seen in the manufacturing industry, machine tool industry as a back bone of manufacturing always has enormous potential to grow and to become one of the top 3 machine
tool producing nations.
Q. How far the factors like government norms, excise duty, taxation, exim policies are affecting your business? Thanks to the new regime in power, things are getting simplified in many areas paving ways for smooth day today operational issues and taxation. At the same time I have to admit that certain policies and new regulations specially meant for MNC’s are making it difficult for operating in India, for ex: BEPS and related party transactions in Indian customs, hope Indian Union Government will look in to these issues.
Q. What are the best possible remedies you can advise in order to maintain the high profitability in the shrinking margins market of India? I believe that the margins in India are reasonable and comparable with several other countries. The ways to improve your profitability is to deliver a reliable quality product, increase local value addition, depend on lean manufacturing and focus on new technologies to save energy which is a day today and long term exepense of your customers.
Q. What is your vision for your company? With the blessings of our beloved owner Dr.Burkhart Grob, support from owner family & with the overwhelming support of our Indian customers, in next 5 years we have set our target to reach business turnover of â‚Ź 100 million from Indian market with an employee strength of 300.
Machine tool automation Additive manufacturing / 3D printing
Machine calibration
Material analysis
Gauging
Motion control
Dimensional measurement
Renishaw has supplied manufacturers in India and around the world with products that help to make products in less time, with more accuracy, higher levels of productivity, and with less waste. Today, our engineering and science based technologies are used in applications as diverse as jet engine, TV and solar-panel manufacture, through to 3D printing, dentistry and brain surgery. Contact one of our 6 Indian offices to find out more.
For more information visit www.renishaw.com
Renishaw India G.K Arcade, 3rd Floor, #125/1-18, T. Mariappa Road, Jayanagar 1st Block, Bangalore 560 011 T +91 80 6623 6000 F +91 80 6623 6060 E india@renishaw.com
www.renishaw.com
TECH TRENDS
Higher Precision for Machining Centers in Automated Large-Batch Production
A
utomobile customers demand a variety of vehicle types and engines in accordance with highly diverse framework conditions, asking about differing vehicle sizes, motor types or engine power within the individual markets, depending on fuel costs, emission standards and tax measures. For automobile manufacturers this hampers any estimation of quantity progressions or capacity planning and the design of production lines. To meet customer needs, automobile manufacturers offer engines with the same number of cylinders but in differing performance classes, which also leads to an increase in variant diversity. Ever shorter vehicle product life cycles in combination with volatile markets therefore lead to changed production challenges for automobile manufacturers [1]. To meet such challenges, the aspect of flexibility is added to the classic production parameters such as quality, time and costs. For production lines for the machining of vehicle powertrain components (engine, transmission and axle components), this means departing from classic transfer lines with fixed timing and high productivity, and adopting lines with linked machining centers and higher levels of flexibility. In addition to the challenge of responding to fluctuations in demand in automotive sales markets, the future will also bring increasing legislative and end-user requirements regarding the emission of pollutants and fuel consumption of vehicles. One approach to dealing with such a situation consists of reducing friction in the powertrain, which in most cases would lead to increased quality requirements for the components
42
MACHINE TOOLS WORLD MARCH 2017
Figure 1: Cylinder head machining in large-batch production (photo: MAG IAS GmbH)
to be produced. The interlinked machining centers used in production lines also have the task of implementing the demands of manufacturers in process-safe ways with large vehicle quantities (see Figure 1). The use of linear encoders in Closed Loop control in the feed axes of the machining centers contributes to meeting such diverse requirements. From transfer lines to linked machining centers Greater flexibility for variants, machines and capacity Transfer lines lack adaptability Because individual stations within a transfer line are designed for machining specific workpieces, these fixed, chained lines cannot be simply expanded by adding additional stations. To make available the maximum planned capacity requirement, it is therefore necessary to implement the main part of production line investment at the start of production (SOP). Because quantities slowly increase (line ramp-up) at the beginning of production or fall away (line ramp-down) at the end of the product lifespan, excess
production capacity is the result (Figure 2) , and as a result the installed capacity is not fully exploited. Additional challenges come about if capaci-ty requirements during regular operation in the transfer line are larger than originally planned, and workpieces required by the market can no longer be produced with the installed line capacity. Duplicating a transfer line to absorb such quantity peaks, however, would lead to significant over-capacity. Flexibility through linked machining centers Production lines with smaller capacity ranges can be installed by using linked machining centers, enabling a wider spectrum of production tasks and therefore higher production flexibility. Adaptation to actual quantity needs during line ramp-up can then be achieved by integrating additional machining centers into the existing production line at free stations or by duplicating the complete line. This method of approximating available capacity to capacity needs is aimed at
TNC 640 – 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 turning—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 have an advantageous chip fall, whereby less cooling lubricant or even minimum quantities of lubricant (MQL) are used to wash chips. Such machines can also be variably automated via easy front or top loading for workpiece supply, enabling use of the same machine model for various production lines even with different loading systems. Double-spindle machines, with only slightly larger support base areas, are sometimes used due to their higher productivity (see Figure 1).
Figure 2: Quantity flexibility—capacity availability vs. capacity needs [4]
expanding the production system with as much cost-efficiency as possible [2]. As a consequence, the large-batch production of vehicle powertrain components is now distancing itself from transfer lines and is increasingly adopting machining centers or transfer centers [3]. The increased flexibility of linked machining centers is directly related to the require-ment for highly rapid and economic re-sponses to fluctuations in demand. As an example, one demand is that differing vari-ants of a workpiece should be machined on the same production line without need-ing to adapt the setup (variant flexibility). Another approach is using additional machines to simply expand production lines. This could be called reuse flexibility, as the use of standard machines and their standardized linking enables simplified integration and reuse of such machines in other production lines. If line capacity is seen with respect to the complete lifespan of a manufactured workpiece, the fluctuations in demand outlined above also lead to differences between capacity needs and capacity availability in the production line. While with transfer lines only comparatively large jumps in production capacity can be achieved, production lines with linked machining centers enable capacity to be increased in smaller steps at production ramp-up. Such production lines can also
44
MACHINE TOOLS WORLD MARCH 2017
be decommissioned again thanks to their high flexibility at production rampdown [4]. Figure 2 shows a step-by-step investment during the ramp-up phase of a workpiece to be produced, and the reduction in the ramp-down phase (quantity flexibility). Figure 3 shows an example of a production line layout for the mechanical machining of a powertrain component. The machining centers are illustrated linked by gantry load-ers and grouped into individual machining operations. A machining operation there-fore consists of several machining centers operated in parallel with the same process-ing content. Advantages of horizontal machining centers Horizontal machining centers are usually used for production purposes, and they
Features of large-batch automotive production In summary, the following characteristics for machining cubic workpieces in largebatch automotive production can be identified as follows: • Automated production with linked horizontal machining centers • One machine operator supervises eight to fifteen machines • A machining operation usually consists of several identically built machining centers operating in parallel with identical processing content • A workpiece is machined sequentially across several machining operations • A single workpiece is produced with several machining centers, meaning that several centers are responsible for tolerance conformity of the workpiece The last point in particular makes clear that the produced tolerances of a workpiece depend on the individual machines or sub-processes of the entire production sys-tem. In contrast to die and
Figure 3: Example of a production line for large-batch manufacturing (photo: MAG IAS GmbH)
TECH TRENDS mold production where workpieces are produced on one machine and supervised by a single ma-chine operator, with large-batch production dependencies exist between the individual machining steps in the process chain. This fact must be taken into account when de-signing the process as well as the produc-tion line. Cubic powertrain components Machining process and tolerances The powertrain of a vehicle can be separated into engine, transmission and axle modules [1], and these modules in turn consist of further component groups such as the valve train and its components. The cylinder head, crankcase and transmission housing are examples of classic cubic components in powertrain production. Because of high quantities and related cost-efficiency, workpieces are normally manufactured to near net shape before mechanical machining. This means that the primary geometry of workpieces is already predetermined by the casting or forging process, e.g. when forging connecting rods or crankshafts, and this is reflected in the machining operations for cubic workpieces [5, 6]. Focus on drilling Figure 4 shows the machining operations for a cylinder head. Milling is relatively
low compared to drilling or similar machining, and this is understandable because the primary geometry of the workpiece has already been cast, apart from a few areas. Specified holes in castings, however, are manufacturable only at high cost or are not possible at all for complex geometries. They have to be integrated into the mechanical produc tion line using drilling opera-tions, so that their share of the machining process clearly predominates. The various machining operations also enable conclusions about the axis movements required for machining. Because of the drilling operations, most of the move-ments consist of positioning the tool to the workpiece and a single-axis feed and re-traction motion. And because the work-pieces usually have no free-formed sur-faces, during milling operations the motion in the working plane (via traverse in two linear axes) is sufficient in addition to a positioning motion. The predominant number of geometrical tolerances on the workpiece to be pro-duced is therefore determined by the majority of drilling operations required. In addition to diameter tolerances mainly influenced by the dimensions of the tool, such as reamers, workpiece drawings also contain tolerance specifications for position,
Figure 4: Machining operations & their share of the manufacture of a cylinder head [5]
46
MACHINE TOOLS WORLD MARCH 2017
Figure 5: HEIDENHAIN linear encoder in a horizontal machining center
distance and hole depth. Linear axes determine dimensional accuracy Complying with specified tolerances is determined among other factors by the capability of the linear axes of a machine tool to achieve precise positioning (Figure 5). Depending on the workpiece or set of drawings, differing tolerance values and tolerance divisions for production features may exist. Figure 6 shows the distribution of tolerance (position, distance and depth tolerances) for a crankcase. The example shows that somewhat more than 30 % of the toler-ances analyzed are ≤ ±0.1 mm, and production features also exist on cylinder heads and transmission housings with tolerances of ≤ ±0.1 mm required by the designers. Examples are the position and depth tolerances of drill holes in the area of a cylinder head valve train as well as the bore axis distances of the main and neck bearing axes on a differential housing. Reliably complying with tight tolerance values To achieve the above-specified need for improved flexibility, producers make it their goal among other things to use standard machine tools in manufacturing, making it unnecessary to use additional specialized machines for individual production dimensions. This in turn means that, even if tolerance values are ≤ ±0.1 mm, they must still be complied with in a safe and reliable way with the machining centers installed in the production lines.
MAKE YOUR MACHINE WORK SMARTER
What if your machine tool could talk? If it could inform you in real time when a cutter is nearing the end of its productive life? Or if a worn spindle bearing was about to cause catastrophic failure? What if it could intelligently adjust feed rate to compensate for material variations? And even assist in seamlessly documenting product quality? Imagination is now reality−thanks to innovative Artis and Brankamp machine and process monitoring technology from Marposs. Many of the world’s most progressive manufacturers rely on easily operable Artis and Brankamp systems to help improve productivity, enhance quality, safeguard operations and reduce cost on a broad range of machine tools.
www.marposs.com
MARPOSS INDIA Pvt. Ltd. 147, Sector 7, IMT MANESAR 122 050 - Tel. +91 124 4735700 |sales@in.marposs.com
TECH TRENDS drawing dimensions s = standard deviation
Figure 6: Distribution of position, distance and depth tolerances for a crankcase
Cubic powertrain components Capability analyses supply specifications for machine capability and process capability The tolerance values specified previously seem large compared to requirements in the die and mold production sector. It must be considered, however, that values for automotive workpieces initially correspond to the designer’s drawing specifications. Automotive manufacturers carry out statistical capability analyses on the machining centers to make sure that the machine tools and implemented production processes are capable of meeting requisite drawing tolerances over a long period with a defined safety margin to the tolerance limits [7].
pro-vides knowledge about the temporary scat-tering behavior with tolerances produced by a machine tool subjected to constraints that are as constant as possible (≡ short-term testing). The process capability aims to determine the long-term scattering be-havior of a machine under process con-straints (≡ long-term testing). See [7] for equations for calculating the indices based on the measured tolerance values of pro-duced workpieces, as well as for further information. Equation 1 specifies the variables Cm & Cp: Cm,Cp = T / (6 ∙ s)
48
MACHINE TOOLS WORLD MARCH 2017
Target: Minimum scattering For uniformly high workpiece quality and minimum scrap rates, the target is to achieve lowest levels of scattering with tolerances produced, and therefore low deviations from the standard. Equation 1 can therefore be construed as follows: Cm,measured = T / (6 ∙ s) ≥ Cm (equation 2) or 6 ∙ s ≤ T / Cm (equation 3)
(equation 1)
T = tolerance range in accordance with Capability tests for machine & process For acceptance testing of the machine tools, 50 workpieces, for example, are pro-duced on the system or single machines and the distribution of produced tolerances is then evaluated using statistical methods. Capability specifications or capability indi-ces are defined for the capability tests. To determine the machine capability the indices Cm or Cmk are defined, and for recording process capability the indices Cp or Cpk. The indices Cmk and Cpk take into account a non-central distribution of measured tolerance values captured on several workpieces. Determining the machine capability
Manufacturers specify capability indices for the quality-relevant tolerances, and production machines supplied by the machine tool builder must at least achieve these during acceptance testing. With regard to the acceptance test, determining the indices leads to a further limitation of tolerance values specified in the workpiece drawing. Figure 7 demonstrates this with the example of a tolerance of T = ±0.1 mm under consideration of the machine capability specification Cm. Automotive manufacturers also specify feature classes for tolerance that are critical (Cm = 2.00), important (Cm = 1.67) or less important (Cm = 1.33) in relation to component functionality.
Cm,measured corresponds to the index derived from measuring a tolerated dimension
Figure 7: Correlation between the drawing tolerance specification & capability index Cm
TECH TRENDS on e.g. 50 workpieces produced during machine acceptance and the standard deviation calculated from them. Capability tests check compliance with maximum acceptable scattering Equation 2 demonstrates that the capability index resulting from the measurements becomes greater the lower the standard deviation is. The value (Cm,measured) from measurements on the workpieces must be greater or equal to the value of Cm specified by the manufacturer. If this is taken into account, specifying a capability index corresponds to specifying the maximum acceptable standard deviation by the man-ufacturer for a tolerated dimension (equa-tion 3 and Figure 7). For the example in Figure 7, with Cm = 1.67 this means that for the original tolerance of ±0.1 mm, 99.73 % of all tolerance dimen-sion values measured on various workpiec-es must be in the range of ±0.06 mm. As a consequence, the acceptable standard de-viation must have a maximum value of only ±10 µm. Achieving such values is a signifi-cant challenge for the linked machining centers in large-batch production.
50
MACHINE TOOLS WORLD MARCH 2017
Error limits for machining Flaw sizes in the process and their effects The previous pages outlined the order of magnitude of tolerances on workpieces for vehicle powertrains. The question arises as to the percentage of available tolerance of a production feature that flaw size arising in the process depletes. If the total flaws are greater than the available tolerance, the machine tool or process cannot fulfill the specified machining task. In the following, the error limits that can occur on a machine tool e.g. due to workpiece clamping or thermal drift behavior on axes are therefore estimated, and the aim is to estimate the residual tolerance reserve by comparing the available tolerance with the existing error limits. This reserve enables the machine tool or process to compensate for unpredictable or difficult-to-control production influences. Index tolerance of workpiece clamping The loading of machine tools is usually automatic, using special loading modules such as gantry loaders. Before a workpiece is machined, it needs to be positioned and fixed in the clamping fixture of the machine, and because this must be carried out without manual intervention, positioning is usually done by index pins in the clamping fixture. This means that the mechanical fitting tolerance between the index holes of a workpiece and the index pins of the clamping fixtures in the production line must be considered. According to the drawing specifications, identical tolerance for the index holes is available for each workpiece produced on the production line, but the actually produced dimension varies from workpiece to workpiece. This also applies to the individual index pins of the clamping fixtures. As a result, constantly identical indexing deviation cannot be expected. The specified maximum tolerance ranges for the index holes and index pins should, however, be complied with in each case as rejects will otherwise be produced. This makes it possible to estimate an error limit.
With the above-specified cubic automotive powertrain components (cylinder head, crankcase, transmission housing), index holes with a diameter of 12 mm are often drilled. Clamping of the workpiece within the indexing pins is not desired because this can lead to excessive loads on the loading systems or workpiece clamping errors, and therefore to possible idle times in the production line. To avoid this, a transition fit of Ø 12 H7/js6 is assumed in the following. These specifications achieve the following maximum error limit for workpiece indexing in the clamping fixtures:
To manufacture features with tight tolerances, the workpieces are sometimes moved in a defined direction using thrust cylinders in the clamping fixture prior to clamping. This means the workpieces are radially pressed onto the index pins, so that from the central drilling axes only a maximum of half the error limit occurs (≡ ±5.88 µm). Because sliding units often make clamping fixtures more complex and therefore more expensive, they are not integrated in all machining stations. Tool change tolerances On the tool side, inaccuracies also occur during tool changes and depending on the tool interface used. In the machining centers of the above-specified production lines, main spindles and tools with hollow taper shank interfaces are normally used. In [8], the predominant repeatability of the hollow taper shank connection is specified as < 1 µm (axial) & < 3 µm (radial) (≡ ±0.5 µm axial; ±1.5 µm radial).
[ To be Continued in Next Issue. ] Courtesy: Heidenhain India Website: www.heidenhain.de
TECH TRENDS
WELD SURFACING Surfacing minimizes downtime required for replacement of worn-out components, Reduces inventory by reducing the amount of replacements needed, and Saves money. For worn-out components, surfacing can save up to 75 percent of the cost of replacing worn parts.
T
oday’s industry is required to manufacture components with superior properties for longer service life and in an economical manner. The aim is to achieve an improvement in surface properties by altering surface characteristics in a component. Components often fail their intended service not only because of fracture, but because of additional factors such as wear, abrasion and corrosion which cause them to lose dimension and functionality. The service conditions most commonly experienced by components are: • Abrasion • Metal to metal wear • Impact • Erosion • Oxidation • Corrosion Out of the above modes of wear, Abrasion occurs in about 50% of cases. Then impact, metal to metal wear, corrosion and others in decreasing order. Most of the components fail from a combination of modes, such as abrasion and impact. For example, a mining bucket tooth is subjected to abrasion and impact, and depending on the type of material mined, one mode may be more dominant than another. This decides the welding product/s to be used. SURFACING Surfacing involves deposition of filler metal on a base metal to obtain desired properties or dimensions. This broad definition can include processes like electroplating and metal spraying. In metallurgical terms, surfacing is depositing a filler metal on base metal to build up wear resistant or corrosion resistant overlayby welding or spraying.
52
MACHINE TOOLS WORLD MARCH 2017
It is composed of one or more stringer or weave beads, on a surface to obtain desired properties or dimensions. Welding consumables designed for wear-resistant applications are commonly referred to as hardfacing consumables, in spite of the fact that hardness is not always a true measure of wear resistance. It is apparent that surfacing consumables are meant to be used as much in the design of new components as in the reclamation of used and or wornout components in order to reduce their wear and tear in service. Based on application requirements surfacing can be classified as: I. Hardfacing Overlay II. Corrosion Resistant Overlay I HARDFACING OVERLAY Hardfacing is the process of the deposition of thick coatings of hard, wearresistant materials on a worn-out or a new component surface that is subject to wear in service. Welding and Thermal Spraying are the processes generally used to apply hardfacing layers. Thermal spraying is preferred for applications requiring minimal thermal distortion of the component and good process control. Cermets such as WC-Co and alumina-based ceramics are deposited by thermal spraying. These coatings are applied to a thickness of about 0.3mm and
Fig. 2 - Hardfacing on Pipe
have limited usage. Weld hard facing by conventional welding processes is used to deposit very thick up to 10mm dense layers of wear resistant material with a good metallurgical bond. Most commonly used alloy system for hardfacing is iron based chromium carbide alloy with Cr>17% and C>3%. This type of alloy can resist wear upto 350OC. With various proportion of chromium carbides in combination with refractory metals such as Nb, W, V can achieve high temperature hardness and wear resistance upto 750OC.
Fig. 3 - Microstructure of Iron based Chromium Carbide alloy
Typical hardness data: Bulk hardness : 55-60 HRc Carbide hardness : 900-1200 VPN Matrix hardness : 500-700 VPN
Fig.1 - Hard-facing on Screw feeder
Apart from bulk hardness, the volume fraction of carbides, its shape and distribution in a matrix decides wear resistance of an alloy. The bulk hardness requirements for wear resistant applications
TECH TRENDS generally vary from 50 to 68 HRc. For hard facing applications, weld deposits are normally restricted to up to two to three layers. Limited-layer products usually are in the metal carbide families such as chromium carbide, complex alloy carbides and tungsten carbide. For multi layer applications there are austenitic alloys and some martensitic alloys too are used. STRESS RELIEF CRACKS The brittle nature of the metal carbides leads to stress relief cracking, and as multiple layers are applied, stress continues to build which concentrates at the root of the cracks, until separation or spalling occurs between the parent metal and the hardfacing deposit. These are the result of high stresses induced by the contraction of weld metal as it cools. These cracks always occur perpendicular to the bead length (Fig.4).
Welding Techniques Various welding techniques used for surfacing are listed in order of popularity. The major factor which affects the economics of hardfacing is deposition rate. Below table shows the estimated deposition rate for each process. Process
Fig. 5 - Corrosion resistant overlay cladding
recommended for use of one layer only. However, for certain applications of wear areas of pump linings a second layer of surfacing is applied. In this process, weld metal dilution is very important to control and affect ferrite percentage in especially in case of stainless steel overlays. Overlay Patterns: Depending on the type of wear, there are several types of surfacing patterns can be used viz.; stringer, weave, zigzag, dot or a combination of all.
Fig. 4 - Stress relief cracks on hardfacing weld
The cracks propagate through the thickness of the weld bead and stop at the parent metal, as long as itâ&#x20AC;&#x2122;s not brittle. In the cases where the parent metal is hard or brittle, there is need to apply a buffer layer of a softer, tougher weld metal. The austenitic family is a good choice for a buffer deposit. Many metal carbide alloys show stress relief cracks when cooled to moderate temperatures; this is normal. Alloys from austenitic and martensitic families do not show this phenomenon when applied with proper welding procedures. II. CORROSION RESISTANT OVERLAY These overlays are used to improve the service life of components made with an otherwise corrosion-prone material. Surfacing for corrosion resistance is
54
MACHINE TOOLS WORLD MARCH 2017
Fig. Straight bead with weaving
Deposition Rate, Kg/Hr
Flux cored arc welding (FCAW)
3.5 to 11
Gas metal arc welding (GMAW)
2.3 to 5.5
Shielded metal arc welding (SMAW)
1.3 to 2.3
Submerged arc welding (SAW)
3.5 to 11
Gas tungsten arc welding (GTAW)
1.3 to 2.3
Strip Cladding (ESSC or SASC) is another technique for corrosion resistance overlaying of Stainless steel and Nickel based alloys. The other special surfacing processes are Plasma transferred arc welding (PTA), Laser cladding, Thermal spraying, and Brazing. With the Oxy-fuel welding (OFW) process too surfacing can be done but this technique is less popular. Welding Filler Metals Surfacing filler metals can be in the form of bare rods for Gas welding, GTAW, GMAW, SAW process to be used with agglomerated flux, coated electrode for the SMAW process, strips for ESSC and SASC process. List of Ador Welding make surfacing welding alloys: Sr. No. I
Application/Hardness
a. Austenitic type
Corrosion resistance, Impact resistance, Work hardening characteristics
b. Martensitic type
Metal to metal wear resistance, Abrasion & Impact resistance, Hardness: 20 to 60 HRc
II
Carbides
Severe abrasion resistance, Hardness: 40 to 65 HRc
III
Nickel Base
High temperature OxidationAbrasion resistance
IV
Cobalt Base
High temperature OxidationImpact-Corrosion resistance, Hardness: 25 to 55 HRc
V
Copper Base
Corrosion resistance and low frictional wear resistance
Fig. Zigzag pattern
Base Metals Carbon and low alloy steels, Stainless steels, Mn steels, Cast irons, Nickel and Copperbase alloys can be hard-faced. For steels with carbon content above 1% a suitable buffer layer is required. For corrosion resistant applications, Carbon and low-alloy steels are most popularly used.
Alloy Base Iron Base
THIS AIN’T YOUR GRANDADDY’S MULTIMETER Introducing the DM284, an all-in-one True RMS digital multimeter and thermal imager that show you exactly where an electrical problem is to speed up troubleshooting. Infrared Guided Measurement (IGM™) is the future of instrument and tool technology. Plain and simple. And for the hardworking professionals in the building and electrical industries, it’s the perfect addition to the toolbox. By helping you identify and verify problems invisible to the naked eye, you’ll save time, money, and maybe even lives. www.flir.in/DM284
For more details call us on: +91-11-4560 3555 or write to us at flirindia@flir.com.hk FLIR Systems India Pvt. Ltd. 1111, D Mall, Netaji Subhash Place, Pitampura, New Delhi – 110034 Fax: +91-11-4721 2006 | Website: www.flir.in
MR176
MR160
TG130
TG167
TG165
• THERMAL IMAGING AT YOUR FINGERTIPS • CONVENIENT, ALL-IN-ONE TOOL • PINPOINT PROBLEMS QUICKLY
C M 1 74
DM284
Thermal Imaging Multimeter
Images used for illustrative purposes only.
NEW
TECH TRENDS ADOR WELDING SURFACING CONSUMABLES HARDFACING OVERLAY Application
SMAW
Moderate Abrasion Impact
Zedalloy 250, Zedalloy 350, Zedalloy350 LH
High Abrasion-Moderate Impact
Zedalloy 550, Zedalloy 550 LH, Zedalloy 600
Work Hardening High Impact
Zedalloy 12Mn/16Mn
Severe Abrasion
Super Zedalloy, Zedalloy VB, Zedalloy 16
Abrasion-Corrosion
Zedalloy Bell, Zedalloy K, Zedalloy 17Cr NS Plus
High Temperature Metal-Metal Wear
Nimoten Plus 535 A, Nimoten Plus 535 B, Nimoten HFD
Sugar Mill Rollers
Maganacane
FCAW
SAW (Automelt H25 & Automelt H35) + Automelt EL8
Automig FC 580
Automelt H55 + Automelt EL8
Automig FC 400
CORROSION RESISTANT OVERLAY Base Material/ Application
SMAW
MIG/TIG
SAW
Stainless Steel Dissimilar Joining, Buffer Layer
Betanox D, Betanox DL, Superinox 312
Miginox-Tiginox 309/309L
Automelt S76+Subinox 309/309L
High temperature Corrosion Resistance
Betanox C
Miginox-Tiginox 310
Automelt S76+Subinox 310
Martensitic Alloy
Betachrome 13Cr, Betachrome 13/4, Betachrome 13/4 LB
Miginox-Tiginox 410/410NiMo
Automelt S76+Subinox 410
Ferritic-Martensitic Alloy
Betachrome 17Cr
Miginox-Tiginox 430
Automelt S76+Subinox 430
Mn steel
Betachrome N/ND
Automotive Exhaust System
Miginox 430LNb Nickel based
Nickel 200/201
Nicalloy 1
Automig-Tigfil Ni-1
Inconel 600
Nicalloy Fe-2, Nicalloy Fe-3
Automig-Tigfil NiCr3
Inconel 625, Inconel 825
Nicalloy Mo-3
Automig-Tigfil NiCrMo-3
Alloy C-276
Nicalloy Mo-4
Automig-Tigfil NiCrMo-4
Inconel 625, Inconel 800
Nicalloy Mo-5
LNG storage system for cryogenic application
Nicalloy Mo-6, Nicalloy M0-12
C-22
Nicalloy Mo-10
Monel
Supermonel
Automelt S76+Automelt NiCrMo-3
Automig-Tigfil NiCu-7
Cobalt Based Elevated Temperature OxidationAbrasion
Zedalloy CoCr-A Copper Based
Copper-Steel joining
Bronze
Corrosion, Erosion, Cavitation
Super CuNi
Automig-TigfilCuNi
Brazing Copper-Steel-Cast Iron
Bracc 2211
Cu & Ni based alloy, Steel, SS, CI, CuZn20Al, CuNi10Fe, CuNi30Fe
Bracs 3343
Surfacing of steel, bronze, CI
Bracc 7700
BENEFITS: For saving time and money on equipment maintenance and repair, surfacing is best available option. The benefits of surfacing are: • Minimizes downtime required for
56
MACHINE TOOLS WORLD MARCH 2017
replacement of worn-out components • Reduces inventory by reducing the amount of replacements needed. • Saves money For worn-out components, surfacing can save up to 75 percent of the cost of replacing worn parts.
[Contributed by Ador Weding Ltd.]
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.
Further information about the PNOZmulti Configurator: www.pilz.com + Web code: web10522 Pilz India Pvt. Ltd Office NO 102 & 202, Delite Square, Near Aranyeshwar Temple, Sahakar Nagar NO 1, Pune - 411009 Telephone: +91 (0) 20 24213994/95, Fax +91 (0) 20 24213996, Web: www.pilz.in, Email: info@pilz.in
AD_PNOZmulti_2_222x285_EN_IND_2015_03.indd 1
23.03.15 11:14
TECH TRENDS
Accusharp tells more about
S
‘Gundrilling’!
ince 1999, Accusharp is in the activity of manufacturing metal cutting ‘Round Tools’ like Carbide and H.S.S. drills, end-mills, reamers, cutters, burrs, form tools, step drills, etc. As a matter of fact, it is difficult to drill a straight and accurate dimensional hole of a depth more than about five times the diameter using a standard twist drill. However, using a ‘Gundrill’ one can make a ‘Deep’ hole of much longer depth; even 200 times the drill diameter. Not only it drills 200 times deep, but also with the precision tolerance of hole size, roundness, straightness, concentricity and surface finish in one pass. As it can cut small diameter and long length holes, the Gundrill can be also suitable for very deep hole drilling to machine parts as up to a 200:1 ratio for drill depth to drill diameter. This typical drill was initially developed 100 years back, to drill Gun barrels having 5.56 mm (0.223 inch) bore caliber barrel of rifles with 508 mm (20 inches) length, - nearly 100 times the diameter of the bore. The Gundrill was developed to drill such long, straight holes of high accuracy dimensional requirements. And since then, this type of drill is known as ‘Gundrill’, even if subsequently it is being used for other industry requirements and applications. Because of the high capabilities of this innovative ‘Deep Hole Drilling Concept’, it was but natural, that various industrial sectors got attracted to assess its appropriate extended use for their metal cutting applications. And since then it became widely popular in other industry sectors, as well. Gundrilling is an ideal solution for most
58
MACHINE TOOLS WORLD MARCH 2017
of the deep and high precision drilling projects. This operation produces deep holes with precision, high surface finish, and can maintain repeatability of the process. Looking at the present increasing need from various industry sectors, those who are in metal cutting, Accusharp, this year, decided to make ‘Gundrills’ to meet the industry requirements. More about ‘Gundrill’ for Deep-Hole Drilling: Gundrills can make holes of exact specified size, with precision tolerances, produce burr-free holes. It can also be used with special formed shapes in blind holes for bottom forming with a minimum of machine revisions. Gundrilling can be done on CNC machining centers, lathes and milling machines with relatively small investment. The process can be made affordable even for small shops with their various production requirements. Gundrill Construction: Gundrills consist of three elements: 1) a carbide tip, 2) a heat treated alloy steel shank, and 3) a steel driver -Typically silver brazed together and ground as one precision unit.
Carbide Tip: This is the real cutting portion of Gundrill, made of special grade of Tungsten Carbide. Tip guides the drill through the work piece and cuts the hole of precision dimensional properties. The drill-point, or nose geometry has two basic angles which may vary according to the work material and process parameters. These angles balance cutting forces on the bearing bush to keep the drill concentric. The tip diameter is slightly larger than the shank diameter, so that the shank can rotate freely without touching the hole. A round, kidney-shaped, or two round holes through the tip are provided through which high pressure coolant passes continuously during the drilling operation.
Gundrill Tip can be resharpened several times to extend their life.
Shank: The shank is made of special alloy steel tubing with a110° -120° Vee-flute. Coolant is pumped in to the driver through the centre of the shank towards the tip, there from it is flushed back along the shank’s flute. The shank has
TECH TRENDS to maintain Gundrill alignment; and therefore it should be strong enough to absorb cutting torque and thrust. If the shank is too stiff it may misalign the entire tool set up. However, if the shank is more flexible, it may sag at high RPMs. Driver: Driver is a cylindrical piece located at the other end of the Shank. It is made of special alloy steel, and dimensionally according to industry standards. Driver has a concentric hole through its length for coolant to pass through in to the Shank. This also has an undercut or flat section for the set screw, which holds in the spindle bore. Two Flute Gundrills, with special nose geometry, are used for non-ferrous materials and allow for up to 80% increase in feed rates. The Working Principle of Gun Drilling Process: Long length of the Gundrill Shank is externally supported by bushes or bearings to avoid vibrations and to maintain the linearity, roundness precision and desired surface finish of the drilling operation. High pressure coolant, assuring sufficient flow rate, is pumped in to the Gundrill towards the cutting edge of the Carbide Tip, through the V- shaped fluted tubular shank. The coolant, this way reaches the machining zone. Thereby it cools and lubricates
the cutting edges of the Tip and also the Shank supporting bearing area. The coolant flow also serves to pick up chips formed at the cutting edges and to transport them into the Chip Box, through the V-flute. Gun Drilling diameters have normal range between 1mm to max. 50 mm. Depth to Diameter Ratios vary according to the type of the drill and process being used. Ratio
Cutting Tool & Process
5:1
Using common twist drills
10:1
Using high performance twist drills with through coolant
20:1
Using special deep hole drills with through coolant
100:1
Using Gundrills on dedicated Gundrilling machine
200:1
Using Gundrilling on high performance Gundrilling machine
300:1
Using Special nose geometry Gundrills in proprietary processes.
What are the advantages of Gundrilling process? • Gundrilling is a single pass complete operation, which does not call for any subsequent operations, like reaming, honing, de-burring after its initial pass. • Constant flow of pressurised coolant not only transports chips into a chip box, but also keeps the cutting area and tool edges cool. Thereby increases tool-life considerably.
Application of Gundrills in Industry Sectors: Mould-Industry, Aerospace, Automobile, Machine Tools, Paper Industry, Defence, Mining Tools, etc. Gundrills practically can be used in any industry wherein close tolerance long length holes need to be drilled in metal components. For Example: • Die & Moulds • Water lines • Heat exchanger tube sheets • Machine Tools, Oil Holes, Fixtures • Turbo Blades • Paper Rolls, etc
On the occasion of IMTEX 2017, Accusharp has introduced ‘Gundrill’, as its ‘New Product’. A wide range of diameters between 3 and 32 mm is on the production programme, and Gundrills from this range were displayed in the IMTEX stall. One Gundrill of dia. 32 mm having length of 1 meter was specially displayed; which became a point of attraction for many customers and visitors at the IMTEX stall. In a short span of time from the launching of this new product, Accusharp has received encouraging response from a number of customers for their requirements of various sized Gundrills.
Accusharp Gundrills
‘Cut Fast & Cut Cost’!
60
MACHINE TOOLS WORLD MARCH 2017
TECH TRENDS
How Mastercam’s design tools provide flexibility Mastercam is known for precision NC programming, but it also delivers a suite of shop-tested design tools aimed at getting parts on and off the machine as quickly as possible
P
owerful modeling tools include not only 3D surfacing and solids, but hole-filling, direct editing without a solids history, geometry repair, and much more. Mastercam Design streamlines and simplifies modeling and editing geometry. It also supports advanced geometry creation, including solid modeling, hybrid machining, NURBS curves and surfaces, 2D and 3D associative dimensioning, surface extension, blending, trimming, splitting, variable filleting, solid modeling, and hybrid modeling to complete your jobs quicker and more efficiently. Enhancements A few new enhancements to Mastercam 2017 Design are: Optimize: Repairs imported solids (whole bodies or individual faces) by improving the
accuracy of edges and be identifying and optimizing blends, allowing other Model Prep functions to work better. Toolpaths on the repaired solid maintain associativity to faces. Solid Disassemble: A Model Prep function that takes a solid assembly and lays each body out in a single plane. It works on models with and without history, imported from other systems, or created from within Mastercam. The user interface has been improved to better support your machining practices, allowing you to place each solid body on its own level at
the toolpath origin, saving you time and extra steps. Preprocess Solid: The Surface From Solids function now includes a Preprocess solid option that can help clean up errors in imported solids by assisting in the conversion of solid faces into surfaces. Mastercam makes a copy of the body, prepares it, and then creates surfaces from this body. After the conversion, Mastercam deletes the preprocessed body, leaving the original intact. Mastercam 2017 design improvements • The X, Y, and Z options in the Plane Selection dialog box have been enhanced to increase functionality, accuracy, and efficiency by eliminating extra steps and guess work • Repair Small Faces analyzes solid bodies (with no history) and reports if it finds small entities such as spikes, sliver faces, edge pinches, or gashes • Solid Impression can speed up the creation of an electrode tool without having to create extra operations. Transform Dynamic now supports AutoCursor snapping to horizontal, vertical, and tangent positions when rotating geometry • You can now dynamically manipulate geometry with Mastercam’s new trio of single-axis arrow controls.
For more information, Website: www.mastercam.com
64
MACHINE TOOLS WORLD MARCH 2017
Taming power quality is now child's play
When you use DigiVolt Stabilizers, Tranquil Ultra Isolation Transformers and Powercon Power Conditioners from Unity Controls, power quality is under total control and would no more hamper your production and product quality. These silent sentinels protect your sophisticated, high precision production equipment from the ill-effects of voltage, spikes, surges, transients, sags, noise and harmonics affecting AC power lines. Thus ensuring continuous uptime and enhanced productivity and consistent quality.
Intelligent Microprocessor-based, High Efficiency, Energy Savers specially designed for CNC machines
Our equipment are approved by major OEMs and exported (up to 2000 KVA) to countries in Europe, Middle East, Africa
Our Allied Products: n
Active Harmonic Filters K-Rated Transformers Light Energy Management Systems
n
KVAR MAX - Real Time Power Factor System
n n
and Asia Pacific. So leave power quality and energy management to the experts â&#x20AC;&#x201C; Unity Controls. With our nationwide network we are only a phone call away!
Contact us for Power Quality & Harmonic Audits to Conserve Energy and Save Costs.
405, Sapphire Arcade, 42 M.G. Road, Ghatkopar (E), Mumbai 400 077, India
The power quality & energy experts
+91-22-2501 3832 / 33 sales@unitycontrols.in www.unitycontrols.in
Ahmedabad l Bangalore l Chennai l Delhi l Gurgaon l Hardwar Indore l Jalandhar l Jamshedpur l Kolkata l Kanpur l Mumbai l Pune l Rajkot
l l
vijayshreyaarts@gmail.com
UNITY CONTROLS PVT. LTD
TECH TRENDS
Family Fluids Business Changes with Times Hangsterfer’s Laboratories evolves while remaining a family company
H
angsterfer’s Laboratories faces the same challenges as other companies in the metalworking fluids industry. Environmental concern and regulatory demands have increased. Customer demands have intensified as manufacturers in industries such as aerospace use more difficultto- machine metals such as titanium and Inconel. Today, metalworking fluids must “comply with the latest environmental regulations while providing the performance requirements for today’s demanding manufacturing needs,” said Edward Jones, COO and technical director at Hangsterfer’s. “We expect the growth of value- added components such as aluminum, composites, nickel and titanium to continue to grow exponentially and advanced fluids will be essential to this industrial sector.” The world and the business are entirely different than when Hangsterfer’s was founded nearly eight decades ago. Hangsterfer’s products include metalworking fluids, coolant concentrates, cutting oils, “grease like” (according to the company’s Web site) metalforming compounds that prevent metal-to-metal contact at the tool-
66
MACHINE TOOLS WORLD MARCH 2017
workpiece interface, machine lubricants and dielectric fluids for EDMs that are used to cut and shape parts. The company also makes rust inhibitors and cleaning fluids. The one thing that has remained the same is the company’s family ownership. The Mantua, NJ-based producer of fluids was founded by William Hangsterfer in 1937. He was born in 1896. The fluids company was his second business. Five years earlier, the World War I veteran started a firm that distributed items such as motor oil and tires. The businessman decided to start a fluids company because in his distribution business, “he learned early on the importance of quality lubricants with the motor oil sales he was involved in,” said COO Jones, 52, and a grandson of the founder. Hangsterfer’s benefited as industrial output rose with the start of World War II. The US war effort required more difficultto-machine parts, which in turn spurred demand for fluids produced by Hangsterfer’s. Today, the company estimates it controls 1% of the world market for its products. Edward Jones has been with the company since 1984. Jones said he worked
with his grandfather in the laboratory and cared for him “in his later years as his personal assistant.” William Hangsterfer died in 1983. Hangsterfer had one daughter, Ann, who was born in 1937, the same year the company was founded. She married Edward Jones, the father of the present COO. The older Edward Jones, whose duties at the company included being vice president of sales, died in 2008. Ann Jones is the company’s CEO. The executive offices at Hangsterfer’s are a family affair, with members of the family’s third generation present. Beth Ann Jones-Sheehan, 46, sister of the COO, is vice president and general counsel. She also is vice president of the Independent Lubricant Manufacturers Association. Another brother, Bill Jones, 55, is a senior vice president who has been with Hangsterfer’s full- time since 1980. Another sibling, Leslie Jones, 58, is retired from Hangsterfer’s. Members of the fourth generation have started to work at the company: Nicolette Jones, 22, daughter of Edward, is research manager; Andrew Jones, also 22 and son of Bill, is executive assistant. There are three other fourth-generation family members who are in their teens. “All are interested in coming into the business,” COO Edward Jones said. “We have really turned into a ‘business family.” A Company Evolves The enterprise has evolved over the course of those generations. “In the 1940s, we developed a synthetic whale oil replacement,” COO Jones said. “We started exporting in the 1950s; at that time our largest export market was Japan. Since the 1950s, our exports have been about 40% of our production and that percentage remains today. Our heavy
TECH TRENDS
involvement with international business has always kept us in line with not just the very important USA regulatory trends, but also other industrial nations’ trends.” With metalworking fluids, European regulators have taken the lead in requiring more “bio-renewable” lubricants. As international regulatory standards tightened, Jones said, “We were for the most part ready.” Another change took place in the 1950s when Hangsterfer’s become involved in the aerospace market. “We developed a full line of chlorinefree cutting fluids at that time,” he said. “Chlorine-free is a very important feature that the aerospace industry demands due to the potential for corrosion. Aerospace is a very important industrial sector.” The COO’s path through the company mirrored the evolution of the fluids business. “I started with our ‘business family’ when it had 12 employees,” Jones said. “One of those key employees who was in charge of compounding our top product of that time, S-500, left the company and I replaced him.” Jones ended up spending two years in the factory. “My experience in our factory has helped me better understand the complexities of manufacturing lubricants,” he said. “Throughout my childhood, the talk at the Sunday dinner table was often about business, so my path into the company was quite natural.” After his factory stint, he took a laboratory job as a quality control chemist and later he went into sales. “Once in the sales [arena], the biggest challenge I faced was price,” he said. “The types of raw materials we used and their influence on the selling price was a sales volume obstacle.
68
MACHINE TOOLS WORLD MARCH 2017
Regulatory Pressure Hangsterfer’s today is dealing with a variety of challenges. “Our industry and our customers are facing major changes to the norm,” Edward Jones said. “The use of boron, chlorine, formaldehyde and secondary amines are being placed under extreme regulatory pressure.” One example is the REACH program of the European Commission. It refers to registration, evaluation and authorization of chemical substances. REACH is intended to “improve the protection of human health and the environment through the better and earlier identification of the intrinsic properties of chemical substances,” according to the European Commission.
REACH “places responsibility on industry to manage the risks from chemicals and to provide safety information on the substances.” The program requires makers and importers to provide data about chemicals and to register the information in a central database operated by the European Chemicals Agency. One response by the company to environmental regulations is its S-787 semisynthetic cutting fluid, which Jones said is free of boron, chlorine and the other substances & works well on machining of nickel and titanium alloys. Hangsterfer’s markets S-787 as a multipurpose fluid. Jones said he made a presentation at a UK aerospace conference about S-787 and plans to present the same materials at IMTS during the Trends in Advanced Machining, Manufacturing & Materials conference. R&D “We have a very thorough research and development system and nothing leaves
our lab unless it passes an extensive regimen of tests and eventually field verification,” Jones said. “We consider a new product on the market to be no less than six months old and often [it will be] two years old before we would consider it suitable for the global marketplace. Petroleum-based cutting oils are quickly being replaced with more advanced synthetic and vegetable-based fluids.” Newer Hangsterfer’s products contain less than 10% petroleum, compared with older products that have more than 60% petroleum. “Since the 1940s, our use of the synthetic whale oil replacement has helped us better understand the use of renewable oils and fats,” Jones said. The company introduced oils with “up to 30% renewables” in the 1950s “and since then have incorporated more and more vegetable oils,” he said. “It took many decades to come out with cutting oils and coolants that were predominantly vegetable oils because the quality of vegetable oils that met our standards and our customers’ needs had not been available until just about 15 years ago.” Beyond technical and environmental issues, “We need to make safe and comfortable workplaces to keep and attract the talent necessary in today’s workforce,” Jones said. “Jobs in our sector of metalworking will continue to rise and the industry has to change… to keep that pace going.”
Hangsterfer’s reminds its customers that it is family run. There’s an image of the founder on the company web site, which also references how it’s being managed by the third generation of the family. COO Jones said the founder still has an impact on the company he started. “One of our core philosophies is environmentally friendly products without sacrifice to performance.
TECH TRENDS Safety: When a safety gate is opened, hazardous machine movements must be stopped and a restart must be prevented. It must not be possible to either defeat or manipulate the guards
Authorisation concepts in machine automation In modern automation architectures, the interaction between machinery safety (Safety) and operational security (Security) is increasingly becoming the key to practicable concepts. It is important to consider not only the technical and normative requirements of safety, but in particular the need to assign information and authorisations carefully – issues that until now have been covered by organisational measures. With a safe operating mode selector switch, manipulation protection and access authorisations can be achieved in terms of overall safety.
T
he development towards a networked automation landscape means that companies face new security challenges. Industry 4.0 systems can be reconfigured and optimised autonomously – i.e. by the system itself during operation, which requires safety to be re-assessed during runtime. It must also be ensured that no new safety risks arise as a result of residual security vulnerabilities. Holistic approach increasingly important There are clear differences in perspective when it comes to the issue of safety: the
70
MACHINE TOOLS WORLD MARCH 2017
internationally used terms are “Safety” for machinery safety and “Security” for operational security; this helps with the basic differentiation. Safety requires that residual risks that emanate from a plant or machine do not exceed the limit values specified in the standards. This includes hazards to the machine surroundings (e.g. environmental damage) as well as hazards inside the plant (e.g. persons inside the plant). Security is concerned with protecting a plant or machine from unauthorised access from outside, as well as protecting sensitive data from corruption, loss and unauthorised access internally. This includes explicit attacks as
well as unintended security incidents. When developing solutions it is also important to consider the needs of the user from the very start, in terms of handling and user friendliness during operation, for instance. If not, manipulation of safety measures will literally be programmed in. Holistic safety concepts require the interaction of safety & security, but that’s not all. In terms of the safety aspect, it’s important to check the extent to which security issues influence functional safety. This is the case if access or authorisation systems can be defeated or copied using simple means, or are
MARCH 2017
MACHINE TOOLS WORLD
71
TECH TRENDS accessible to everyone when a master password is written on a note stuck to a screen, for example. Key issues here include clear, safe proof of identity for products, processes and machines as well as for authorised persons, including safe information exchange across the whole production process. Safety must be considered from the start In the internal European market, there is an obligation for machine manufacturers only to supply safe products to its customers. All relevant hazards must be identified, based on the intended use – taking into consideration all the lifecycle phases once the machine is first made available on the market. All the various groups who come into contact with the machine, such as operating, cleaning or maintenance staff for example, are also considered. The risk is estimated and evaluated for each hazard. Risk-reducing measures are established in accordance with the state of the art and in compliance with the harmonised standards. Ultimately, an intelligent safety concept must provide the greatest possible leeway and freedom as well as the highest possible level of safety. Access points to the machine or process are of vital importance. These must be protected against unauthorised opening and must guarantee beyond doubt that nobody is inside the hazard zone when the machine is started.
The operating mode selector switch PITmode enables the operating mode to be switched safely & access authorisation to be controlled within one unit
72
MACHINE TOOLS WORLD MARCH 2017
No danger to people … To ensure that deliberate or accidental opening of access doors cannot cause a hazard, they are protected in classic safety style with a safety gate system. This combines safety gate monitoring with safe guard locking inside one system and also provides safety functions such as emergency stop, escape release and a mechanical restart interlock. This means that anyone who is locked in accidentally can leave the danger zone quickly and easily in the case of danger. It will not then be possible to restart the plant until it is established beyond doubt via the integrated safety and reset functions that there is nobody else in the danger zone. With a safety gate system such as the PSENsgate from Pilz, human protection is guaranteed, in terms of safety. However, the matter of process protection in terms of operational security is still open. … or process In practice, protection against unauthorised access can be achieved via a safe operating mode selector switch. It fulfils two functions: it selects the operating mode and controls authorisation for machine access. Operating mode selector switches such as PITmode from Pilz allow you to switch between defined operating modes. The operating mode is selected by inserting a transponder key with the relevant authorisation and pressing the pushbutton defined for the relevant operating mode. Each key is individually coded to enable unique user authentication, which prevents manipulation. As the unique key can be used on several machines and can have different authorisations stored on it, several mechanical keys can be combined within one transponder key. This in turn reduces administrative work. Clearly defined responsibilities Using the coded key, each operator is given access to the machine functions or machine operating modes allocated to him. Individual (access) authorisations
can be assigned for each operator via the RFID-based keys. These can be assigned via identification management in the machine control system. Thanks to operating mode selector switches like PITmode, authorised personnel are able to operate and control the plant in various operating modes. Operators are given the machine enables that match their individual abilities and qualifications, providing a high degree of protection against unintended actions and manipulations, as well as security of information. On delicate or sensitive machinery, all operator actions need to be logged. Here too the system can provide support, as all operator actions are reported to the control system anyway. The authentication system can be used to assign the actions clearly to an operator. As a result, any changes during the machine operation can be documented, increasing traceability. Should anyone change a machine parameter during operation, this step will be documented. If errors then occur, the reasons can be identified more quickly. Through self-monitoring, PITmode switches safely from one operating mode to the other. Five selectable operating modes are possible: automatic mode, setup mode, manual intervention under limited conditions, special mode / process monitoring and service mode. Thanks to the LED display, the currently selected operating mode can be clearly identified, as can the key’s authorisation level. The operating mode selector switch can be used for applications up to PL d of EN ISO 13849-1 or SIL CL 2 of EN 62061. With the definition of safe operating modes it is possible to harmonise the requirements of operator safety, process security and availability. After all, issues such as manipulation protection, demarcation of areas of responsibility/ jurisdictions and clear proof of identity for machines and operators must be safely regulated before a process can be deemed “safe to operate”. Pilz India Pvt. Ltd.
BOOK NOW!
International Exhibition and Conference on Metalworking Industry
August 2017 Scan this QR code for more information
JIExpo
Kemayoran, Jakarta
Jakarta International Expo
INDONESIA
Organized by :
INDONESIA CONTACT:
INTERNATIONAL CONTACT:
Budi Santoso Project Executive Budi.Santoso@ite-asia.com
EARLY BIRD DISCOUNT
Kerstin Koschnicke Exhibition Director Kerstin.koschnicke@ite-asia.com
Chossy Chintanu Putja Project Executive Chossy.Putja@ite-asia.com
Until January 2017
www.mtti-exhibition.com
THE NEXT BIG THING
Organized By Supported By
Gold Participant
+91 79 40305602 | +91 9328899503 | bjhala@imtos.com | www.kdclglobal.com
Welcome to the World of Machine Tools, Multifarous Opportunities & MagniďŹ cence
CNC Automation CNC Machine Tools
KNACK
SOLUTION
Concord CONCORD UNITED PRODUCTS
HYTEK
H YDR A UL IC AC C E S S OR I E S
Solutions in Sheet Metal
ASIAN NATIONAL
Lifting Equipments
International Particiption Turkey
SUPPORTED BY
China
Korea
Taiwan
Japan
USA
DIAMOND PARTICIPANT
Germany
Spain
Italy
GOLD PARTICIPANTS
Govt. Of India Ministry of New and Renewable Energy
CNC Machine Tools
ORGANIZED BY
Secure your space NOW
SILVER PARTICIPANTS
AWARDS BY
Contact: +91 98795 66567 | rajesh@imtos.com | www.kdclglobal.com
TECH TRENDS
Swift Drilling
Through Tough Metals
S
parkonix has been leading the way in EDM/Spark Erosion technology since the last four decades. Sparkonix is also one of the first Indian companies to develop and launch the EDM Drill back in early 2000s. With the recent launch of Speed III, Sparkonix is now the first Indian machine tool manufacturer to develop CNC EDM Drills and also the largest Indian manufacturer of EDM Drills. Full range of EDMs for Wide Range of Applications Sparkonix’s EDM Hole Drilling machines include several advanced features to deliver high performance levels for your operations. The EDM Hole Drilling models come with versatile capabilities that support numerous critical applications. Easily Drill Holes of diameter ranging from 0.3 to 3.0 mm and depths up to 300 mm, special applications requiring drilling of up to 10.0 mm diameter can be achieved. Applications • Start holes for wire cut EDMs • Gas escape holes • Drilling in super alloys and tungsten carbide dies • Drilling operations for spherical shaped, curved & tapered workpieces • Ejector pins, cooling pins of pen moulds • Air vent holes for forging die Speaking on the launch of Sparkonix’s CNC EDM Drills, Shailesh Patwardhan, Director at Sparkonix says, “This is a 100% indigenous development. It means, customers not just get the CNC technology or machine but, an entire ecosystem of application engineering expertise, spares, support is now
80
MACHINE TOOLS WORLD MARCH 2017
available. In near future too, we see more and more customers switching to CNC based controllers and that remains a key focus area for us as well.” EDM Drill High performance in precision small hole drilling With 500+ installations across India, Sperkonix’s Speed I and II have been serving the customers in various industries for more than a decade. Known for being sturdy, the EDM Drills have earned a reputation for their enduring performance year on year. CNC EDM Drill High speed drilling for small holes The development CNC EDMs is a direct response to the need of the import dependent customers in the Indian market for an advanced, precision technology in EDM Drilling. While there are several international suppliers, end customers have reportedly faced repeated challenges in the service and spare parts supply chain. The Speed-III from Sparkonix is Sparkonix CNC EDM Drill
an advanced CNC high speed small hole drilling machine with distinctive features in its class with the capability to repeatedly size and accurately produce the jobs as per the application. For more information, Website: www.sparkonix.com Sparkonix EDM Drill
www.capitalfirst.com
FULFILL YOUR PERSONAL AND BUSINESS GOALS WITH OUR WIDE RANGE OF PROGRAMS
Personal Loans
Our programs: • Financial based assessment • Banking program • Assessment basis loan tracks • Card receivables • Transactions on e-commerce platforms • Personal loan (salaried and self-employed)
What’s in it for you? • Personal loans ranging from `1 lakh to `15 lakhs* • Business loans ranging from `3 lakhs to `75 lakhs* • Tenure from 6 months to 60 months* • No security/collateral required
For Business Loan, SMS CF <space> BIL to 56363 | For Personal Loan, SMS CF <space> PL to 56363 | Write to us at cfl.connect@capitalfirst.com
*Conditions apply.
Business Loans
TECH TRENDS
Getting the balance right iBalance is a unique ANCA software product which proactively alerts users to potential wheel vibrations and uses the technology already built into our range of machines By Simon Richardson, NCA MX machine Platform Product Manager
S
ince humans invented the wheel, the need to maintain the right balance and stop vibrations has been an ongoing challenge. Simply put, if your grinding wheel is causing vibrations, there is no point in having a rigid grinding machine. Correctly balanced wheels result in superior surface finish and geometry. That is why all good grinders know the enemy of grinding is vibration. When a wheel is out of balance, the vibration is felt throughout the spindle assembly of the machine, and in severe cases wheel imbalance can be felt through the entire machine. This can lead to excessive wheel wear, inaccurate tools and poor surface finish on the tool. iBalance is a unique ANCA software product which proactively alerts users to potential wheel vibrations and uses the technology already built into our range of machines. It has been designed to determine whether a wheel is out
82
MACHINE TOOLS WORLD MARCH 2017
of balance then prompt and guide the operator through a series of steps to bring the wheel into balance. Measuring the amount of vibration iBalance can detect and measure the amount of vibration and the direction of imbalance of the grinding wheel. To help our customers achieve superior surface finishes on their tools, the specially designed software uses sensors in the machine servo drives to detect wheel imbalance. Variations in electrical current from the motors are monitored and this
data is used to determine and show the operator exactly where balancing weights need to be added to the spindle â&#x20AC;&#x201C; similar to a tire balancer, but on the machine. The software user interface easily identifies where to add weight to the wheel and how much is required to correct any issues. The wheel packs are balanced by adding weights to the end of the wheel nut at the locations identified by the software assistant. Several additional benefits include extending the wheel life and removing the need to purchase an expensive offline piece of balancing equipment. Finally, as there is no additional hardware to maintain, the iBalance system is as reliable as the machine itself. ANCA understands the effects of an imbalanced wheel when grinding tools and has created a solution to ensure you can get balance right. For more information, Website: www.anca.com
CASE STUDY
How 3D printing technology increased Land Rover BAR’s performance Using Renishaw’s expertise, Land Rover BAR’s design office can with the click of a mouse create a plastic version of almost anything the designers plan to create
L
ike many other cutting edge technologies – artificial intelligence, big data analytics – additive manufacturing (3D printing) has been incorporated into daily use at Land Rover BAR with the help of the team’s Technical Innovation Group (TIG). In this case, TIG partner Renishaw, a global metrology firm which manufactures metal additive manufacturing machines, as well as working with the more familiar 3D printing in plastics for its own prototyping. TIG project manager, George Sykes of PA Consulting commented, “We use 3D printing at three different levels within the team. The simplest level is as a prototyping and visualisation tool. We
84
MACHINE TOOLS WORLD MARCH 2017
manufacture a large number of custom parts and 3D printing allows us to make full size prototypes in-house before we commit to a design.” The 3D printer sits in the Land Rover BAR design office, and with little more than the click of a mouse will create a plastic version of almost
anything the designers plan to create. “The prototyping process is really useful when we are trying to develop something,” said Land Rover BAR’s Chief Technology Officer, Andy Claughton. “It allows us to get our hands on it, put it in place on the boat or link it up with other parts of the system and see potential issues and refine the design before we commit to the production of the final piece.” Reduced costs
The team has its own, fully equipped traditional machine shop, and it has an extensive composites team. Between them, these facilities can make almost anything, but if the final part can be 3D printed then
CASE STUDY www.mtwmag.com
manufacturing supplied by Renishaw,” continued Sykes. “The manufacture of custom parts in metal is the cutting edge of this technology.” The components are manufactured from paper thin layers (typically 0.05 mm) of fine metallic powder (cornflour consistency). The system works in an argon inert atmosphere – similar to that inside a light bulb; heat can be applied to melt the metal powder without it burning; or reacting with oxygen or impurities found in air. The heat is applied using a laser beam – this is directed using software controlled mirrors, and focused to accurately weld the areas required to create the part. Unmatched flexibility
that’s the option that will be used. One of the big advantages in the system is that the cost can be significantly reduced. An example is the end cap for the boat’s bowsprit. This is a complex shape, designed to reduce the aerodynamic drag. It was ideal for 3D printing in plastic because there was no load involved, and a single item was required. In years gone by this would have been built in carbon fibre to the finish and standard of a piece of custom furniture, and at great expense thanks to the time and skill of those involved. Now, once the design has been developed it can be produced in a handful of hours for a few pounds. “But the top level of our 3D printing programme is the metal additive
One of the earliest components the Land Rover BAR team created using this technology was a custom sheave case for the pulley in the daggerboard lift line. There was a high compressive load involved and it needed good resistance to wear; so metal was the ideal choice. All high strength metals have a higher density (weight per volume) than carbon fibre, so to keep weight down the final design was hollow. It would have been very difficult to make this part any other way than additive manufacturing. “The potential of additive manufacturing in terms of saving weight and improving efficiency is tremendous,” explained Andy Claughton. “For example, we took a long hard look at our hydraulics system. Before 3D printing came along all the parts in this system would have been manufactured by taking
metal away from a solid block. The shapes that you can create with this method are limited, so the design is limited and so too is the efficiency. “Hydraulic fluid doesn’t take kindly to going around hard corners for instance, and there is a loss of power when it has to do so. With traditional techniques this might be the only way you can manufacture the part, but with additive manufacturing you can build it with smooth rounded corners that significantly improves efficiency in the fluid transfers involved. “In addition to the improvements in efficiency, we can now build it much more lightly as we are only adding material specifically where it is needed. In the past, the geometry of manufacture on a lathe or other cutting tool meant that some material couldn’t be removed and we would have to carry around the excess weight. No longer.” Renishaw has manufactured several parts for the hydraulics, and while the team are reluctant to reveal too much design detail, it has said that weight in a new AM manifold design was reduced by 60%, with an increase in performance efficiency of better than 20%. David Ewing, Product Marketing Engineer at Renishaw’s Additive Manufacturing Products Division, commented, “Our involvement with Land Rover BAR is also helping to raise the bar in additive manufacturing. It’s a complex manufacturing option and there are considerations both in component design and process expertise. The best applications are ones which use the minimum amount of material to achieve the design requirements, offer a functional benefit in service and have been designed with the manufacturing method in mind. Our work on hydraulic parts for the team is a perfect example.” “Renishaw is at the top of this particular game and they have really helped us out with their facilities. This is one technology that’s here to stay and its role within our build processes will only increase in the future,” concluded Andy Claughton.
MARCH 2017
MACHINE TOOLS WORLD
85
PROJECTS www.mtwmag.com
Airport / Aviation Bhoga puram Inter national Airport Corporation Ltd (BIACL)
Airport / Aviation Automotive Components Bottling
PROJECT
Material Handling Metro Rail Oil & Gas POWER
UPDATE
Railways
Plans to set up a Greenfield airport at Orvakal. The State government has recently allowed the Revenue Department to alienate nearly 639 acre in Orvakal, Pudicherla and Kannamadakala villages in Kurnool district for this airport project.
Place: Andhra Pradesh
Pricol Ltd Coimbatore based automotive component manufacturer has recently commissioned a new factory at Phulgaon on the outskirts of Pune. The unit is spread over 6.58 acre.
Place: Maharashtra Contact: Srinivasan, Marketing Manager, 109 Race Course, Coimbatore - 641018, Tamil Nadu. T: 0422-4331100/ 4336000, F: 4336299, E: factory@pricol.co.in, W: www.pricol.com
Contact: Venkateshwar Rao, Project Manager, 1st Floor, FDC Complex, AC Guards, Hyderabad 500028, Telangana. T: 040-29803752-53/69, M: 9949096275, E: pmbiaclvsp@gmail.com, W: www.biacl.co.in,
Automotive Components Sona BLW Precision Forgings Ltd Auto component manufacturer plans investment in the next three to five years to take up capacity expansion and to develop new products for the global market.
Bottling Greentech Mega Food Park Plans to assign the design, installation & commissioning of Aloe-Vera Processing and Bottling plant at Primary Processing Centers (PPC) Churu under package 32.
Place: Rajasthan Contact: Arun Verma, Project Manager, A-3, Ganpati Enclave, Civil Lines, Ajmer Road, Jaipur-302006, Rajasthan. T: 0141-4017190, M: 9119195113, E: greentechfood@gmail.com, ak.gmfpl@gmail.com,
Place: Haryana Contact: Ratan Singh, AGM-Supply Chain, 38/6, NH-8, Delhi-Jaipur Road, Gurgaon 122002, Haryana. T: 0124-4685000, E: procure@ sonagroup.com,
Material Handling Greentech Mega Food Park Plans to assign the installation & commissioning of Material Handling Equipments for PPCs at four locations in Rajasthan under package 31.
MARCH 2017
MACHINE TOOLS WORLD
87
PROJECTS Place: Rajasthan Contact: Arun Verma, Project Manager, A-3, Ganpati Enclave, Civil Lines, Ajmer Road, Jaipur-302006, Rajasthan. T: 0141-4017190, M: 9119195113, E: greentechfood@gmail.com, Schwing Stetter India Pvt Ltd XCMG China, one of the leading construction machinery companies, has partnered with Schwing Stetter India to set up manufacturing unit for the construction and material handling machinery.
Place: Tamil Nadu Contact: R Shanmugam, Assistant Manager, F71/72 SIPCOT Industrial Estate, Irungattukottai, Sriperumbudur, Kanchipuram District 602117, Tamil Nadu. T: 044-71378100/1, E: shanmugam.r@ schwingstetterindia com,
Metro Rail Paradip Port Trust (PPT) Delhi Metro Rail Corporation Ltd (DMRC) Plans to assign the part design and construction of elevated viaduct and twelve elevated stations including PEB works, architectural finishing and plumbing works for Vijayawada metro project.
Place: Andhra Pradesh Contact: Anuj Dayal, Executive Director (Corp Comm), Metro Bhawan Fire 88
MACHINE TOOLS WORLD MARCH 2017
Brigade Lane, Barakhamba Road, New Delhi - 110001. T: 011-23417910, 12, 23418415, E: anujedcc@dmrc.org
MMRDA Plans to assign the part design and construction of elevated viaduct and 6 elevated stations viz. Bhakti Park Metro, Wadala TT, Anik Nagar Bus Depot, Suman Nagar, Siddarth Colony & Amar Mahal Junction of Wadala - Kasarvadavali Corridor of Mumbai Metro Rail Project. The completion is targeted in 26 months.
Place: Mumbai Maharashtra Contact: PRK Murthy, Director (Project), Plot Nos.C-14 & 15, Bandra Complex, Bandra(E), Mumbai-400051, Maharashtra T: 022-26594000, 26595994, E: dpmetro@mailmmrda. maharashtra.gov.in MMRDA Plans to assign the part design and construction of elevated viaduct and 7 elevated stations viz. Garodia Nagar, Pant Nagar, Laxmi Nagar, Shreyas Cinema, Godrej Company, Vikhroli Metro & Surya Nagar of Wadala - Kasarvadavali Corridor of Mumbai Metro Rail Project. The completion is targeted in 26 months. Place: Maharashtra
Contact: N D Patankar, Superintending Engineer, Plot Nos.C-14 & 15, Bandra Complex, Bandra (E), Mumbai-400051, Maharashtra. T: 022-26597608, 26594000, E: dpmetro@mailmmrda. maharashtra.gov.in
Oil & Gas Hindustan Petroleum Corporation (HPCL) The company plans to expand the refining capacity of Mumbai refinery located in Chembur district from 7.5 million tonne per annum (MTPA) up to 9.5 MTPA including Propylene Recovery Unit (PRU) and revamp of existing Captive Power Plant (CPP). Environment clearance was recently received for the project.
Place: Maharashtra Contact: Rajeev Goel, Dy. General Manager (PR and CC), 3rd foor, Petroleum House, 17, Jamshedji Tata Road, Mumbai-400020, Maharashtra. T: 022-22845158, 22863315, 22863243, E: rajeevgoel@hpcl.in IMC Ltd The company is laying 7 MMTPA, petroleum pipeline from Ennore Port to Manali Industrial Area in Chennai.
southern Indian state of Tamil Nadu. The second unit of the Kudankulam Nuclear Power Plant (KNPP) has reached 100 percent capacity (1000 MW) recently. Rosatom from Russia constructed the nuclear power plant, which is now being operated by NPCIL. The work on constructing Units III and IV would begin soon.
Place: Tamil Nadu Contact: Jaya Krishnan, Chief Construction Engineer, Keloor - Kudankulam Road, Kudankulam, Tirunelveli-627106, Tamil Nadu. T: 04637-282334, M: 9443317882, E: jay-akrishnan@kknpp.com CESC Ltd The company has emerged as the winner of a bid foated by Jodhpur Vidyut Vitran Nigam Limited (JdVVNL) and has been appointed by JdVVNL as the electricity distribution fran- chisee for the city of Bikaner in the state of Rajasthan for a term of twenty years.
Place: Tamil Nadu Contact: S M Lele,
Place: Rajasthan
General Manager, Neeladri, III Floor, 9, Cenotaph Road, Alwarpet, Chennai - 600018, Tamil Nadu. T: 044-45902222
Contact: Joyneel Mukherjee, Head Corp Cmm, CESC House, Chowringhee Square, Kolkata - 700001. T: 033-66340531, 66340497, 22256040, F: 22253495, E: Joyneel.Mukherjee@rp-ac. in, cesclimited@rp-sg.in, W: www.cesc.co.in
POWER Nuclear Power Corporation of India Ltd Indo-Russian venture Kudankulam Nuclear Power Plant is the single largest nuclear power station in India, situated in Koodankulam in the Tirunelveli district of the
Ajmer Vidyut Vitran Nigam Ltd (AVVNL) Plans implemention of system improvement, strengthening and augmentation of subtransmission & distribution
PROJECTS www.mtwmag.com
network for bringing down AT&C Losses and providing 24X7 power supply in urban areas including provisioning of solar panels on Govt. buildings and metering of feeders/ distribution transformers/consumers in the urban towns of Bhilwara District of Ajmer Discom under IPDSscheme.
Place: Rajasthan Contact: Bhupender Kumar, Superintending Engineer (TW), Room No. 216, Vidyut Bhawan, Panchsheel Nagar, Makarwali Road, Ajmer, Rajasthan. T: 0145-2644507, F: 2644507, M: 9890069259, E: setwavvnl@gmail.com, W: www.avvnl.com
Railways East Coast Railway Plans to develop Visakhapatnam railway station upto international standard on Swiss Challenge Method. The project entails redevelopment through commer- cial exploitation of the encumbrance free land and air space at the railway station. Bids are currently invited for the selection of project proponent.
Place: Andhra Pradesh Contact: Umesh Singh, General Manager, Rail Sadan, Chandrasekharpur, Bhubneshwar-751017, Odisha. T: 0674-2300773, E: sdgm@ecor.railnet.gov.in Ircon International Ltd Plans to assign the design, supply, installation, testing &
commissioning of electronic interlocking based signaling system at three stations between Kharsia-Gharghoda for Cerl Project Chhattisgarh. The completion period is 10 months.
Place: Chhattisgarh Contact: Arun Kumar, General Manager (S&T), C-4, District Centre, Saket, New Delhi-110017, Delhi. T: 011- 29565640, F: 26522000, M: 9560595048 East Coast Railway (ECoR) The Centre has also sanctioned three new surveys for construction of a new line between BhawanipatnaKesinga via Utkela (35 km), Sambalpur-Jhara- pada (3rd line) and Jharsuguda-Sambalpur (3rd and 4th line)
Place: Odisha Contact: Umesh Singh, General Manager, Rail Sadan, Chandrasekharpur, Bhubneshwar-751017, Odisha. T: 0674-2300773, E: sdgm@ecor.railnet.gov.inâ&#x20AC;? Indian Railways The foundation stone was recently laid for the gauge conversion project of DhasaJetalsar section of Bhavnagar division of Western Railways.
Place: Gujarat Contact: Anil Saxena, Additional Director, General (PR), Room No. 310, Rail Bhavan, Raisina Road, New Delhi-110001, Delhi. T: 011-23381332, 23303665, M: 9810046241, 9868679525 MARCH 2017
MACHINE TOOLS WORLD
89
PRODUCTS SHOWCASE
PRODUCT SHOWCASE KING CUT PRO – The Large Gantry Type CNC Cutting Machine Ador’s KING CUT PRO is a CNC portal cutting machine which is very precise and reliable. The machine has one head for plasma sheet metal cutting and one head for flame cutting of sheet metal with a dual side longitudinal drive with AC motors. The standard equipment comes with a basic machine package with CNC controller, one torch, central gas diffusion with manometers and a remote flame ignition.
The following equipment are supplied as required by the customer: Additional Equipment: • Plasma power source KJELBERG with machine torch • Programming software MOST 2D • Support table for sheet metal with segment extraction system • Extraction-filter system • Laser position indicator for determining the cutting point Optional : • Extension of the longitudinal rail • Additional cutting head
The CNC Controller – Phantom:
For Product Enquiry Contact Ador Welding Limited Akurdi Chowk, Chinchwad, Pune 411 019 Tel.: 020- 4070 6000 Email: cmo@adorians.com Web: www.adorwelding.com
90
MACHINE TOOLS WORLD MARCH 2017
The Phantom brings you the performance of a cutting edge CNC that is built on more than 40 years of experience in the motion control and cutting industries. This controller is designed for multiple axis cutting machines and features the latest advances in CNC technology on a proven platform engineered to increase productivity, reduce costs and enhance profitability. The software provides flexibility, ease of operation and technologies that put Ador’s experience and expertise in your operator’s hands, resulting in extremely good cut quality and high productivity. The Phantom can operate any cutting machine and interface with virtually all plasma systems. Following are its standard features: Bright touch screen interface, Touch screen interactive display, Expandable shape library, True multi-tasking environment, Fast Dxt file conversion, Go to(Job interrupt), Quick plate alignment, and Monitor & track consumables. Advanced Plasma Process Control (Plasma Process Wizard) is available as optional extra. Ador offers cost-saving height control unit for simple plasma cutting applications. The KHC1 system provides all the essential functions that are needed for good cuts and optimum utilization of work-piece.
PRODUCTS SHOWCASE www.mtwmag.com
Avantin Metal Cutting Fluids
For Product Enquiry Contact Carl Bechem Lubricants India Pvt. Ltd. Plot No.28-D, Bidadi Industial Area Bidadi-Harohalli Road, Bangalore 562 109 Phone: 080-6690 0800 Web: www.bechemindia.com
Precision at high cutting speeds, excellent surface finish at increased feed rates, longer tool life with minimal consumption of coolants, cleaner and hazard-free working environment are some of the desired parameters that directly affect cost per component and productivity levels in metal working processes. Collaborating with machine tool and tool manufacturers and end users, Bechem has developed metal working fluids for the entire spectrum of metal working processes. The Bechem Avantin range is the most advanced breed of cutting fluids that has set new benchmarks in the industry by achieving maximum performance with minimal consumption. Fortified with a series of additives and biocides, the Bechem Avantin range is equipped to contend harsh external impurities such as hydraulic oil, swarf and grinding dust while delivering unmatched performance. Avantin comes with different characteristics with varying oil content, pH values, corrosion protection properties and refractrometer factors. Each model is designed for specific applications. For instance, Avantin 320 has excellent dirt carrying capacity and is suitable for all types of grinding applications and cast iron machining. Avantin 331 contains lubricating improvers and possesses excellent flushing properties. It is ideal for all types of grinding applications and cast iron and steel machining. Avantin 342-I is recommended for grinding and cutting operations of cast iron, SG iron, steel alloys, automotive grade alloys and other non-ferrous alloys. This oil is free from chlorinated paraffin. Avantin 352-S is a universal product for machining and grinding applications. It is suitable for steel, SS, aluminium and cast iron. Avantin 359 is used for severe applications. It improves tool life and surface finish and is best suited for stainless steel machining. Avantin 361 possesses good lubricity and is suitable for aluminium, steel and SS machining. It is ideal for high coolant pressure machines due to lower foaming tendency. Avantin 255 AL is an Amine and Boron free coolant. It is best suited for sensitive aluminium and non-ferrous metals as well as stainless steel. On the other hand, Avantin 405 is a fully synthetic coolant with excellent EP properties used for machining of alloy steel and cast iron. Its synthetic character ensures high stability and long lifetime of the emulsion.
LMW JV 80 High Speed Vertical Machining Centre
For Product Enquiry Contact Lakshmi Machine Works Ltd. Machine Tool Division, Arasur, Coimbatore 641407 Phone: 0422-3021393 Webstie: www.lakshmimach.com
The LMW JV 80 high speed Vertical Machining Centres are ideal for die & mould machining, particularly for roughing and finishing operations on medium and large parts. Automobiles and aerospace are two crucial markets for high-end machine tools and this model suits their exacting requirements. The machining centre comes with a BBT40 spindle taper and direct driven 12,000 rpm spindle speed. The machine has a 1000 x 560 mm working table with X, Y and Z axis travel of 800 mm, 540 mm and 600 mm respectively. Excellent repeatability, high reliability and performance are the key features of this machine. The JV series employs high precision linear motion guide ways and large diameter, pre-tensioned ball screws for the axis traverses.
MARCH 2017
MACHINE TOOLS WORLD
91
PRODUCTS SHOWCASE
Linear Encoders for machine tools
LC 485 up to 2040 mm
LC 185 up to 4240 mm
LB 201 up to 28 040 mm
For Product Enquiry Contact HEIDENHAIN Optics & Electronics India Private Limited Citilights Corporate Centre No. 1, Vivekanandan Street, Off Mayor Ramanathan Road, Chetpet, Chennai – 600 031 Tel.: +91 44 3023-4000 Email: info@heidenhain.in Webstie: www.heidenhain.in
Linear encoders for position feedback are indispensable for high positioning accuracy of machine tools. They directly and immedi-ately measure the actual position of the feed axis. Mechanical transfer elements therefore have no infl uence on position measurement—both kinematic errors and thermal errors or infl uences of forces are measured by the linear encoder and taken into account in the position control loop. This makes it possible to eliminate a num-ber of potential error sources: • Positioning error due to thermal behavior of the recirculating ball screw • Reversal error • Errors due to deformation of the drive mechanics by machining forces • Kinematic errors through pitch error in the recirculating ball screw Therefore, linear encoders are indispens-able for machine tools on which high posi-tioning accuracy and a high machining rate are essential. Linear encoders from HEIDENHAIN for numerically controlled machine tools can be used nearly everywhere. They are ideal for machines and other equipment whose feed axes are in a servo loop, such as milling machines, machining centers, boring machines, lathes and grinding machines. The benefi cial dynamic behavior of the linear encoders, their high permissible tra-versing speed, and their acceleration in the direction of measurement predestine them for use on highly-dynamic conventional axes as well as on direct drives.
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
92
MACHINE TOOLS WORLD MARCH 2017
• • • • • • •
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.
PRODUCTS SHOWCASE www.mtwmag.com
HSS Cutting Tool Indian Tool Manufacturers (ITM), is pioneer in HSS Cutting Manufacturers in India, it offers wide range of HSS Drills, Taps, Reamers, End Mills, Bore Type Cutters etc,. ITM is one of the largest HSS Cutting Tool manufacturers in India.
HSS Drill: ITM produces best quality of HSS Drills in its range, on latest CNC Machines like Karl Haux and Hertlein machines. The flute profile and geometries are unique and originated by the ITM in India.ITM have stringent manufacturing control methods to produce high quality drills, also have in-house facility of Heat treatment to get accurate handedness. In addition to that, ITM drills are made out of imported steels, to meet the standards of international market. We are serving to Indian and International customers, since 1937. due to highest quality of tools, on time delivery, availability of stocks etc., Only ITM HSS Drills can operate L/D ratio up to 100 times, where as in Carbide drills up to 3,5,7,10, times. We have drill series of Stub, Jobber, and Long Series, Extra Long series in both Parallel Shank and Taper Shank. ITM also can supply the Tools with TIN, TiCN, Ti(Al)N for better performance of Tools. Drills can be supplied in HSS M2, HSS M35, HSS M42 premium grades of HSS steels.
HSS Taps:
For Product Enquiry Contact Birla Precision Technologies 206 Dalamal House, 1st Floor, Jamnalal Bajaj Marg, Nariman Point, Mumbai - 400 021 Web: www.birlaprecision.org Email: itmth@indiantool.com.
Even in modern machining era, every CNC machine opts for only HSS Taps. Tapping is the final operation of every component; hence, they prefer to use HSS Taps to avoid any breakage in component due to tapping. if tap breaks / damages, component get rejected. Only HSS materials have the property of can with stand on heavy machine vibrations, interrupted cuts, inclination faces, and wavy faces, where as carbide Taps cannot work on these working conditions. ITM produces high quality of HSS Taps made out of from CNC machines like GT 77, Normac FT-80 flute grinders etc.,. ITM geometries are unique with difference cutting angles with different flute forms for different machining applications. And also our taps are made out of imported steels. ITM is one of the prominent supplies in Indian market due to its quality and on time delivery. ITM is offering H&S M/c Taps, LS M/c Taps, Spiral and SPPT Taps in both HSS and HSS-Co grades. Only HSS Tools can operate at moderate speeds either at low or high speeds, these formulae cannot applicable for Carbide Tools. Carbide Tools will work at only recommended speeds and feeds. Hence HSS Tools are only solutions for conventional machines as well as CNC machines.
New Adjustable Heads from Alberti, Italy
For Product Enquiry Contact Nickunj Eximp Entp P. Ltd. Sri Joravar Bhavan, Maharshi Karve Road, Marine Lines, Mumbai - 400020 INDIA Tel: +91 22 43220300, Fax: +91 2222060415 Email: media@nickunjgroup.com Web: www.nickunj.com
Latest born, already big and powerful: the new adjustable heads of Linea P are the latest news from Alberti. With completely new design and improved capacity of their sisters, Head TCU-8 andTCU-10 can be adjusted â&#x20AC;&#x201C; 120 to +120 degree with possibility of digital reading of the angle and internal coolant capability. Despite the big size, these heads can reach high RPM while keeping temperature and noise under control. This line of heads features a second of the standard units high-performance version with double the torque which enriches the HP family.
MARCH 2017
MACHINE TOOLS WORLD
93
PRODUCTS SHOWCASE
Roundtest RA- 2200 A sophisticated, highly accurate form-measuring system capable of assessing the important attributes of roundform workpieces such as roundness, straightness, flatness, concentricity, coaxiality, perpendicularity, runout, inside/outside diameter and surface finish. Mitutoyo RA-2200 provides high accuracy, high speed and high performance roundness measurement. With extremely high rotational accuracy, both in the radial and axial directions, the turntable allows high accuracy flatness testing to be performed in addition to roundness and cylindricity measurements. Mitutoyo uses high accuracy, highly repeatable linear scales in the X/Z drive unit to guarantee high precision positioning vital for repetitive measurement. Centering and levelling of the workpiece on the air-bearing-equipped turntable is guided by the DAT system to help in setting up. The fully-automatic or DAT (Digital Adjustment Table) function aids manual workpiece centering and leveling, turning a challenging task into something simple enough for even an untrained user and significantly reducing overall measurement time. Independent or simultaneous multiaxis CNC delivers maximum productivity in handling large or small batch runs to fit in with production schedules. Mitutoyo RA 2200 model is available in AS/DS/AH/DH variants including the CNC option, to suit any application requirements. This machine comes with the ROUNDPAK, powerful data analysis software with enhanced functionality and easy operation through the use of the mouse and icon selection.
Main Specifications: 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
• Rotational accuracy radial: (0.02+3.5H/10000) µm; H: probing height (mm) • Rotational accuracy axial: (0.02+3.5X/10000) µm; X: distance from rotational centre (mm) • Z Axis- Straightness accuracy: 0.10µm/100mm (λc2.5, Common), 0.15µm/200mm (λ c2.5, Z: 300mm), 0.25µm/300mm (λ c2.5, Z:500mm) • X- Axis- Straightness accuracy: 0.7µm/150mm(λ c2.5)
EDM DRILL : Make small hole drilling possible at economic cost Ratnaparkhi comes up with yet another fully Indian made economical solution for Small hole drilling, with the new EZEEDRILL model you can drill from 0.2mm to 3.00mm diameter in hard materials. EZEEDRILL works on the EDM technology and makes possible to drill holes up to 300mm height. Working on regular water and low power consumption EZEEDRILL is the best Indian made EDEM DRILL machine in market. Compact footprint, SS table, ball screws for all axis are the added advantages with features like depth control,PCD and ARRAY programming making it aces on any other EDM Drill machine.
Features: For Product Enquiry Contact Ratnaparkhi Electronics Ind. Pvt. Ltd. E-52, M.I.D.C,Satpur, Nasik. Pin.:-422007. Phone: 0253-2351125, E-mail: vgp@ratnaparkhiedm.com; reiplnsk1@gmail.com
94
MACHINE TOOLS WORLD MARCH 2017
• • • • •
Small hole drilling in any hard metal Both brass & copper electrode tubes can be used Large drilling range Tap water is used as dielectric fluid Compact footprint
ADVERTISERS INDEX COMPANY NAME
PG. NO.
COMPANY NAME
PG. NO.
G
A ACCUSHARP CUTTING TOOLS PVT. LTD.
33
ACE MANUFACTURING SYSTEMS LTD.
GLOBE-TECH ENGINEERING EXPO - 2017
76
BACK PAGE
GROB MACHINE TOOLS INDIA PVT. LTD.
21
ACTCAD ENGINEERING SOLUTIONS PVT. LTD.
67
H
ADOR WELDING LIMITED
59
AMTEX - 2017
77
ANCA MACHINE TOOLS PRIVATE LTD
7
APEX PRECISION MECHATRONIX PVT. LTD.
29
BIRLA PRECISION TECHNOLOGIES LIMITED
25
23
D DOWEL ENGINEERING WORKS
43
HYUNDAI WIA INDIA PVT. LTD.
9
IMEX - 2017
86
IMTOS - 2017
79
J
KRISHNA PARK GROUP OF HOTELS & RESORTS
15
81, 83
E
NICKUNJ EXIMP ENTP P LTD
PANSWORLD TELEVISION (INDIA) PVT. LTD.
73
PILZ INDIA PVT. LTD.
57
R RATNAPARKHI ELECTRONICS IND. PVT. LTD.
35
RAVISON'S CORPORATION
51
RENISHAW INDIA
41
SANJAY TOOLS & ADHESIVES
69, 89
SPARKONIX (INDIA) PVT LTD
27
STARRAG GROUP
31
TECHNO INDUSTRIES
69
53
TRUCUT PRECISION TOOLS PVT. LTD.
FALSE COVER
11
U
LAPP INDIA PVT. LTD.
62 - 63
LASER TECHNOLOGIES
ELECTROTHERM (INDIA) LTD.
13
LOSMA INDIA PVT. LTD.
EMAG INDIA PVT. LTD.
17
M
ENGIMACH - 2017
78
74
EPPINGER TOOLING ASIA PVT. LTD.
61
MACHINE TOOL TECHNOLOGY INDONESIA - 2017 MARPOSS INDIA PVT. LTD.
47
Y
MITUTOYO SOUTH ASIA PVT. LTD.
INSIDE BACK COVER
YG CUTTING TOOLS CORPORATION PVT. LTD.
F FLIR SYSTEMS INDIA PVT. LTD.
55
37
T
L 75
INSIDE FRONT COVER
S
K
C CNC SOFTWARE, INC.
HEIDENHAIN OPTICS & ELECTRONICS INDIA PRAIVATE LIMITED
JYOTI CNC AUTOMATION LTD.
MMC HARDMETAL INDIA PVT. LTD.
P
45
BETTINELLI AUTOMATION COMPONENTS PVT. LTD.
PG. NO.
N
I
B
COMPANY NAME
UCAM PRIVATE LIMITED
49
UNITED GRINDING GMBH
19
UNITY CONTROLS PVT. LTD.
65
MARCH 2017
FRONT GATEFOLD
MACHINE TOOLS WORLD
95
Mr.
L.J.
Inside Story
Naidu
Managing Director, GROB Machine Tools India Pvt. Ltd.
My Life’s Goals Aim & Ambition: Wants to be a self driven, highly motivated and successful professional to reach highest levels in my career, setting examples to others. Be always a trend setter and team player defining the direction for others to follow, strongly believing in “WE” rather than “I”. To treat all my employees like my own family members. Not to make others feel bad or hurt with my acts “if I cannot carry good wishes or blessings of people with me, at least not their curse”. Vision: To position our company at no.1 in the country by developing a highly enthusiastic, motivated and satisfied workforce. Everybody is equal and everyone is as important as you are, treat them like you want to get treated. Social Goal: Always have kind heart and feel responsible to do maximum possible to the needy. Every citizen deserves to have better life, we are socially responsible to ensure that they get equal opportunity, share and leads a peaceful quality life. Business Goal: To give 100% dedication and to deliver hard & intelligent work for the growth of GROB Group and its business. To deliver high quality products and service to customers, to become their the most preferred supplier. Increasing market share and achieving multi fold growth in business to cross € 100 million turnover with in next 5 years with 300 highly skilled work force.
My Leisure Choices Favourite Tourist Spot: My small beautiful village to spend time with my parents, brothers family and sisters children Music I Like: Classical and Carnatic, also I enjoy film music from Ilayaraja and Rahman. Sports I Love : Cricket & Kabaddi which I use to play in my childhood.
Ask my Taste Buds Favorite food: Home food cooked by my mother and my wife, also the spicy chicken fry made by myself. Favourite Drink: Sugar cane juice with ginger, lemon & green chilly
In Awe of I Admire: My mother, Father, Dr.Burkhart Grob, Shri P.Ravindra Reddy & all the respected ones who helped me in life to be at what I am today.
96
MACHINE TOOLS WORLD MARCH 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
98