Machine tools world July 2017 by Divya Media Publications Pvt. Ltd.

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Volume 03 No. 02 | July 2017 | ` 150

Pages 118 | RNI No. MAHENG/2015/64267

CEO CORNER GST: Is it a game changer? The Goods and Services Tax (GST) officially came into effect from July 1. India is now “One Tax One Nation”. The new paradigm in India’s cooperative federalism is expected to rein in improved tax compliance and facilitate the ease of doing business and pave way for increased investments. Manufacturing sector has been accorded prime importance by the Government of India. Make in India programme is a shining example of this. The manufacturing industry believes that GST could enable India figuring on the world map as a hub for manufacturing. From an end-customer’s outlook the indirect tax cost applicable on machine tools was on the higher side, attracting excise duty and VAT depending on the state. Additionally there was a cascading of taxes on account of levy of CST, input tax credit retention under VAT, levy of entry tax, octroi, local body tax, etc. up to the time the product reached the customer. This has been eliminated with the standard rate of GST at 18% for machine tools. It is expected that there would be a reduction in the overall indirect tax cost. Such reduction in indirect tax costs can lead to reductions in production cost and an increase in baseline profits. Alternatively, such reduction in costs may also provide headroom for price reductions, benefiting end-users. There is a need to correct some anomalies in GST rates, whereby some industrial intermediates (as for example, CNC system, ball screws, etc., which are critical inputs to building CNC machine tools) attract GST at 28% whereas the end products (CNC machine tools) are at 18%. The ideal situation would be to tax raw materials, intermediates and finished products at successively increasing GST rates (say 5%, 12% and 18%). It may take some time for SMEs to move from the earlier tax compliance to GST and once it is done it would be a game changer for the Indian machine tool industry.

CEO

MACHINE TOOLS WORLD JULY 2017

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

www.mtwmag.com

Publisher & Printer Shirish Dongre

CEO

Contents

Vol 3 Issue 02 | JULY 2017

COVER STORY

Shekhar D.

Marposs: The metrology expertise with technological perfection

Editor Shilpa Dongre

Assistant Editor Shweta Nanda

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

WEST (Maharashtra & Gujarat) Pune Shilpa K. - 09833373371 Gujarat Dinesh Shah - 09327344559 Rajkot (Saurashtra) Swapnil Bhatia: 09227909005

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

MACHINE TOOLS WORLD JULY 2017

Mr. S.M. Sood Managing Director, Marposs India Pvt Ltd

34 BUSINESS NEWS

IN FOCUS

COMPANY UPDATE

Shavo’s high performance regenerative blowers

Mastercam 2018 focused on efficiency & speed

Autodesk showcases nextgeneration design technology

Sutton Tools achieving a 10% improvement on its surface finish using ANCA’s linear technology

‘Make in India needs a design component to become a guaranteed success’

HIGH-TECH MANUFACTURING

We give strategic advantages to our customers from diverse industries: Rupesh Paparaju, Bettinelli Automation, India

DeburringEXPO to showcase innovative solutions

Dormer Pramet to showcase expertise at EMO 2017

Enhancing the additive manufacturing process chain

WIL & High-tech Manufacturing

Young Buhmwoo India: The Rising Star

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

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IMTEX 2017

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

Hall 4, Stall No. A134

Contents INDUSTRY FOCUS

TECH TRENDS

Hermle machines maintain desired accuracy

Vol 3 Issue 02 | JULY 2017

PECM radically shortens 68 EMAG toolmaking processes

Premiere Tool Presetting - A New Design with True Added Value

Higher Precision for Machining Centers in Automated Large-Batch Production

Rollon: Reducing Linear Bearing Wear

7 Things that could make your Fiber Laser Cutting Machine much dynamic

CASE STUDY GROUP innovates cutting tools using 96 KOMET metal 3D printing technology

Tool successfully delivers on an 94 UPaggressive growth strategy

PRODUCTS SHOWCASE

110

KING CUT PRO The Large Gantry Type CNC Cutting Machine

MACHINE TOOLS WORLD JULY 2017

111

Mitutoyo Formtracer SV-C3200

114

New Chip Breakers Added to MVX Indexable Insert Drill Series

Double Disk Grinding Machine

113

112

High efficient, more productive Rotary Table Model URX series

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Editorial Board

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

Mr. Arjun Prakash Managing Director Effica Automation Ltd.

Mr. GK Pillai Managing Director & CEO

Mr. Rupesh Paparaju Director,

Walchandnagar Industries Ltd.

Bettinelli Automation Components Pvt. Ltd.

Ms.Samina Khalid Marketing Manager

Mr. MIHIR Baxi President – Global Sales

Renishaw Metrology Systems Ltd.

Jyoti CNC Automation LTD

Editorial Index A Ador Welding 88, 110 Alex Machine Tools 114 ANCA 22, 94 Autodesk 20 B Bettinelli Automation 54 Birla Precision 113 Bosch Power Tools 30 D DeburringEXPO 24 Dormer Pramet 30, 34 E Elesa and Ganter 114 EMAG 68 ESPRIT F FARO 22 H HAIMER 36 HEIDENHAIN INDIA 78 Hypertherm 34 I IMTMA 44 K Kennametal 24

L Lakshmi Machine Works 111 M Marposs India 40, 116 Mastercam 18, 74 Mitutoyo South Asia 111 MMC Hardmetal 112 P Phillips Machine Tools 48 R Renishaw 38, 96 ROLLON INDIA 70 S Sahajanand Laser Technology 50 Shavo Technologies 18 Shell Lubricants 20 U UCAM 76, 113 Unity Controls 112 W Walchandnagar Industries 60 Y Young Buhmwoo India 58 Z ZOLLER India 66

For editorial contribution contact E-mail: shweta@divyamediaonline.com

Mr. Dinesh Khambhayta President MTMA-RAJKOT

Mr. Ayaz Qazi Director

Precihole Machine Tools Pvt. Ltd.

Mr. Suhas Belapurkar Director - Sales & Marketing ( Industrial Products) Sanjay Tools & Adhesives

Mr. P.K. Balasubbramaniian President VBS Corporate Support

Mr. B.P. Poddar Vice President - Sales & Marketing FEMCO Fatty Tuna India Pvt. Ltd.

MACHINE TOOLS WORLD JULY 2017

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

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

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

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

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

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

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

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

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

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BUSINESS NEWS

Shavo’s high performance regenerative blowers Pune-based Shavo Technologies Pvt. Ltd has introduced a new range of high performance Regenerative Blowers in an effort to increase its offerings to customers in India. Goorui is the main brand of FLS Hongkong and has its design origination from Hannover University in Germany since 1933. With the core research and design technologies in global vacuum pump industries, Goorui has got nearly 72 product technology patents and is being used globally in key applications such as Air Aeration , Blower–off & drying, Central Vacuum Systems, Pneumatic conveying, Vacuum pick up & hold down. Vapor & Fumes Extraction, and Biogas Conveying

Goorui Regenerative Blower Regenerative blowers (also called side channel blowers or ring compressors, terms that refer to their physical construction) are the ideal solution for moving

large volumes of air at lower pressures or vacuums. Unlike positive displacement compressors and vacuum pumps, regenerative blowers “regenerate” air molecules through a non-positive displacement method to create a vacuum or pressure. When system parameters fall within the range of a regenerative blower, it can be the most cost-effective method for producing pressure or vacuum.

Technology Goorui side channel blower adopts Benz wheel like ADC 12 materials and high precision high temperature bearings, casting pig iron across the old technology, has a “high ,fine, light” and other characteristics, high technology content, energy saving, low carbon, high quality first-class products, Quality derived from inside SKF, NSK in use. Every Goorui side channel blower is strictly through Germany, Japan high precision testing equipment

(50/60Hz) • Pressure Range: 80-1040mbar • Vacuum range: 70-730mbar.

About Shavo Techologies

testing, high pressure, large flow rate, light weight, no oil pollution, which can maximally ensure the product quality.

Features and advantages: • • • •

Challenge High Temperature Oil free with low noise No routine maintenance SKF/ORS/NSK bearing, temperature range - 40-2000C • Approved by CCC,CE, RoHS,ISO9001-2008 Certification • Insulation Class F, Protection Class IP54 • Air flow range: 45-2330m3/h

Formerly a part of Shavo Norgren India Pvt. Ltd, one of India’s largest pneumatic equipment manufacturers, Shavo Technologies is now on a pan India basis representing some of the choicest engineering manufacturers in the world. In the field of Air Moving Technology , for the past 30 years the company has been representing GAST USA ( compressors, vacuum pumps, air motors, etc ) catering to a variety of market segments like Medical, Analytical, Packaging, Automobile, Printing, Laboratory, Material Handling & Industrial Machinery, etc.

Web: www. shavogroup.com

Mastercam 2018 focused on efficiency & speed CNC Software announces the release of Mastercam 2018. Mastercam 2018 brings a new suite of programming tools focused on delivering speed, automation, and efficiency for all machining jobs. Mastercam 2018 offers new 2D/3D Milling features, Design improvements, powerful turning and Mill-Turn enhancements, and so much more. Stock awareness has been added to select 2D toolpaths and allows tool motion on the top, bottom, or both values of the stock. This provides a safer and more optimized tool motion. You can also optimize finish passes based on your rough stock, giving you more efficient and safer tool motion. The workflow for all 3D High Speed toolpaths has been streamlined and gives you fine control over exactly where to cut. High speed Hybrid

MACHINE TOOLS WORLD JULY 2017

toolpaths now offer smoothing controls and deliver a finer finish, requiring less handwork. Expanded Turning and Mill-TurnIf you work with stringy materials such as aluminum or plastic, Mastercam’s new Chip Break control prevents problems by allowing you to set length and time conditions, retract, and dwell options. Mill-Turn machine definitions now contain tailstock and quill components, tailored

to your machine. Exclusive to Mastercam, a new set of turning strategies automate toolpath generation and support for Sandvik Coromant CoroTurn® Prime inserts and PrimeTurning™ method. PrimeTurning provides superior metal removal rate, productivity gains of over 50%, and increased tool life in a variety of materials. Shops can model their own designs, but they also get in models that need to be corrected or prepped for machining. Mastercam’s CAD functions are designed for the machinist. Angle Sweep improves the creation of more complex wireframe functions and when creating or editing primitives, there are now on-screen sweep and rotate controls which can snap to the AutoCursor positions of existing entities.

BUSINESS NEWS

Autodesk showcases next-generation design technology Autodesk, the global leader in 3D Design technology, for the fourth consecutive year, successfully organized the Moldflow User Conference at Novotel, Pune on 2nd June. The event saw participation from around 200+ professionals in plastic industry and marquee Autodesk customers like Tata Technologies, Robert Bosch Engineering and Business Solutions, L&T Technology Services and Rheomold Engineering Services among others. The event showcased the success stories of these customers along with new features and enhancements in Moldflow 2018 and the related R&D.

In his keynote address, Pradeep Nair, Managing Director, Autodesk, India and SAARC discussed about the convergence of how things are designed and made across all industries. He further talked about Autodesk’s role in fueling this convergence and ushering “The

Future of Making Things” in India. A key highlight at the event this year was an interactive session on Generative Design, one of the latest innovation from Autodesk for Indian customers, and how it can be done in Autodesk Simulation. This session was presented by Dr Nanda Santharam, Sr. Software Architect, Autodesk. Generative Design lets users create highly optimized designs that meet predetermined goals and constraints. It is capable of designing thousands of design options basis the available specifications for any required product. Autodesk Moldflow Conference

is an annual event organized by Autodesk in different countries across the world. It is a platform that provides an opportunity to the professionals in the plastic industry to earn the latest techniques and trends in plastics design. The attendees get to learn about how to use the latest enhancements in Moldflow, discover new and different approaches for injection molding, and receive guidance from industry experts. Further, they get to see how their peers in the plastics industry are solving today’s challenges and the best way to approach these problems using real-world examples.

Shell Lubricants unveils its new global positioning Post a successful launch across major business hubs in the country like Mumbai, Pune, Chennai and Bengaluru; Shell Lubricants, the global market leader in finished lubricants, with CII recently unveiled “Empower” –an introduction to its new global direction for its B2B sectors, as a partner to its allied industries in Delhi. The event served as a platform to discuss the concept of total cost of ownership and how the different stakeholders from the industry can come together and help reduce TCO and enhance profitability. Highlighting the message of “Together anything is possible”, Shell introduced the concept of total cost of ownership with an aim to inspire customers by addressing the

MACHINE TOOLS WORLD JULY 2017

efficiency challenges and help them towards achieving their day-to-day ambitions. Post the events in other cities across India, the launch in Delhi served as the grand finale of the launch series; focusing on the Auto Components and General Manufacturing Sector for the first

day and construction, mining and the fleet industries on the second day. The event witnessed participation from eminent industry leaders including Toshiba, Windsor Machines Ltd. ,Varun beverages, Makino, Dilip Buildcon Ltd., Chetak Logistics, ABC transport Pvt. Ltd. and associations like Delhi Goods

Transport Association. As part of its renewed focus on creating greater customer interaction, the event highlighted the importance of lubricants to counter the challenges faced by relevant sectors and assist them to achieve significant reduction in operational cost. The impact of Shell’s products and services in delivering Total Cost of Ownership in Manufacturing and Construction can be assessed by the examples of Plastics manufacturer Amaray, specialising in injectionmoulded covering inlays for DVD trays, reducing their maintenance costs, extend oil drain intervals and save USD $10,708 by switching the hydraulic fluid to Shell Tellus S4 ME 46.

BUSINESS NEWS

Sutton Tools achieving a 10% improvement on its surface finish using ANCA’s linear technology Australia’s largest manufacturer of rotary shank cutting tools, Sutton Tools, has gained market share in the highly competitive aerospace industry by producing superior tools using the linear motor technology on ANCA’s MX7. To gain traction in the aerospace market Sutton’s needed to push the boundaries of what could be expected from a tool machining materials in the aviation industry. Jeff Boyd, Export Manager at Sutton Tools said: “By really focusing on how we could improve the surface finish, and with the added capabilities of the linear motor, we have created a product that is delivering significant productivity gains for our customers. The team are now consistently achieving a longer tool life and faster cycle times in some of the higher strength materials such as titanium, which is a great result.” “With our new MX Linear machine, we have seen dramatic improvements in the surface finish of the cutting tools. This change

has been achieved by moving away from the traditional ball-screw movement on machines to a linear motor. We conducted a direct comparison as we have ANCA ball-screw grinders and have also experimented with different grinding wheel grades and grinding parameters to ensure we are achieving the best possible finish.” “A better surface finish has also meant we get better adhesion of the coating and stable performance to the cutting tool which is important for our customers. Tool stability is important because it means our customers can confidently forecast their production schedules and reduce machine down time. It makes

their day easier!” “A company in France had been buying a competitor’s brand but we saw an opportunity to make a better product and win the business. After studying surface roughness of a tool we felt that the linear motor could achieve a higher accuracy of

surface finish. We conducted some tests and found that was exactly what we could achieve and now we have a tool that performs better than our compeditors. “To validate our grinding methods, we use an optical 3d scanning technique to measure the area surface roughness on the rake face and the cutting rake on the tools. This means we can manage our quality levels to a level of accuracy which is world class in the industry;” concluded Jeff. ANCA is well known in the industry for its rigid grinding machines and has combined this with its sister company, ANCA Motion’s, LinX linear motor technology. Tools ground using the linear motor have a consistently high-quality cutting edge and surface finish. The LinX cylindrical linear motors ensure there is no loss of preload or rigidity when grinding tools and reversal errors are eliminated and higher contouring accuracy can be maintained due to a control algorithm we use which is unique to ANCA.

FARO releases FARO Zone 3D for public safety professionals FARO has announced the availability of the FARO Zone 3D software. This revolutionary platform, through its advanced smart tools, is the first of its kind to enable investigators to move fluidly between 2D and 3D environments and enhance the quality of incident reconstruction analysis or presentations for public safety professionals. The FARO Zone 3D dramatically elevates the visual impact of presentations, including courtroom exhibits, by enabling accurate 2D

MACHINE TOOLS WORLD JULY 2017

and 3D scene diagrams, 3D scene walk-throughs, and full scene reconstruction animations. FARO

Zone 3D also enhances the ability of public safety professionals to plan for, and respond more

effectively to, emergencies by creating accurate representations of real-world locations within local communities. “FARO is committed to delivering innovation that enables investigators to do their job faster, easier, and more effectively” states Jeff Ruiz, Vice President Global Public Safety - Forensics business unit. “FARO Zone 3D is a major industry milestone that harnesses the power of 3D in a solution specifically developed for crime, crash, and fire investigators.”

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BUSINESS NEWS

Kennametal board names Christopher Rossi Chief Executive Officer; De Feo Appointed Executive Chairman Kennametal Inc. (NYSE: KMT) announced that its board of directors has appointed Christopher (Chris) Rossi as president and chief executive officer and has named him a director. Chris succeeds Ron De Feo whom the board has appointed executive chairman of the board. Both appointments are effective August 1, 2017. “With more than 30 years of leadership experience, Chris has delivered sustainable results across a breadth of functions including operations, marketing and sales, R&D, product management, supply chain and technology innovation,” said Lawrence W. Stranghoener, Kennametal chairman of the board of directors. “We expect Chris will bring continuity to the transformation

presently underway at the company while evolving a strategy and vision for the future that will continue to deliver results for our customers, team members and shareholders.” “We want to thank Ron De Feo for the dramatic progress he has made to reposition Kennametal over the past 18 months,” Stranghoener continued. “Ron will work closely with Chris to ensure a smooth transition for all our stakeholders

and we appreciate his continuing leadership.” Rossi previously served as the chief executive officer of DresserRand at Siemens from September 2015 through May 2017. Prior to that, Rossi held numerous leadership positions at DresserRand Group Inc., its affiliates and predecessor companies since he joined in 1987, including executive vice president of global operations, vice president of technology and business development and executive vice president of global aftermarket sales. Rossi holds a bachelor of science in mechanical engineering from Virginia Tech and an MBA in corporate finance and operations management from the University of Rochester’s Simon School of Business.

“I am excited to join a company with such well-respected brands and a legacy of continuous innovation and customer commitment,” commented Rossi. “I look forward to working together with the Kennametal team across the globe to continue building a strong future for the company, our customers, its shareholders and our communities.” “We look forward to the perspective Chris’ experience will bring to lead Kennametal into the next chapter of its transformation,” commented Ron De Feo, current Kennametal president and CEO. “It has been my pleasure to lead the Kennametal team over the past 18 months and together we have made great strides in positioning the company for a successful future.”

DeburringEXPO to showcase innovative solutions More and more attention is being focused on deburring, rounding and surface finishing due to highly demanding specifications with regard to tolerances and surface quality for the production of precision components. With exhibitor bookings already at the 125 mark as of 15 June 2017, DeburringEXPO will present the world’s most comprehensive offerings in its respective field covering innovations, further developments and time-tested solutions. The 2nd trade fair for deburring technology and precision surface finishing will offer valuable know how, not least of all at the bilingual expert forum. The event will take place at the Karlsruhe Exhibition Centre (Germany) from the 10th through the 12th of October 2017. Regardless of the fact that

MACHINE TOOLS WORLD JULY 2017

surface finishing requirements for precision components vary depending on product, application and industry sector, they’re resulting in new challenges for manufacturing companies. For example, burr-free components and workpieces with defined edges and roundings have to be produced with ever greater levels of precision. Surface finishes which minimise

friction, wear and noise, and which increase performance and extend service life, are also in demand. Manufacturing steps for precise shaping are required as well, and in this respect machining and surface finishing are converging to an ever greater extent. As the procurement and communication platform for deburring, rounding and the production of precision surface

finishes, DeburringEXPO presents innovative and advanced products, processes and services, in order to be able to fulfil these growing requirements efficiently and reliably. “As of the 15th of June, 125 companies from 14 countries had already booked booth floor space for DeburringEXPO, including numerous market and technology leaders. We’re expecting 150 exhibitors, many of whom will take advantage of the trade fair in order to unveil new solutions”, reports Hartmut Herdin, managing director of event promoters fairXperts GmbH & Co. KG. The 2nd trade fair for deburring technology and precision surface finishing will thus be significantly larger and more international than the premiere event in 2015.

BUSINESS NEWS

Bosch introduces ‘My Bosch Rewards Program’ Bosch Power Tools India, that offers a complete range of power tools for construction, woodworking and metalworking industry, recently announced the launch of its ‘My Bosch Rewards Program’, an exclusive rewards and loyalty program designed for hardworking and well-connected Bosch Power Tools customers and dealers. Target customers include masons, carpenters, electrician, plumbers, fabricators, installers and applicators that use Bosch Power Tools on a day-to-day basis and visit dealer outlets frequently. These dealers then refer the customers to the program by promoting participation and awareness about the My Bosch Rewards program amongst target customers to earn attractive incentives. Bosch Power Tools is developing a mutually

rewarding relationship with the dealer through the ‘My Bosch Rewards’ program to further support its loyal customers besides attracting new customers. Commenting on the launch, Panish PK, Regional Sales Director and Business Head - India and SAARC - Bosch Power Tools said, “Our customers are important for us and we have created the loyalty program to show our appreciation for their continued loyalty“. He

added, “Most companies try to acquire new customers through discounts & deals, but we realised we had a very loyal set of customers who keep coming back to us - some of them almost every day, & we decided to do something special for them”. My Bosch Rewards is a rewarding loyalty program for customers who buy Bosch Power Tools for everyday work. They can avail unlimited rewards and unlock many other benefits by participating in the loyalty program to strengthen the relationship with Bosch. To receive reward points, customers will enroll in the My Bosch Rewards Loyalty Program and earn reward points on purchase of eligible products & referrals. Customers can redeem rewards in exchange of reward points from My Bosch Rewards catalog.

New Dormer logo unveiled Dormer Pramet has revealed an updated design of the Dormer logo – the brand used to identify its range of rotary cutting tools. The company has two global product brands: Dormer, featuring a wide assortment of HSS and solid carbide round tools for drilling, milling and threading applications; and Pramet, covering a variety of indexable tools for turning, milling and hole-making. The new Dormer logo brings it in line with the company’s global identity, creates a closer connection between the two product brands and further promotes its now widely used ‘chip symbol’. It now has the same font style and size as the Pramet logo, which remains unchanged. The official launch of the new Dormer logo will be at EMO Hannover 2017 in September, although it will start to appear in several locations from July onwards. This includes product packaging and labelling, as well as marketing collateral including technical material

MACHINE TOOLS WORLD JULY 2017

and product brochures. John Rushbrooke, branding strategy manager at Dormer Pramet, said: “There are several reasons for the change, but the main driver is that the previous Dormer logo design was not consistent with the Dormer Pramet corporate logo or the Pramet brand logo. “A legacy from our Dormer Tools heritage, the previous logo design has been the same for more than 25 years. Before this it has evolved and changed many times. In fact, 2017 marks the 100th anniversary since the Dormer name was first attached to our cutting tools. It seemed appropriate to mark this milestone with a strong statement for the next century with a new design. Gautam Ahuja, managing director of Dormer Pramet India, said: “The new Dormer logo incorporates our now familiar ‘chip symbol’. Also, the new design brings numerous marketing related benefits, especially in a digital age with growing E-commerce requirements. We will, of course, be keeping the Dormer red!”

SNIPPETS

13%

The machine tools industry in India expected to grow at a CAGR of around 13% between 2016 and 2020

10th

India is the 10th largest consumer of machine tools globally

40%

The automotive and auto components industry has accounted for about 40% of machine tools consumption in India.

13th

India ranks 13th in the production of machine tools globally

76%

76% of Industrial heavy machinery OEMs plan Investing in product R&D and enhance innovation

45.1% 45.1% Industrial heavy machinery OEMs plan toCreating a line of lower-priced equipment for select global markets

US$35 billion

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

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BUSINESS NEWS

Dormer Pramet to showcase expertise at EMO 2017 It is the first time that Dormer Pramet will exhibit at EMO in Germany following the merger of round tools manufacturer Dormer Tools and indexable specialist Pramet Tools in 2014. Although still a relatively new entity, Dormer Pramet’s product brands can boast more than 150 years’ collective experience in specialized cutting tool manufacture. During this time, both have built a global reputation for high quality products that provide consistently high levels of performance. The collective product range now offered by the company represents one of the widest – if not the widest – portfolios in the market, covering from solid to indexable, high speed steel to solid carbide and general purpose to application specific tooling.

Stefan Steenstrup, Dormer Pramet President, will attend the event and said: “Even though we have an established global reputation, EMO 2017 will be a strong building block in the foundations of our future development and allow us to establish long-term growth both in Germany and in key markets around the world.” Particular highlights showcased during EMO include the new Force X family of carbide drills. Designed

to support consistent performance and repeatability across diverse machines and conditions from 3xD to 8xD, all drills feature the unique Continuously Thinned Web (CTW) technology. This provides a very strong web design, reducing thrust requirements during drilling which has the dual benefit of improving both performance and tool life. In addition, the ‘flagship’ product of its indexable range – the Force AD universal 90° milling cutter - will also feature heavily at EMO. Supported by a wide program of inserts, all offer improved stability in a wide range of applications, even in unfavorable cutting conditions. Combining solid performance with the ability to support ramping, helical interpolation and plunging operations in multiple materials, the Force AD assortment is – like

the Force X carbide drills - an ideal choice for general engineering and sub-contract environments.

Hypertherm honored with awards from EPA & Manufacturing Institute Hypertherm, a U.S. based manufacturer of plasma, laser, and waterjet cutting systems, announced its selection as an Environmental Merit Award recipient from the U.S. Environmental Protection Agency. The award, presented annually, recognizes outstanding environmental advocates in the New England region for making significant contributions toward preserving and protecting our natural resources, and ensuring New England remains a vibrant community with clean air, land, and water. Hypertherm is one of X honorees from New Hampshire and X

MACHINE TOOLS WORLD JULY 2017

businesses in New England to receive the award. In selecting Hypertherm, an independent EPA panel looked at Hypertherm’s work to identify and measurably improve its environmental impact, replicate its sustainability programs, and share its model with other organizations. Achievements cited include Hypertherm’s success in reducing its landfill waste to 2.2 percent last year, as well as the company’s work to increase the energy efficiency of its operations by 30 percent

and reduce its operational carbon impact by 50 percent. In addition, the EPA considered Hypertherm’s use of Life Cycle Assessments and a Design for Sustainability scorecard to reduce the environmental impact of the products it manufactures and sells. Separately, Hypertherm announced the selection of Robin Tindall, its Environmental Stewardship Manager, as a Women in Manufacturing STEP (Science, Technology, Engineering and Production) Ahead honoree. The STEP Ahead Award, presented by The Manufacturing Institute, honors women who

have demonstrated excellence and leadership throughout their careers. It is meant to examine and promote the role of women within the industry through recognition, research, and leadership.

BUSINESS NEWS

Tool Presetting with HAIMER quality Successful machining requires powerful machines and highlyprecise tool holding technology, which ensures that the precision is transferred from the spindle right to the cutting tool edge. Within the last couple of years HAIMER, the European market leader in the area of tool clamping technology, has become the complete system provider for tool management. Managing Director and President of the Haimer Group Andreas Haimer summarizes the development as follows: “After the recent acquisition of Microset GmbH from DMG MORI and the expansion of our product portfolio we are now able to offer the entire process chain from one single source.” For him it was especially important that the Microset presetting devices meet the very high quality standards of HAIMER. Andreas Haimer explains that there is absolutely no doubt that the quality is met because “all Microset machines - starting with the entry-level models up to the fully automated measuring machines -distinguish themselves through first-class hardware, ideal ergonomics, as well as easy handling. They are supported by a stable cast iron base construction which reduces the need for frequent calibration and helps subsequent problems in the

MACHINE TOOLS WORLD JULY 2017

production environment.

Premium machines with linear drive One highlight from the comprehensive product portfolio is the VIO linear series. It is the only machine series on the market with a linear drive for efficient and highly precise presetting of drilling, milling and turning tools. The direct drive within the x- as well as z-axis offers the user a very dynamic positioning precision and reliability of even the largest tooling. The repeatability of +/- 2 μm indicates the high degree of quality inherent in these machines. The increased speed of linear drive can guarantee a productivity increase of up to 25% during the measuring process – all of that at a very good price-performance ratio. All machines of the HAIMER Microset VIO series have a modular design to cover a wide spectrum of

needs. Tools that weigh up to 160kg and have a diameter and measuring length of up to 1000mm can be measured. Depending on your needs the devices can be upgraded to fully automated CNC measuring machines with integrated HAIMER shrinking technology. The unique design ensures ergonomic functionality for ideal ease of use for the operator. This applies both to the spindle access as well as the central control panel. The innovative one-hand-operation makes it possible to manually or automatically measure the axes and guarantees a μm-precise fine positioning. Finally, maximum quality during the manufacturing process is achievable through fast and exact measuring with the image editing software Microvision VIO. The tool measurement is even easier with the help of the large high-resolution flat screen monitor.

Even simple devices deliver highest precision With the HAIMER Microset UNO series the focus lies on precise tool presetting as well as consistent performance. Due to the many different options the UNO series offers, price-performance ratio is very good. Next to a Touch-Display, RFIDChip-System and post processors for all conventional control systems, the equipment options also include upgrades such as autofocus or automatic drive. The difference between the UNO autofocus and the manual version is the ability to automatically focus on the cutting edge with a CNC control system in the c-axis. For tools with many cutting edges, this option is a proven time saver. Furthermore, the automatic drive version independently positions the different planes in the z-axis and automatically approaches the x-axis. The user does not need any special skills, because with the push of a button the machine independently measures complex tools with multiple cutting edges and levels. If required both versions can also be operated manually like the standard model. The UNO series machines are available in two different sizes. The series starts with the UNO 20/40 with a maximum tool length of 400mm on the z-axis; the UNO

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Creating Tool Performance

BUSINESS NEWS 20/70 has a maximum tool length of 700mm. Both versions are available as table devices with a 19” flat screen. A 22” or 23” touch display and the comfort system cabinet is also available as an option. By using the snap gauge method even the standard models offer the possibility to measure tools with a diameter of up to 100mm. With use of spindle adaptors that configure to the base SK50 taper interface, it is possible to also use most popular interfaces such as HSK, Capto, VDI, KM or BMT.

Thermally stable cast iron construction The FEM optimized and thermo-

stable cast iron construction is the solid foundation of the Mircoset tool presetting machines. The extremely rigid base unit with a 3-point-support system provides stable and safe positioning of the machine and ensures an overall easy set-up for the highest possible flexibility in production. Additional features such as visual inspection camera mode and optional “infinite fine adjustment” further enhance the functionality of the machines. With its release-by-touch, function (an intelligent sensor control to measure the x- and z-axis) the UNO series is setting new standards for entry-level tool presetting machines by

making them easier than ever to use. Microvision UNO offers the operators intuitive functionality that produces very precise measuring results. A precise focus window enhances the accuracy and even provides accurate measurement values for the most complex tools. The UNO series is rounded off with options like a thermo-label printer, a vacuum clamping system, a second camera for presetting stationary turning tooling and a highly precise ISS spindle with direct clamping adapter (2 μm accuracy). Andreas Haimer summarizes: “Microset offers a high-performance alternative and solution to every customer who wants to

purchase something new in the area of presetting technology. Even if your presetting room is currently equipped with other technology it definitely pays off to purchase new presetting devices whenever you invest in new machines. This way you can prevent long waiting periods and also avoid machine breakdown. The easy and intuitive operation of the machines guarantees that even in a three-shift-operation the devices can be operated by every single employee. In short, in order to use the Microset devices you don’t need to be trained for weeks in advance and you don’t need to place them in an air-conditioned measuring room to get repeatable results.”

Enhancing the additive manufacturing process chain The design freedom provided by additive manufacturing (AM) or ‘3D printing’ technology is an important enabler in cutting-edge product innovation. As part of the revolution in digital manufacturing, AM can radically simplify the production of complex parts, while simultaneously improving functional performance, reducing part weight and minimising component counts. To take full advantage of AM’s unique capabilities, however, complementary software tools need to be optimised to satisfy the new requirements of ‘design for additive manufacturing’ (DfAM) rules and guidelines. Dassault Systèmes, a world-leading provider of 3D design software, 3D Digital Mock Up and Product Lifecycle Management (PLM) solutions, collaborated with Renishaw to streamline its 3DEXPERIENCE® platform to deliver a no-compromise end-to-end AM design experience. The 3DEXPERIENCE platform comprises a whole suite of 3D software applications supporting the complete product life cycle, from

MACHINE TOOLS WORLD JULY 2017

design and development to simulation and reliability analysis. Available to users on premise or on-cloud, and accessible via a single user interface, it enables the creation of ‘social enterprises’ where collaboration in the product innovation process becomes simpler and more efficient. Topological optimisation is a key step process in the manufacture of 3D parts, ensuring material usage within a defined space is fully optimised. Dassault Systèmes’ CATIA applications for generative design provide product modelling powered by the 3DEXPERIENCE platform.

Dassault Systèmes’ companion DELMIA software application then enables users to design and test a product in a simulated production environment. Importantly, the software manages product build set-up and the generation of laser

(scan) tool paths required by the AM systems. Simulation of the complete AM build process, including full product stress analysis and distortion prediction, is carried out using the 3DEXPERIENCE platform’s simulation application. In its close collaboration with Dassault Systèmes, Renishaw employed a broad range of its state of the art precision manufacturing and metrology products. These included the flagship RenAM 500M metal additive manufacturing systems with laser powder bed fusion technology, QuantAM build preparation software, machine tool probing systems, EquatorTM gauging systems and CMM with REVO 5-axis measurement system. Renishaw applied its technologies for characterisation of the build process, design validation and automated process control of a final subtractive machining operation. These, combined with the 3DEXPERIENCE platform’s applications, delivered a seamless AM process and the end-to-end manufacturing solution required.

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COVER STORY

Mr. S.M. Sood Managing Director, Marposs India Pvt Ltd

MACHINE TOOLS WORLD JULY 2017

COVER STORY www.mtwmag.com

Marposs : The metrology expertise with technological perfection Q. MARPOSS has leadership position in metrology industry, how did MARPOSS India manage this significant growth? Marposs started its operation in Italy way back in 1952 and the first product was an electronic gauge for grinding machine. It was a real innovation at that time since for the first time mechanics & electronics were combined together for a gauging solution on machine tools to increase productivity, improve quality, with drastic drop in rejection. Marposs, a world leader in metrology equipment provide a global answer to customerâ&#x20AC;&#x2122;s production quality control by making high precision equipment for machine tool control and for part measurement & inspection in the shopfloor environment. From the beginning, Marposs adhered to the policy of being present in close proximity to customers to understand their quality requirements, investing continuously in R&D and giving utmost attention to customer satisfaction. With these objectives the company deploys economic & human resources & carries out its best commitment to offer top quality innovative products & applications developed in close cooperation & in simultaneous

engineering with its customers. Following the same philosophy, Marposs India managed this significant growth by offering its customers a combination of advanced products, market knowledge & commitment to long- term partnerships.

Q. What are the plans to promote MARPOSS brand in India? Marposs is presently well known in automobile sectors & considering India will play an important role as a quality manufacturing hub for mechanical production, there is tremendous scope for Marposs in entering other sectors like, aerospace, energy, glass, medical etc. With the positive change in government policies, we expect these sectors to grow and plan to promote our products to them since precision is of utmost importance for each machining operation. For promotional activity we have been participating in all major Manufacturing & Machine Tools exhibitions to ensure that our customers are continuously updated on the new technologies /applications. We have also started to focus on new potential industries by participating in specific fairs / exhibition /seminars.

Q. How about MARPOSSâ&#x20AC;&#x2122;s initiatives in measurement technology space? Which are your focus areas? Marposs plays very important role in measurement technology as a partner to engineering industries starting from initial project discussion till production of precision components. Machining processes are optimized with new materials/ tooling, Marposs offers Machine monitoring systems for continuous monitoring of cutting tools & machine condition. For high precision machining, these systems will be an essential part of each manufacturing line since high cost of parts demands zero defect production. Every manufacturing company wants to be equipped with flexible facilities due to frequent change of models & Marposs has developed expertise in providing retool-able measuring solutions with which similar parts of different dimensions can be checked without any compromise on precision, our optical solutions is a major step in this direction For companies, ready to adapt Industry 4.0, we are able to support customers to continuously monitor every product production process,

JULY 2017

MACHINE TOOLS WORLD

COVER STORY

guaranteeing its quality & analytical traceability. Statistical analysis of measuring data for process control is also an important tool to optimize any manufacturing process and improve overall productivity of the line.

Q. What are the market opportunities for MARPOSS products in India? How do you plan to position these products? Manufacturing of precision components, mainly for aerospace, defence & export of auto components will enhance opportunities for Marposs Products. To cater the demand of components with tight tolerance, Marposs uses feedback from measuring systems & thereby controlling machine tools. Eventually these measuring solutions will be used as an integral part of manufacturing line for ensuring the quality at each step & the final product. Marposs has been working globally in close co-operation with all important OEM’s and end users. In India, we also plan to share our knowledge & experience of other markets so that the latest developments for improvement in processes can be also implemented here.

Q. Can you brief us more about MARPOSS’s top line product range? Marposs is committed to provide any kind of measuring solutions desired by the market. We supply products ranging from an individual gauging component to turkey machines or fully automated lines to give a global answer to

MACHINE TOOLS WORLD JULY 2017

customer’s needs, supplying the metrology equipment in association with non destructive testing, leak testing & wide variety of sensors & machine tool controls. With the wide range of products and applications , today Marposs can cater to the needs of most of the industries from automobile, electronic industries, aerospace, biomedical, energy, glass, bearing etc. In last few years, Marposs group acquired new strategic companies to offer our customers, additional product lines to monitor & control important machining operations. These products include Machine Monitoring systems for metal cutting & metal forming industry. We plan to introduce these products in India to Machine Tools manufacturers as well as to end users who are interested in high precision & consistency in each operations

Q. What do you think are the strengths of Indian metrology industry & How it is positioning itself against the global market? Indian metrology industry has in due course of time acquired sufficient knowledge on high technical solutions. This skill & knowledge has not yet fully benefitted the industry at grass root level. With the expansion in manufacturing sector,there is tremendous scope of enhancing our capability by utilizing the skill available here and working on technology transfer from more advanced countries. This will surely help in upgrading quality awareness at small & medium scale industries and

making our industry to move faster for global participation.

Q. What are the key technological trends that are driving metrology industry? Manufacturing industries has trend to adopt technology to cater with demand of multiple models & the flexibility to produce variety of components on a single machine tool. Measurement technology should also support to achieve this capability to measure within least possible time. Post process measurement with optical technology is an innovative solution for such type of demand. Leakage testing in any housing/ sub-assembly of engine is an important check for the performance of the engine & therefore becoming an essential part of the manufacturing process.

Q. What is your vision for MARPOSS India for forthcoming years? In the present scenario, quality in each manufacturing plant is essential to compete with global manufacturers. Marposs India is playing vital role in providing solutions for checking component before machining, during machine & final inspection. Also monitoring of machine as well as cutting tool condition has become essential for achieving overall accuracy of the component produced. Also, automation will be key prime mover, since the quality should not depend on operator’s skill, therefore automatic measuring solution will have huge potential to cater to these needs.

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More information

IN FOCUS

‘Make in India

needs a design component to become a guaranteed success’ While Make in India has changed the mindset of the business community and enhanced their entrepreneurial potential, Design in India will take the campaign to another level and place India on the global map, says Parakramsinh G. Jadeja, President, IMTMA. In an exclusive interview, he talks about the key challenges faced by the Indian machine tools industry, its future outlook, & steps IMTMA is taking to increase R&D and innovation. Excerpts:

Parakramsinh G. Jadeja, President, IMTMA

Q. Where does Indian machine tools industry stand globally? What is the future outlook for the industry? Indian Machine Tool industry registered an impressive growth rate of 18% during 2016-17 as against 3% decline seen globally. Domestic manufacturing caters to over 40% of the country’s needs and the aim of the industry is to increase this considerably. India stands 8th in Consumption and 12th in Production, as per Gardner’s World Machine Tool Output Survey 2017.

•

Q. According to you, what are the key challenges for the Indian machine tools industry?

•

Indian companies need access to technology as well as gain access to global markets. Acquiring technology in the manufacturing space will pay rich dividends. India’s domestic market is huge and absorbs much of its production. Our industry needs to focus on exports.

•

Q. What concrete steps the industry is taking to address these challenges and support export development? • Indian companies are moving

•

MACHINE TOOLS WORLD JULY 2017

towards using new technologies such as Industry 4.0, Internet of Things, 3D Printing, etc. These would take manufacturing to the next level and make the Indian machine tool industry globally competitive. Our R&D capabilities are growing and we see industries focusing towards innovation and new product development. Industry is working with academic institutions to bring forth new technologies and commercialize their research projects. IMTMA participates in reputed overseas Exhibitions and encourages its members to participate. The technology tie-ups with global machine tool industries are creating opportunities for Indian companies to develop their business overseas.

Q. What steps is IMTMA taking to increase R&D activities and innovation in the industry? IMTMA is working closely with premier institutions such as IITs to encourage R&D and innovations. The Government of India is supporting the machine

tool industry in this endeavor. The collaborative approach has resulted in the development of new products which were displayed during the recently concluded IMTEX 2017 exhibition in Bangalore.

Q. Please share your views on the Make in India campaign? What steps do you suggest to take the campaign to the next level? Make in India is a key initiative designed to facilitate investment, foster innovation and enhance skill development in the manufacturing sector. The campaign has provided a broad direction for manufacturers to invest in India, focus on infrastructure development and enhance manufacturing growth. Make in India has changed the mindset of the business community and enhanced their entrepreneurial potential. With GST coming into play and opening up of FDI in various sectors, the ‘Make in India’ movement has got a fillip. Moving forward, Make in India needs a “design component” to become a guaranteed success. Designed in India will make the country an outsourced production hub. It would also place us strongly on the global map.

INDUSTRY FOCUS

Hermle machines maintain desired accuracy Customer closeness and a solution-oriented approach are the company’s strategic cornerstones, together with verifiable and documented improvements in total cost of production

Mr. Atul Mohkhedkar, General Manager (Production) Seco Tools India

eco Tools actively contributes to improving your productivity and competitiveness in metal cutting machining. Customer closeness and a solution-oriented approach are the company’s strategic cornerstones, together with verifiable and documented improvements in total cost of production. The company values long-term relationships as it is possible to gain a better understanding of the challenges and allows it to actively contribute to the customers’ development. A comprehensive range of cutting tools is another central component of Seco’s strategy and the quality and innovation built in its tools is the key to profitable production. In order to offer the best total solutions, it also provides technical support, demonstrations, technical advice, new ideas and practical experience.

State-of-the-art Solutions

Established in 1988, Seco Tools India is an export oriented unit (EOU) supplying state-of-the-art tooling solution to the global market. The company’s facility in Pune manufactures metal cutting tools besides inserts and carriers. Every year the facility and capacity at the manufacturing unit is being increased with special production unit catering to local customers. It is one of the best shops in the industry.

MACHINE TOOLS WORLD JULY 2017

Seco Tools India has been using Hermle machines at its manufacturing facility ever since the unit came into existence. Explaining the reason behind this, Atul Mohkhedkar, General Manager (Production) of Seco Tools India said, “Choosing Hermle as our machining partner was easy. We are following the group standard machine specifications and Hermle is one among them.” Technical Benchmark

“While selecting the machine, we conducted technical benchmarking. We looked into the thermal stability of the machine, reliability of operations, support availability and track record of the supplier within Seco and entire industry.

Since Hermle has special polymer concrete base, the thermal stability is good. Our workshop is exposed to almost 10 degrees of temperature variation in 24 hours and Hermle machines maintain the same. This prompted us to zero-in on Hermle,” Mohkhedkar said. “Besides, Hermle machines are reliable that helps in maintaining the accuracy. Also, support from Hermle’s local office has been good always. Seco has three different models of Hermle machines from smaller (C 22) to bigger (C 50). After-Sales Service

“Since we manufacture different component, the tolerance varies. On Hermle machines, it varies from 4 microns to 30

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INDUSTRY FOCUS microns which is well within our expected tolerance level. Even process capability is well maintained on these machines,” the official said and added that with Hermle there is reliability of operation and process capability. “If we require after-sales service, Hermle’s support from Germany as well as local back office is very prompt and good. Hermle is our business partner,” he lauded. When specifically asked about Hermle’s service support backup, the official said, “Once we had a major problem in the machine and when we discussed it with Hermle officials, they specially deputed one of their engineers from Germany who reached our manufacturing facility on third day. Their team is always there as and when required and we are satisfied with the service backup.” Satisfactory Results

“Since it was Seco that started Hermle market in India, the machine manufacturer gives primary supplier benefit to us. Even the availability of local service is good. As breakdowns in the machines are limited, their service engineers visit us whenever we call them. They are keeping us satisfied. Even the competency of the people as well as company is good

MACHINE TOOLS WORLD JULY 2017

and service documentation is extremely proper that creates very less problems in the machine,” Mr. Mohkhedkar added. When asked whether Seco is satisfied with Hermle’s performance, the official replied in the affirmative. “Yes, we are really satisfied. Interaction between Seco and Hermle will be as it is and increase year-after-year. We are looking forward for better and improved support from Hermle in the future,” Mr. Mohkhedkar concluded. Partners in Growth

Stating that Hermle is market leaders in 5-axis machining centres, Mr. Maximilian Waizenegger, the Regional Sales Manager of Hermle Machine Tools, said Seco Tools is using the machining centres developed by Hermle since past many years and are satisfied with the performance of the machines. “For Seco, using Hermle 5-axis machines has been a great experience since the rotary table is very rigid and reliably designed. This is one of the reasons why we are market leaders,” he said. Elaborating on Hermle-Seco partnership, Mr. Waizenegger said, “Seco is most important for us. In India, we share a strong relationship. Hermle started supplying macines in India after

Seco purchased these machining centres. We also share a good relationship Phillips Machine Tools India. We have a good product and the machines are reliable that helped us develop long standing relationship.” “The most important thing is we are able to give prompt after-sales support and remain close to the customers which is very important for Hermle. Even Seco has approved the kind of support they are getting from Phillips Machine Tools India. Now we have to convince others and establish ourselves more in the Indian market,” he said. “Now that we have Phillips Machine Tools as our partners in India, the spare part support will be good. Our machines are 100% manufactured in Germany and the target is to maintain the quality of the machines. We will be doing this in India with Phillips Machine Tools. I think the one reason why people are buying Hermle machines in India is the availability of technical support and training locally. We have to maintain customer relations. We believe that quality of after-sales service reflects in quality of machines and are happy to partner Phillips Machine Tools India in this endeavor of ours,” Mr. Waizenegger concluded.

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INDUSTRY FOCUS

7 Things that could make your Fiber Laser Cutting Machine much dynamic 1. Machine Hardware

Focal Lens • The fiber laser cutting machine is provided with lenses of different focal lengths. Use them appropriately on thin & thick sheets to get fine quality finish. • Follow the prescribed procedures to clean the lens » Clean the lens before usage. » Always use the Laboratory grade Acetone solution and cloth not having lint provided along with the machine. » Handle the lens gently. » Store the lenses properly when not in use. » Restrain the lens from use if you find any cracks or tough distortions. Nozzle • Similar to lenses, the nozzles of appropriate Diameters has to be put into use for different cutting operations. • Always perform the ‘Nozzle Centring’ procedure to ensure proper passage for laser beam. • Replace the nozzle immediately if you find any burr or molten particle hindering the nozzle’s hole. • Always use the prescribed model of nozzle for better results. Sheet metal • At all times, store the sheet metals in a proper dry place to avoid corrosion. • Make sure the sheet metal is clean from any dirt. However, coated (protective layer) sheet metals could be directly used for the cutting operation if free from any rubbish. Sheet stacker • It is advisable store sheet metals on a stacker for quick inventory traceability and to avoid shuffling. • It also facilitates easy accessibility to material.

MACHINE TOOLS WORLD JULY 2017

Sheet loader • For easy handling and quick loading of sheets, use the sheet loader. This could reduce the labour and time involved. 2. Gas

• Select the right gas for the required materials. Always prefer N2 for Stainless Steel as its delivers oxidation free cutting. If not bothered about the oxidation effect on the cut edges, you shall opt for O2 as it could penetrate further more during the cutting operation. Use only O2 for Mild Steel. • Always opt for highly pure gases available. Any level of purity above 99.8% is acceptable. (Note: Cutting quality is determined by the purity of assist gasses as well) • Before switching between O2 and N2, always flush the existing gas present in the pipe for 4 - 6 seconds. This prevents the mixing of gasses during the piercing and delivers a perfect operation.

1 laser safety enclosure. Always keep the doors closed during the laser cutting operation to avoid any damage to the operator & nearby electronic devices. • Operators are recommended to use Laser safety goggles in the absence of laser safety enclosure and while troubleshooting. Data Security • Use the administrative tools and features in your machine to Define work authorisation for Plant Manager, Machine Operator and Trouble-shooter. This facilitates easy tracking of work and output. • Data Security is ensured by implementing administrative features. • Use Local Area Network (LAN) to transfer the work files. Using illegitimate USB devices could result in malicious attacks. 4. Efficiency

3. Safety and Security

Operator Safety – Keep your work force safe for optimum productivity • We strictly recommend using the Class

Nesting software • The cutting operation could be much optimised both in terms of Time and Sheet utilisation through SLTL’s own

INDUSTRY FOCUS

nesting software: Technest. Refer to the nesting guide in the software for incredible nesting options. Cutting Parameters • The machine has predefined cutting parameters for different metals and thickness. This makes material change much convenient and time saving. Pallet changer • Fully utilising the Dual pallets will double your daily productivity. Sheet orientation • Instead of manually aligning the sheet for each cutting operation. Checkout the Auto sheet orientation feature in the Laser cutting machine to speed up the process. • In case of any upward dent in the sheet, use the Auto Height Sensing feature to have a clean and uniform cut

MACHINE TOOLS WORLD JULY 2017

quality throughout the nested area. Machine diagnosis • Check for system notifications/alerts and initiate necessary actions to avoid unnecessary downtime.

the operational cost. 6. Environment

Controller: Regularly check the environment for any Temperature/ humidity breaches. This ensures consistent performance of the system.

5. Output Management

Finished components • It’s advised to collect the finished components and place them properly to save time and avoid missing pieces. • Strap and store the cut components for traceability, easy handling and transport.

Fume extraction: Regular maintenance of the fume extraction is a must practice to avoid indirect damages to the lens. Malfunctioning of the fume extraction might result in fume (carbon or dust) deposits on the focal lens. 7. Periodic Maintenance

Scrap handling • Remove the scrap during each change in cutting material. Isolate scraps of different materials to avoid contamination (oxidation). Doing this could fetch you a good buyback offer from the scavenger- hence marginally reducing

• Cutting head Check and change the Deionised water periodically for proper cooling of the cutting head. The Laser cutting head has to be well cooled as it has direct impact on the cutting quality. • X, Y and Z axis Drives Periodically check for any oil leakage in the axis. Abundant lubrication (time based) in the axis might result in unnecessary wastage of oil. Recent laser cutting machines of SLTL is equipped with motion based lubrication for better performance and cost saving. • Cutting table Clean it periodically and if needed replace it to avoid oxidation & unnecessary burring on the cut piece.

www.elesa-ganter.com www.elesa-ganter.in Elesa and Ganter India Pvt. Ltd. : A-54, Sector-83, Noida - 201305 (UP) | Ph: +91 120 472 6666 | info@elesaganter-india.com

COMPANY UPDATE

We give strategic advantages to our customers from diverse industries: Rupesh Paparaju, Bettinelli Automation, India

ettinelli S.p.A, established in 1953, specializes in the development and manufacturing of precision motion control components and systems. In 1996 a separate division named CDS Cam Driven Systems was created for engineering solutions in automation and motion technology. CDS produces the widest range of mechanical Cam Driven Units, commonly known as rotary / indexing tables for precision motion control applications, requiring rotary or linear transfer, positioning and handling. The products range includes, cam indexing and servo-driven 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.

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. 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

Wide ranging products

The broa4d 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, FT-HT 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

MACHINE TOOLS WORLD JULY 2017

Rotary Indexing Tables, TR Series

COMPANY UPDATE Closer to the customer

Parallel Shaft Indexer 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

MACHINE TOOLS WORLD JULY 2017

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.

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.

- P.K. Balasubbramaniian

NC4 non-contact tool setting system Non-contact tool measuring and broken tool detection on a variety of machining centres

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COMPANY UPDATE

Young Buhmwoo India:

The Rising Star

oung Buhmwoo India Company Private Limited (YBI in short), a subsidiary company of the Global Buhmwoo Group, came into existence in India, in the year 2005, via the manufacturing route, after setting up a modern plant to produce industrial and automotive grade lubricants in Sriperumbudur, near Chennai and, very near to the Hyundai Motor India plant. The parent company, Buhmwoo Chemical Ind. Co. Ltd., started it’s operations in the year 1973 and is currently headquartered in Seoul, South Korea. The Global Buhmwoo Group along with its subsidiary companies have manufacturing bases in South Korea, China, India, Indonesia, Vietnam, Mexico and, a sales and distribution setup in the U.S.A. The global vision of Buhmwoo and its core value is : “Good to Great, New Challenge for our next 100 Years !” In India, YBI is following the footsteps of its parent company, by manufacturing and selling world class quality lubricants and also by providing efficient technical backup support, related to the usage of its products for its clients. YBI’s product range includes metalworking fluids (for metal cutting, forming, stamping and fin press applications), cleaning & washing fluids, anti-corrosion or rust preventive fluids, heat treatment / quenching oils, gear and hydraulic oils, automotive wax, automotive engine & gear oils, greases, and several other related products. YBI also manufactures customised products for the special requirements of its esteemed clients across India. YBI products are sold in India through

MACHINE TOOLS WORLD JULY 2017

their offices in Chennai, Delhi, Pune, Bangalore, Coimbatore, Vadodara and Indore, with several such other offices to open up soon in other locations. YBI is totally dedicated to the lubrication related requirements of its customers and is continuously trying to improve upon its existing levels of capabilities and trustworthiness by the way of R & D activities and also with the help of its efficient manpower deployed in the manufacturing plant and the sales offices across India. For more information, Website: www.buhmwoo.com www.youngbuhmwoo.com

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HIGH-TECH MANUFACTURING

WIL & High-tech Manufacturing High-tech manufacturing is not everyoneâ&#x20AC;&#x2122;s cup of tea. Having a sophisticated manufacturing set-up with the best of men and machines performing multiple operations for producing quintessential components is only part of the high-tech story. It also presupposes design and process capabilities and the entire chain of manufacturing including raw material management and in-process quality check to ensure that the final product meets the complex geometries, close tolerances and stringent specifications, discovers P.K. Balasubbramniian in an interview with G.K. Pillai, Managing Director & CEO of Walchandnagar Industries Ltd. WIL is known for its eminence in high-tech manufacturing to cater to the stringent requirements of products and equipment of priority sectors like defense, aerospace, nuclear, missile and energy. Excerpts: aspects to harvest the final product. Only a synergy of these advances will provide the maximum efficiency and produce an immaculate product and only then the process can be titled as High-tech manufacturing. Achieving this synergy becomes a prime objective in industries such as ours where complex geometry, close tolerances, stringent specifications, and the usage of exotic raw material becomes a common occurrence. Q. What are your capabilities and

G.K. Pillai, Managing Director & CEO, Walchandnagar Industries Ltd. Q. How do you define High-tech Manufacturing?

Iâ&#x20AC;&#x2122;m glad the question came up. Whenever a topic of High-tech manufacturing kicks in, our imagination intuitively glides to a place with sophisticated machines performing multiple operations and producing quintessential components. However, one should not forget the prominence of activities associated with the entire manufacturing process. Advances are happening in all levels of product development whether it be designing, setting up the processes, managing the raw materials or even packaging of the final product. High-tech manufacturing can thus only be achieved by accommodating all these

MACHINE TOOLS WORLD JULY 2017

facilities for high-tech manufacturing?

Walchandnagar, today, have three manufacturing facilities which are located in Walchandnagar (135 km from Pune), Satara, and Dharwad (Near Hubli, Karnataka). The Walchandnagar plant carries out production activities for Defense, Aerospace, Nuclear, Missile, Gear, Cement, Sugar and Energy, and Centrifugal businesses. We have our Foundry business running in Satara and Instrumentation division in Dharwad. As Walchandnagar is associated with the manufacturing of different types of products and equipments, our facility has been fortified with machines of not only different sorts but also sizes. CNC multi-axis boring machines, milling machines, Gear cutting and grinding, Plate bending machines, Lathes

are some of the machines available in different sizes in our plants. We respect the quality requirements and uniqueness of different businesses and thus have ensured that the machines are allocated to different divisions to provide superlative efficiency and quality. Our Missile, Aerospace, and Nuclear businesses involve working with exotic materials which are very challenging to work with. We have sophisticated Automatic Welding Systems to deal with these subjects. Our qualified and dedicated welding engineers deployed in the Welding Development Section and skilled welders have also proved themselves on multiple occasions. Our plant is also equipped with Dustfree enclosements for critical welding and assembly of intricate components utilized in Nuclear, Aerospace and Missile divisions. And not to forget the Heat treat-

Heavy Duty Plate Bending Machine

HIGH-TECH MANUFACTURING

Series of Horizontal Boring Machines ment facility comprising furnaces of wide ranging sizes. The quality aspect is taken care by the Optical tooling and measuring instruments. Our material handling system is also well advanced which not only consists of overhead cranes (25 tons to 250 tons) with an area under the crane of 56,000 sq mtr but also hydraulic cranes, industrial lifters, trolleys, etc. Apart from this we also have equipped our engineers with high-end design and analysis softwares which help us create products that define our superiority in the market. It is this why we proudly say that our gearboxes, cement equipment, centrifugal machines deliver a life not less than 20 years. Apart from this, we also have our own Hydraulic test facility for Missile, Aerospace and Defence jobs and test facility for Gearboxes. I would also like to update you on the fact that WIL maintains a dedicated design team ‘Walchand Technology Group’ and Tooling design team which is essential keeping in mind the fact that we manufacture special project based products. Apart from this, we are also proud of our 1000 plus workers and 200 plus engineers. Q. What are the business opportunities available for your Division?

Walchandnagar has a portfolio of wideranging businesses under its canvas. With Defense, Nuclear, Aerospace already in its DNA, we also provide tailormade Gearboxes, Cement equipment, and castings. Walchandnagar is also distinguished for its ability to provide EPC plants to its Sugar and Co-gen customers. Our business segments allow

MACHINE TOOLS WORLD JULY 2017

Large Capacity Lathe and Double Column Plano Miller

Heavy Duty Vertical Boring Machine capacity 220, 540, and 700 MWe. Some of the components include Calandria, Moderator Heat Exchangers, End Shields, Air Heat Exchangers, Core support, Core Catcher, etc. and we look forward to supplying them in the future too.

4-Axis Vertical Milling Centre us to serve both Government as well as Private organizations. The current growth emphasized government has brought to the table all-round reforms, in turn, creating many growth-oriented prospects. The foremost “Make in India” program now also followed by the “Buy in India”, Finalising the long pending CLND Act, Union Budget 2017 which focussed on infrastructure growth and Agriculture; They all have unlocked new business mines. It is thus not surprising to note that we carry a good load of orders in our kitty and envisage much more shortly. Q. What do you offer to critical segments like nuclear power, aerospace, defense and missiles?

Nuclear Sector The nuclear sector in India saw a very tepid growth over the last decade. A lot of projects were stagnant due to the CLND Act. But a complete turnaround of this scenario has happened with the finalization of the crucial points in the act and suddenly the market has been inundated with new Nuclear Power Plant projects that will be undertaken by the NPCIL. We have supplied, in the past, critical components for Nuclear Power Plants of

Aerospace WIL has been an integral part of all space projects/ programs driven by Indian Space Research Organization (ISRO). This association has been spanning over 4 decades. ISRO views WIL as a reliable manufacturer of various strategic and critical components for various space programs. • SLV-3 (Year -1980) Weight- 17 tons, Payload Capacity – 40kg, Height – 22 m • ASLV (Year – 1987) Weight- 19 tons, Payload Capacity – 150kg, Height – 23.5 m • PSLV(Year- 1993) Weight- 295 tons, Payload Capacity – 1600kg, Height – 44 m • GSLV(Year- 2003) Weight- 414 tons, Payload Capacity – 2.5 tons, Height – 49 m • GSLV MK-III(Year- 2014) Weight- 620 tons, Payload Capacity – 4 tons, Height – 42 m WIL is currently supplying PSLV, GSLV, and GSLV MK-II on a continuous basis. The GSLV MK-III launch that took place on 5th June 2017 had S-200 motor casings supplied by WIL. It gives me immense pleasure to state that WIL has played a crucial role in Chandrayaan-I (India’s first Moon Mission) and Mangalyaan (India’s Mars Mission).

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

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HIGH-TECH MANUFACTURING Defense WIL has been closely functioning with DRDO, R&DE, and other defense organizations on various defense projects and have supplied Aluminum alloy bridges, Container and Launchers, Surface launchers. Currently, WIL is executing surface launcher projects (Wagon mounted and Trailer mounted) with associated hydraulics and control systems for the Missile programs and other confidential projects. WIL has also contributed to the Indian Naval ships and has a track record for supplying high-speed gearboxes (up to 18 MW) for frigates, corvettes, fleet tankers, and survey vessels and submarines. Over the last 11 years, WIL has successfully met various stringent program requirements with demonstrated capabilities for indigenous design, engineering, manufacturing, testing and supply of gearboxes. Missiles WIL is one of the very few industries that partnered with DRDO during the development phase of its ambitious missiles programs viz., Akash and Agni. It was more than two decades ago that DRDO approached WIL for their flagship projects. The combined expertise of the WIL engineers and the DRDO scientists as well as extensive R&D has helped in the development of critical manufacturing techniques to meet the design and stringent quality parameters for its strategic and tactical missile programs. The development phase of Akash missiles demanded a strong knowledge of the manufacturing technology in order to convert the designs into actual products and today a dedicated facility is

Process Layout for Missile Manufacturing

established in Walchandnagar to supply these critical components with close tolerances and stringent quality checks. Q. Could you give a brief account of your recent achievements?

Our list of achievements come from the combined efforts of all businesses. Aerospace Division allowed us to be a part of the elite group which supplied critical components for “Chandrayaan-I” and “Mangalyaan”. We are a trusted source to the Indian Navy for supplying Marine Gearboxes and I’m proud to state that we have recently supplied a gearbox to the DMDE (18400 HP). It gives me immense pleasure to point the fact that WIL has supplied 50+ gearboxes to the Indian Navy. We have contributed in supplying the critical components for India’s “Agni-V” and continue to do so. Apart from Akash, our missile division has also added Astra and QRSAM to its portfolio. Our Defense business is also involved with many confidential programs. Recently our Instrumentation business has also started catering to the needs of PSUs which is a great breakthrough for us. We are also going to play a major role in Government’s vision to increase the utilization of Nuclear Power as an energy source by supplying components for the Nuclear Power plants, orders to which have already started to flow in. In the past, we have already supplied critical

Marine Gearboxes

MACHINE TOOLS WORLD JULY 2017

equipment to 20 Nuclear Power Plants in India and it is a big achievement when the total count of Nuclear Power Plants is 22 for our nation. Apart from this, WIL’s Centrifugal business has also flourished owning a market share of 60%. Q. What are the challenges you face and how are you geared to meet them?

Being a project-based manufacturing firm, every new project brings with it new complexities and complications. Efforts are indispensable when it comes to design and engineering, process planning, project management and even hunting for new suppliers. This on occasion, makes it difficult for us to adhere to the delivery schedules resulting in delays in product delivery. But as previously mentioned, to bring in Hi-tech manufacturing, improvements in all these sectors is imperative. These issues are critically studied and improvements are planned to bring about the change. Our engineers are even burning the midnight oil to standardize the process wherever possible. With new developments happening daily, it is also very crucial to keep in step with the latest technology and maintain the skill set of employees to be at par with the competition. Actions are being taken in this aspect too with our firm planning to establish new business lines.

TECH TRENDS

Premiere Tool Presetting - A New Design with True Added Value ZOLLER, the world’s leading manufacturer of presetting, measuring, and inspection devices, unveils the »venturion«, »smileCompact« and »smile« presetting and measuring devices in a NEW design and the same uncompromising quality that comes standard with all ZOLLER products. The unbeatable combination of optimized ergonomics and comprehensive hardware and software functionality guarantees highly precise measuring results for every tool and creates true added economic value.

he “handy” and functional design of the operating elements, and the ergonomically designed separate »cockpit« operating unit create true added value and unique operating comfort. The futuristic redesign of ZOLLER’s classic »eQ« one-hand control handle, „beams“ — not only with a new, ergonomically adapted form and integrated LED light, but also because it enables preprogrammed functionalities like spindle clamping using the newly included function button. The »venturion« is equipped for the highest demands, providing professionals maximum flexibility and the greatest precision, as one expects from a ZOLLER product. With features such as the »ace« highprecision spindle, a high-end camera for even the smallest tool geometries, options such as RFID technology for reliable process data transmission, and comprehensive software capabilities, this device offers the right setting, measuring, and inspection solution for every application. For Beginners in Tool Presetting: »smileCompact«, the “Mini-Must-have“ NEW: The “mini-must-have” »smileCompact« is ideal for small operations or as a second device for simple, efficient tool presetting. This rugged, entry-level model scores big points with unrivaled cost-effectiveness and maximum performance.

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Choose from a Variety of Measuring Ranges and Image Processing Technologies with »smile« The »smile« accomodates measuring ranges of 350 to 800 mm maximum tool length and tool diameters of 320 to 620 mm. A choice of three powerful image processing technologies guarantee the right performance range: »pilot 1.0«, the basic version for simple presetting and measuring of standard tools; »pilot 2 mT« with modern touch-operation technology and user-specific menu guidance; and »pilot 3.0«, which covers the entire bandwidth of tool measuring, inspection and management. Ready for Networked Manufacturing ZOLLER creates added economic value for today, and new prospects for tomorrow: All presetting and measuring devices are ready for the networked manufacturing of the future. Process security is guaranteed, thanks to intelligent software developed in-house and the highest security standards. The system securely and reliably transmits tool data to machines made by any manufacturer, and commonly available third party systems. From ERP and CAM systems, to cabinet and lift systems, all can be networked easily with ZOLLER. With a focus on the future, Industry 4.0 requirements of tomorrow are already a reality today. For more information, Website: www.zoller.info

The new »eQ« one-hand control handle creates true added economic value due to its unique user comfort and an additional functional button

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Choose between measuring ranges for a maximum tool length of 350 to 800 mm and tool diameters from 320 to 620 mm with »smile«

TECH TRENDS

EMAG PECM radically shortens toolmaking processes Many branches of the industry need highly challenging, complex tools for their mass production. These are often one-offs with precise shapes and contours, perfect for the precision electro-chemical machining process (PECM) from EMAG. The PECM process has a number of advantages over EDM (eroding) When tools and molds are subsequently machined in presses or punching machines, they are subject to enormous loads. This is why they are frequently made with highly heat-resistant materials, the tensile strength of which achieves their necessary service life. The question is: how can these materials be machined with precision? Cutting processes are here often pushed to their limit and the life expectancy of milling cutters is continuing to decrease. EDM or PECM? In the past, toolmakers frequently relied on the EDM process, where an electrical discharge between an electrode and the workpiece removes the material. But eroding has one enormous disadvantage: it is a slow process. In addition, heat enters the workpiece, and has a negative effect on the life expectancy of the component contour produced. Now, PECM technology is here and is an excellent alternative! It’s noticeably faster and produces parts with maximum surface quality – without burr formations and with no changes in material structure, as no heat enters the component. And (unlike the eroding process) tool wear is minimized. Radically shortened processing times The basics of the process are quickly explained: The workpiece becomes the positive anode, the tool the negative cathode. An electrolyte solution flows between the two and removes metal ions from the workpiece. The tool is contoured in such a way that the metal removal results in the creation of the

MACHINE TOOLS WORLD JULY 2017

desired component contour. The PECM technology is a development from EMAG that provides a particularly effective metal removal capability and noticeably shorter processing times. The process is currently used in the manufacture of forging dies for large

batch production in the automotive industry, where it has been possible to reduce the processing time of the component from 6 hours (with EDM) to 1.2 hours. It is also expected that the life cycle of the finished forging die will increase by 20 to 30 percent. This does, of course, quite noticeably reduce the production costs of automobiles. And it is exactly this massive advantage that EMAG ECM wants to push more emphatically in the market place. “The tool and mould makers have to work harder on standardising their processes, with a greater focus on processing times. That will make it hard for the users to ignore PECM”, summarises Richard Keller, board member at EMAG ECM. Benefits: • Reducing machining times with PECM • Surfaces of maximum quality • No changes in the material structure of the tool.

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TECH TRENDS

Rollon: Reducing Linear Bearing Wear

Unlike recirculating ball linear guides, Rollon’s Compact Rail system utilizes large rolling elements that can pass over any debris that fall into the rail.

Rollon’s Compact Rail ball bearings are permanently lubricated and sealed within the rollers, which isolates these small rolling elements from contaminants.

o get the longest working life out of a linear bearing you must keep it clean and well lubricated but in the real world of round-theclock, high-cycle manufacturing operations, bearings do get dirty and dry. And when either of these conditions happens, linear bearings will wear prematurely. In the worst case scenarios, contamination and inadequate lubrication can create metal-on-metal contact between the bearing’s rolling elements and raceway. This can cause excessive wear in the form of denting, pitting or galling results. This warning about contaminants and the importance of lubrication will not come as news to anyone who has designed or worked around industrial machines. When using linear guides on medical, food, packaging, semiconductor or other sensitive equipment, machine builders often take extraordinary measures to keep the contaminants out and the oil in. They may add expensive bellows to cover the guides, or they may opt for a

MACHINE TOOLS WORLD JULY 2017

pricey automatic greasing system. Yet in their zeal to keep linear motion systems running smoothly, machine builders can overlook less expensive design solutions to contamination and lubrication issues. COmbating Contamination Contamination comes in many forms, some more aggressive than others. Metal chips from machining operations, for

example, qualify as one of the biggest offenders from a wear perspective. Silicon dust produced during semiconductor manufacturing can also be tough on linear bearing surfaces. Modern manufacturing processes can throw off a long list of other abrasive, wearinducing contaminants. Less aggressive contaminants can pose problems too. Even soft contaminants such as those found in food processing

Rollon’s Compact Rail ball bearings are permanently lubricated and sealed within the rollers, which isolates these small rolling elements from contaminants.

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TECH TRENDS can gum up linear bearings. This kind of debris is not necessarily a wear issue, but it can keep the linear motion systems from functioning smoothly. Consequently this can have a negative impact on positioning accuracy and product quality. If a linear bearing gets gummed up to the point it stops working, then there are also potential maintenance and downtime costs. Keep in mind, too, that contamination is a two-way street. In addition to worrying about contamination from the product interfering with the linear motion system, machine builders also worry about stray lubrication or particulate from the linear bearing contaminating the product. This type of machine-to-product contamination is a cause for concern in contamination-sensitive industries such as medical, semiconductor and electronics. To combat contamination, machine builders will often supplement the linear bearing’s built-in seals with bellows or other types of covers. Though these can substantially add cost to a machine and add to the maintenance burden, they do have their place. Some clean-room environments, for example, may require some physical barrier between the product and the machine elements. And inside machining centers, it is crucial to physically protect any motion systems from metal chips. But there are many less severe contamination scenarios. And in these cases, machine builders should consider bearing styles that are less affected by contamination and less prone to generate any of their own. Bearings with large, sealed rolling elements fall into this category. With conventional linear guides, the tiny recirculating balls in a raceway have very little clearance. So even a relatively small pieces of debris can interfere with the balls. Bearings based on larger diameter rollers, by contrast, can roll right over even relatively large contaminants. Rollon’s Compact Rail system, for example, is built around rollers that are from 14 to 50 millimeters in diameter. These linear bearings can roll over all kinds of contaminants that can stop smaller rolling elements dead in their tracks including metal chips, plastic particulate, paper dust

MACHINE TOOLS WORLD JULY 2017

The Compact Rail slider incorporates an integrated wiper (see inset) that automatically satisfies the systems minimal lubrication requirements.

and more. Large rollers are also more damage tolerant than smaller rolling elements. Even if a contaminant does happen to mar the roller or the rail surfaces, the large rolling element can usually keep on running. Well-Oiled Machines Lubrication problems are often described in terms of not enough grease or oil. And sometimes that is the case as lubrication leaches out or is squeezed out of linear bearings, leaving them susceptible to metal-on-metal wear. There is a flip side to the lubrication issue too. Maintenance workers, with grease guns in hand, often over-lubricate linear bearings, potentially blowing out seals and introducing oil into environment. And keep in mind that lubrication also qualifies as a contaminant. So over-lubed bearings can also worsen contamination problem or force machine builders to opt for bellows or physical covers. Getting just the right amount of lube into a linear bearing at the right interval can be tricky because it depends on application-specific factors such as the type of bearing and the duty cycle. The application’s sensitivity to oil contamination comes into play too with sensitive industries demanding lighter lubrication schedules. There are ways to make sure linear bearings stay properly lubricated throughout with little intervention on the part of maintenance workers. On the expensive end of the system are expensive automatic greasing systems. These systems are a legacy of the linear way systems used in the machine tool industry. The auto-greaser was crucial for maintaining the film of oil that separate a linear way’s bearing surfaces. Some of these expensive auto-lubrication systems have made their way into applications that employ more modern linear guides, and they can be a valid way to get the lube levels right while reducing the

maintenance burden. But aside from their cost, auto-greasing systems can introduce unacceptable levels of contaminant into the factory environment which, again, will create problems is an issue in clean-room and other sensitive manufacturing operations. A lower-cost, cleaner alternative to automated lubrication exists in the form of self-lubricating wipers that integrate into the linear bearing’s carriage. Rollon, for example, has an optional self-lubricating wipers on its Compact Rail system. These provide lubrication for 2 million cycles before they need to be refreshed, and they cost a fraction of what PLCcontrolled auto-greasing systems cost. The very idea automatic lubrication is the only way to achieve optimal lubrication is somewhat outdated. Some linear guides, such as those based on recirculating balls, do require regular lubrication in all applications. But bearings based on sealed rolling elements may not need much, or any, external lubrication at all in many applications. With Compact Rail, the roller acts as a true sealed bearing. Its ball bearings, raceway, and their lubricant are contained inside the outside housing of the roller. The need to add lubricant between the roller and the profiled rail thus becomes less important or even unnecessary in light duty applications. This capability makes a big difference in contamination-sensitive applications industries that would normally resort to expensive bellows or covers to keep stray oil off their shop floors, out of their air and off their products. For more information, Rollon India Pvt. Ltd. 1st floor Regus Gem Business Centre 26/1 Hosur road, Bommanahalli Bangalore 560068, INDIA Tel.: +91 80 67027066, Fax:+91 80 67027004 E-mail: info@rollonindia.in Website: http://www.rollonindia.in

TECH TRENDS

Mastercam’s MachiningCloud connection is now available

astercam and MachiningCloud jointly announce that with the release of Mastercam 2018, Mastercam is now connected to MachiningCloud, thereby providing Mastercam users access to the cutting tool knowledge and product data available within the MachiningCloud. This partnership provides Mastercam users access to MachiningCloud’s cutting tool product data from within Mastercam. Customers now have direct access to complete and up-to-date cutting tool product data, from the leading cutting tool manufacturers available on the MachiningCloud. With the completed Mastercam MachiningCloud connection, key benefits are available to customers: • Search for tools from multiple manufacturers quickly in one place • Access manufacturer’s expert cutting tool recommendations • Quickly filter a universe of possibilities down to an optimum solution for a given workpiece • Import the selected product data into Mastercam for programming • Utilize the 3D models for simulation and 2D drawings for documentation “The mission of MachiningCloud is to bridge the gap between physical cutting tools and digital shop software, and streamlining the programming process to save time and increase accuracy,” says Christophe Rogazy, Director of Product Management for MachiningCloud. “By bringing together valuable cutting tool data and knowledge in one application, this simplifies the cutting tool search process and gives users many more options and helps them make better tooling decisions. By joining forces on MachiningCloud, Mastercam

MACHINE TOOLS WORLD JULY 2017

ensures greater and more seamless flow of information throughout its customers’ shops.” Says Rich Taft, Product Development at CNC Software, Inc., ”Accurate tool definitions are a critical factor in achieving safe and efficient toolpath motion. MachiningCloud offers a wide variety of tooling options that make it easy to import well-defined tools into Mastercam.” About Mastercam Developed by CNC Software, Inc., Mastercam is Windows®-based CAD/ CAM software for 2- through 5-axis routing, milling and turning, 2- and 4-axis wire EDM, 2D and 3D design, surface and solid modeling, and Swiss machining. Privately owned and founded in 1983, CNC Software provides CAD/ CAM solutions to more than 224,000 installations in 75 countries in industries including moldmaking, prototyping, automotive, medical, aerospace, consumer products, and much more. About MachiningCloud MachiningCloud is dedicated to leading a digital shift within the discrete manufacturing industry to deliver a new level of operational efficiency. Cloudbased applications, resources, services,

knowledge, and digital product data from the world’s leading manufacturers of cutting tools, machine tools, workholding and specialty products are providing efficiency improvements by facilitating the flow of data to and from today’s data intensive shop-floor. For cutting tool manufacturers and their customers, the MachiningCloud app is an Industry 4.0 solution delivering up-todate cutting tool manufacturers’ product knowledge and data, fast-tracking cutting tool selection, CNC programming, simulation and shop floor operations. By providing data from the world’s leading suppliers, MachiningCloud eliminates the hassles of searching through printed catalogs, telephone calls and multiple websites to find optimal tooling, while also removing the burden of manually typing tooling data into CAD/CAM software.

For more information, Website: www.mastercam.com www.machiningcloud.com

TECH TRENDS

The age of men is over. The time of the Machines has come

n the movie, The Lord of the Rings, while marching on to Minas Tirith with huge thundering army of Orcs, Gothmog, lieutenant of Morgul (The land of the Dark), announces ‘The age of men is over. The time of the Orc has come.’ Gothmog’s confidence resonates with the situation of 3 Axis machines in the Metal Cutting Industry today. An industry which turned around with the advent of the Computer Numerical Control technology and the introduction of Vertical Machining Centres (VMC) and Horizontal Machining Centres (HMC) has now hit a plateau in its development of 3 axis machines. And while there have been developments in the form of 4th axis and 5th axis machines, these machines are yet too expensive to completely replace 3 axis machines. 3 axis machines themselves have a few distinct advantages such as Rigidness of construction, lesser machine cost as compared to 5 Axis machines, availability of trained manpower, standard workholding and tools available at reasonable costs and service support. While these advantages make 3 axis machines the most popular machines in the metal cutting industry, flexibility for angular machining is still a major lacuna. UCAM’s rotary tables are a ready solution to improve the flexibility of 3 axis machines. UCAM’s solutions include: • 4th Axis Rotary Tables – for positioning or continuous interpolation of job • 4th & 5th Axis Tilting Rotary Tables for compound angle positioning and interpolation of job • Multi Spindle Rotary Tables for multiple part machining simultaneously

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time. With the need to change fixtures or transfer parts eliminated, using UCAM’s Rotary Table or Tilting Rotary tables, the throughput time is reduced effecting into lower cost per component and increasing the profits.

• Large Size Rotary Tables for heavier and voluminous components These solutions are available in standard configurations but may also be customised to serve your machining needs. Following are advantages that UCAM’s rotary tables offer to your existing 3 axis machining system: 1. Indexing and Machining at angles: Machining at different angles on a 3 axis machine is difficult and time consuming. Rotary tables provide this much needed flexibility for your 3 axis machine. For component positioning and machining at angles, UCAM’s CNC Rotary Table or Multi Spindle Rotary table would be an ideal solution. For mass volume automotive components UCAM’s Rotary Production System is the right choice. For high speed and precision machining of components the Direct Drive Rotary Table with zero backlash is an ideal solution. 2. Setup time Reduction / Elimination: A process which may usually take 2, 3 or more setup changes for a standard automotive part machining, may be completed in just a single setup. This reduces or even eliminates the time taken for part setup and fixture change. 3. Lowering Throughput Time: The business of automobile part machining is all about lower throughput

4. Dedicated Workstation to Flexible Workstation: In a routine shop floor 3 axis machines are dedicated to a certain metal cutting process. This may be due to setup changes required in machining or to balance the production line. With UCAM’s solutions, each machine becomes an entire production line in itself. With the need to change setups drastically reduced or even eliminated, the 3 axis machine becomes a flexible workstation completing part machining in one go. 5. Reduced Rejections: When a part is machined partially and moved or transferred to a second setup, an inaccuracy is added due to the changed position (location, resting and clamping of the part). UCAM’s Rotary Table solutions allow the machining to be completed in a single setup thus reducing the stack up of inaccuracies and hence component rejections. The metal cutting machining world is moving fast towards intricate designed geometries and precision machined components. The demanding customer now requires such precision machined parts faster. Through UCAM’s well engineered solutions you can deliver and exceed your customer’s expectations. With UCAM…you can!

For more information, Website: www.ucamind.com.

TECH TRENDS

Higher Precision for Machining Centers in Automated Large-Batch Production

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

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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 (Figure2), 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

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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

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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]

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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.

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)

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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.

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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

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TECH TRENDS

Automation in sheet metal cutting and welding The paper examines welding and cutting process trends in the sheet metal and plates used in various industries like automobiles, infrastructure, ship building, aerospace industries, wind tower manufacturing etc. Productivity gains in arc welding are reviewed, and the increasing use of laser cutting and welding, as well as laser-arc hybrid welding, particularly in Europe, is discussed and explained. Some friction technologies are already widely adopted, but they could make more impact with further development. Electron beam welding could also be used with economic benefit in some situations, but as with all non-arc processes, it will only be adopted if significant gains in productivity and cost reduction can be created to justify the more specialist welding equipment required. Many productivity improvements can come from non-welding activities in the fabrication process. 1. INTRODUCTION Leadership in manufacturing (welding and Cutting) can come from addressing the factors of QUALITY, COST, PRODUCTIVITY, SAFETY and CONTINUAL UPGRADATION OF TECHNOLOGY. Inflection in Metal Fabrication Technology has taken place in the Manual / Semi-Automatic Welding Power Sources - (Digital control inverters), Welding Automation - (Developments in HNG SAW, HNG MIG, Tandem MIG / SAW, Friction Stir, Electron Beam, Saddle Welding Automation, Robotics, Laser spot welding, Hot wire TIG, Orbital systems, automation with hybrid welding systems like Plasma â&#x20AC;&#x201C; MIG, Laser - MIG) and major advances in the cutting processes (Precision Plasma, Laser Cutting, Waterjet cutting etc.). This paper reviews current trends in arc welding and cutting processes used for Sheet metal processing and will discuss some of the newer processes which are beginning to replace arc welding for such steels, or have potential to do so in the next 10 years. 2. ADVANTAGES OF AUTOMATION a. Consistency in weld result - Error Proofing: A welding supervisor can limit the amount of changes an

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operator can make during a program, preventing him from accessing the override screen through the use of a key switch or password. Multiple parameters for multiple weld-run: In addition to the ability to adjust parameters between weld passes, operators of microprocessorbased welding machines can also program changes to weld parameters during each pass, which offers distinct advantages for certain applications. Store parameter for sharing on other machines with same applications: A microprocessor-based power source can store programmed welding procedures on data cards. This allows the operator to easily transfer programs developed on one machine to other machines being used either in the same facility doing the same type of work. Quality control: Microprocessorbased machines can immediately alert the operator if weld parameters fall outside pre-selected limits. Parameters can be directly to a quality-control computer program for storage or statistical analysis. This eliminates time-consuming radiography in many applications. Date storage and records: It is now

very easy to display a set of welding parameters and operator or supervisor can observe the welding procedure. Moreover, the data can be printed in the form of reports, which can be presented to the customer as quality assurance procedure. f. Quicker Weld-Fault diagnostics lower repair time: The system can be stopped if the measured values cross a certain preset variation limit. It is possible to stop the machine in out-oftolerance conditions. This enables the operator to perform timely functions and take necessary steps to prevent the deposit of faulty welds. 3. TANDEM MIG AND ROBOTIC WELDING Significant improvements in productivity are nowadays hard to gain in this mature process. In gas-shielded MIG/MAG processes, the growth of tubular wire over solid wire is still slow despite the deposition and bead shape benefits of the former although tubular wire usage is higher in the USA and Japan compared to other parts of the world. The lower price of solid filler wire, particularly in Europe, is still a dominant factor that continues to favour their use. Selfshielded cored wires are still widely used

TECH TRENDS in the USA but less so in Europe because of the fall-off in fabrication of large offshore installations. Care is always needed in selecting self-shielded wires if weld metal toughness is a critical design factor. Schematic of Equipment for TANDEM MIG

installations per annum, but generally robot take-up for welding is still majorly for the automobile sectors. Robots are being employed in situations where product repetition and/or tonnage throughput are high, combined with relatively standardised designs. Robot profile cutting is increasing in usage and in Japan, some building frames are now being welded on robot lines and agile robots are also used for site welding building column joints at height. The applications most suited to robot use involve butt and fillet welds in the fabrication of beams, welding of stiffeners to beams, welding of end plates and the assembly of panels or decking. A likely trend is to ‘take robots to the work’ and use them for large part and sub-assembly manufacture in cells which house autonomous vehicular robots. These robots, mounted on moving platforms are manoeuvred around the parts to be welded and are capable of all-positional welding using the MAG process with tubular wires, (Fig.2).

Fig. 1: TANDEM MIG

Advantages of TANDEM MIG: • Exceptional welding speeds • High weld metal deposition rate • Superior weld quality: ◊ Reduced heat input ◊ Resists burn-through on thin materials ◊ Maintains low spatter levels ◊ Produces good penetration on thick materials ◊ Improves bead wetting at weld toes ◊ Resists undercut • Bead profile control • Lowers production costs • Increases productivity The greatest potential for productivity improvements comes from using robots. Japan still leads the work in new robot

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Fig.2. Schematic diagram showing autonomous robot vehicle navigated by vision system, being used for all positional MIG / MAG welding

4.NARROW GAP SAW In submerged arc welding, multi-wire, iron powder additions and narrow gaps are common ways to increase productivity. However, the use of tubular wires is increasing in popularity and can offer better weld quality compared to solid wires in some situations, e.g. when submerged arc welding of primed plate. In building and bridge construction MIG/MAG welding is more suited to automation and is now beginning to replace submerged arc welding, reducing costs and distortion significantly.

5 . LASER – IN CUTTING AND WELDING Low power CO 2 lasers were originally developed in the late 60s for cutting and welding operations, while Nd: YAG lasers entered the market only in the early 1980s. In the shipbuilding and off-road vehicle sectors, higher power lasers (3-10kW CO 2 and 2-4kW Nd:YAG) have become popular in the last decade because their use brings more precision in dimensional control, and greater accuracy in assembly, as well as the additional advantages of high cutting and welding speeds, and cleaner working. Laser cutting is now an essential route to accurate assembly in steel fabrication. Parts can be cut to a precision of ±0.3mm in 10 metres compared to ±1-2mm for conventional plasma cutting. Sub assemblies can then be arc welded to tolerances of a few millimetres in 15 metres, with the same lasers being used for marking and hole drilling on the cutting table. Even though arc welding is still regularly used for assembly of laser cut parts, cost reductions can be dramatic because of the improved accuracy of assembly and the potential for eliminating distortion correction and other processing operations downstream from welding. Direct costs have been cut by up to 50% using lasers for cutting in many shipyards, and this shows the extent of benefit which could follow from more widespread use of laser cutting in building, bridge and public infrastructure construction.

Fig.3. A typical laser welded sandwich panel and advantages over conventionally stiffened panels

6. LASER-ARC HYBRID WELDING There is tremendous interest in the use of CO 2 laser-arc or Nd: YAG laser-arc for steel construction at the present time. The concept has been around since 1978 and was actively developed in Aachen in the late 90s using high power CO 2

TECH TRENDS

Fig. 5.Schematic diagram of the FSW process: (A) Two discrete metal work-pieces butted together, along with the tool (with a probe). (B) The progress of the tool through the joint, also showing the weld zone and the region affected by the tool shoulder.

Fig.4a. Nd:YAG laser - MAG hybrid process being developed for land pipeline girth welding. Picture of the welding head

Fig.4b. macro section showing MAG root and cap beads & central hybrid weld bead

lasers in combination with one or two MAG torches directed into the same weld pool in series with the laser. Already one shipyard in Germany has such a system in production on a panel line, the process replacing submerged arc welding. The advantages of moving from simple arc processes to a hybrid laser-arc system include higher joint completion rates and associated control of distortion. As noted above, laser systems alone are usually not sufficient to cope with variations in joint gap in large structures. However, where plates are thin, it is possible to produce stiffened panels successfully by laser welding. 7. FRICTION TECHNOLOGIES There have been many exciting develop-

MACHINE TOOLS WORLD JULY 2017

ments in friction welding and probably more process innovation in the last decade than in the previous 40 years when friction welding first came on the scene. In the context of metal joining and construction, friction stud, radial friction and friction stir welding are good examples of more recent approaches, with friction stud already being used in the production of sandwich structures comprising steel skins and a concrete core and for welding attachments in high volume such as shear connectors and reinforcing bars to end plates. Attachment of anodes under water to offshore installations using steel studs and electrical connections to railway lines are other applications of friction stud welding. APPLICATIONS Shipbuilding and Offshore, Aerospace, Automotive, Railway Rolling Stock, Fabrication

8. ELECTRON BEAM TECHNOLOGY There have been several key improvements in this process in the last decade which have made EB welding increasingly attractive for large-scale fabrication of steel structures such as buildings and

bridges. The two main areas of improvement are in gun development and reduced pressure technology. Reduced pressure electron beam welding system Reduced pressure EB welding using chamber pressures of around 1mbar has been another major step forward in simplifying EB welding operations. The beam shape and beam penetration at, say 5mbar, is identical to that at the

TECH TRENDS www.mtwmag.com

more conventional pressure for EB welding of 5 x 10 -3 mbar. This reduced pressure option does away with the need for large vacuum chambers and worries about leaks and seals. Simple mechanical pumps and local seals are sufficient to achieve ~1 mbar. These systems are also more tolerant to fluctuations in working vacuum pressure, gun to work distance and work-piece cleanliness. 9. WIND TOWER MANUFACTURING – SPECIALIZED CUTTING AND WELDING PROCESS APPLICATIONS Wind Tower fabrication employs extremely precision applications of metal cutting and welding processes like gas cutting triple torch, with Single pass three torch cutting Automatic setup which provides High accuracy, Capacitive height adjustment, Infinite rotation of cutting head, Automatic angle adjustment 20 - 50° (Option for 30 - 60°). In addition, plasma cutting system is used with Automatic Setup, Highest Accuracy, and Bevel angle adjustment: +/- 52°, Initial height setting with tactile sensor, Cutting height adjustment via automatic arc voltage sensing process. Precision High end CNC Plasma cutting process is utilized with high degree of automation needed to guarantee consistent quality. Programming software, Numerical control and Automatic rotating bevel tools are used to dispense with manual tasks. Automated SAW systems with

Twin Wire, Tandem, Tandem – Twin and Multi – wire systems are used along with customized welding heads, wire feed systems, joint tracking systems, Column and Booms, TELBO systems, Rotators and Positioners. In addition, Tractors and Fit – up units are all used for this application and also for many other welding applications. 10. CONCLUDING REMARKS Where will engineering construction be in five years time? Productivity improvements can come from many different areas in the total fabrication process, e.g. general design, detailed

design, contract drawings, CNC instructions, cutting and profiling, welding, inspection, finishing etc. It needs to be realised that optimising the welding process and procedure in isolation may have only a small effect on overall productivity. As an example, fabricators in the bridge and building sector continue to make big improvements in reducing the cost per tonne of steel fabricated by focussing on efficiency improvements in non-welding operations. These non-welding areas will continue to receive much attention in the next few years. For example, 3D solid modelling is expected to be at the heart of the improvement process enabling virtual assembly, direct instruction of cutting and welding machines, computer modelling of metal processing and welding operations and optimising of welding sequences. In addition automated inspection and data gathering will increase in usage to give more comprehensive Quality Assurance. Productivity improvements could also come from greater standardisation in steel specifications and in joint details and from modularisation of large structures to reduce the time spent on site fabrication and erection. Use of new welding processes and an increased use of automation and robots will take place slowly and gradually, only being justified where the introduction creates significant gains in productivity or cost reduction. As such, these changes can be expected particularly in situations where skilled labour is short, where welding cells can be kept fully occupied or where customised, made to order components are needed. (Contributed by Ador Welding Ltd.)

For more information Web: www.adorwelding.com

JULY 2017

MACHINE TOOLS WORLD

CASE STUDY

UP Tool successfully delivers on an aggressive growth strategy A specialist South Korean tool manufacturer, U P Tool, is investing in automation to increase production while reducing man hours

ounded on August 1st 2012, UP Tools originally purchased one ANCA RX7 to make special custom tools and medical implants. Business partners Sung-Jae Lee and Byung-Seung Choi have since grown their facilities to have 12 CNC machines, including ten ANCA CNC tool grinders and two cylindrical grinders. Lee, joint representative director said: “We think our aggressive growth strategy - having installed 12 machines in three and a half years - has been challenging but we have learnt some important lessons along the way.” “Our Chief Technology Officer ByungSeung Choi, has a lot of experience in tool processing technology and benchmarking the capabilities of cutting tools. To grow as rapidly as we have, Choi advised investing in more ANCA technology for its flexibility and efficiency.” “In the beginning we produced special custom and medical implant tools and from there we entered the standard end mill and customized cutter market. When

MACHINE TOOLS WORLD JULY 2017

the mobile sector started using smart phone technology we knew it was a good opportunity but needed the cylindrical function and laser measurement available in ANCA machines to enter that market. Investing in our machines gave us the capability to provide customers with optimized tools for mobile quickly with a fast cycle time while producing complicated shape processing. It set us apart from other suppliers.” “Another challenge we face is keeping up volume without having people manage the machines 24 hours a day. The government in South Korea has mandated shorter working hours and even though we have grown to eight people we needed something else to enable us to meet our customer’s needs. The automation available on ANCA machines has been a great help in this regard. With the automatic loading system and Management Suite software, tools like Production Monitoring

will mean we can maintain our competitiveness with less operator hours but not being concerned about reduced quality.” Constant evolution

“Like other industries, the tool industry in constantly evolving, experiencing shorter product cycles and increasing demand for tools in a variety of shapes. In addition, due to technological advances in 3D

CASE STUDY www.mtwmag.com

The automation available on ANCA machines has been a great help in this regard. With the automatic loading system and Management Suite software, tools like Production Monitoring will mean we can maintain our competitiveness with less operator hours but not being concerned about reduced quality.” printing, competition with other industries is inevitable. To future proof our business, we will continue to focus on research and development and invest in technology. Furthermore, given our success in Korea, we plan to aggressively expand our presence not only the US, Vietnam, Japan, Thailand, Hong Kong

and China but also in other countries “Our motto at U.P.Tool is Promise, Trust, Relationship and Partnership and I think success of every business starts with the above four words. I look forward to continuing to work with ANCA so that we can continue to succeed together.” Lee concluded.

- Lee, Joint Representative Director

JULY 2017

MACHINE TOOLS WORLD

CASE STUDY

KOMET GROUP innovates cutting tools using metal 3D printing technology The group is using Renishaw metal additive manufacturing technology to produce new ranges of innovative cutting tools

ermany’s KOMET GROUP is one of the world’s leading suppliers of precision cutting tools and has supplied innovation to the machining industry for almost 100 years. The Group, which has its headquarters in Besigheim, currently employs more than 1,500 people, including its subsidiaries, and is represented in around 50 countries. KOMET GROUP is a global technology leader in the fields of high-precision drilling, reaming, milling, threading and process monitoring. In addition to developing, manufacturing and distributing high-quality premium products, the company uses its years of technical know-how to analyse customers’

MACHINE TOOLS WORLD JULY 2017

production processes, right down to the smallest detail, and then develop tailored solutions to help them achieve greater efficiency for all stages of their machining. With such a strong focus on innovation and continuous development, it was perhaps inevitable that KOMET GROUP staff would come up with some tooling designs that were too expensive, or even impossible, to make with conventional manufacturing methods. As a result, Dr. Reinhard Durst, Research and Development Manager for hard metal tools at KOMET GROUP, has been investigating the potential of additive manufacturing for tooling production and the equipment available on the market for several years.

CASE STUDY www.mtwmag.com

Dr. Durst has been working with Renishaw for the last year, “because its offer has convinced us from a technical as well as an application point of view.” This transfer of knowledge and knowhow is inherent throughout Renishaw’s new and growing network of Additive Manufacturing Solutions Centres. Before buying the machine outright, customers can lease the latest Renishaw equipment at a Solutions Centre and work independently on their projects. Renishaw staff are always available to provide advice on the use of the machines. In this way, potential customers can familiarise themselves with additive manufacturing technology, with expert help on hand, and discover how it might meet their specific requirements, without the need for a large up-front investment. “We are aiming for a win-win situation,” explained Ralph Mayer, the manager responsible for additive

manufacturing services at Renishaw GmbH. “With our support, the customer shortens their learning curve and reduces the number of potential mistakes to a minimum. We only raise the question of purchasing a system when the customer is clear that it will provide added value for them. At the same time, we gather valuable information about the needs of the industry, which we can use to develop our machines and technology further “Parts produced with additive manufacturing can reach an up to 99.9 percent consistent structure, just like rolled or cast metal components,” explained Mr. Mayer. “However, the correct strategy must be applied for every component. Our strength lies in our skill in analysing the technical challenges of our customers’ components and working with our customers to find the most effective solution.” Renishaw’s metal additive

manufacturing system uses laser powder bed fusion technology in an inert argon atmosphere. An extremely thin bed of metal powder is laid down and areas that will form the component are melted using a high performance ytterbium fibre laser and then solidified on cooling. This process is repeated with layers of metal powder, typically between 20 and 60 μm thick, until the part is finished. The thinner the layers, the better the accuracy and surface quality of the finished part. Results

The first of the projects handled jointly between Komet and Renishaw was the development of a new range of PCD (PolyCrystalline Diamond) screw-in milling cutters. The main bodies of the cutters are manufactured on a Renishaw metal additive manufacturing system, with multiple bodies produced during each cycle of the machine, and then fitted with PCD blades

JULY 2017

MACHINE TOOLS WORLD

CASE STUDY

“Renishaw has contributed a wealth of knowledge to help us find the parameters that are needed to produce a good tool” Dr. Reinhard Durst, R&D manager for hard metals, KOMET GROUP

KOMET JEL® screw-in cutter.

MACHINE TOOLS WORLD JULY 2017

and screwed onto their tool holders. The use of the Renishaw technology to manufacture the tools allows geometries to be produced that would be almost impossible by conventional means. “Thanks to the additive process we have been able to place many more PCD blades on each tool,” explained Dr. Durst. “We have changed the arrangement of the blades and achieved a substantially greater axis angle. Compared to conventional milled tools, we have greatly shortened the grooves. These changes mean that the tool is a lot more productive for the user.” For example, with a 32 mm screw-in head, the number of grooves and blades has been increased from six to ten, achieving a feed rate that can be up to 50% higher. In addition, the ability to optimise the paths of the coolant channels ensures that each cutting edge is supplied precisely with coolant through a separate channel, while the external design of the bodies helps to ensure that chips are removed reliably from the face of the tool AM also offers the potential to reduce component weight since material can be used only where it is necessary for the optimum functionality in the component. It also outperforms conventional production methods in terms of delivery time for any special or experimental tools

needed by Komet’s customers. “The ability to freely design the internal and external tool geometry alone means that excluding this additive process from our future plans would be inconceivable,” predicted Dr. Durst. “It gives us the ability to increase tool performance and productivity to such a great extent that it creates considerable added value for our customers.” Dr. Durst considers the decision to work in partnership with Renishaw to be fully justified. “It is not easy for a company that is new to metal additive manufacturing technology to work out the best laser parameters on its own,” he claimed. “Renishaw has contributed a wealth of knowledge to help us find the parameters that are needed to produce a good tool. The new design freedom from additive manufacturing technology and the cooperation with Renishaw is helping us to develop even more innovative tool solutions,” says Dr. Reinhard Durst, R&D manager for hard metals, KOMET GROUP.

For more information Web: www.renishaw.com

Renishaw laser powder bed fusion technology

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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

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Hall 5, 6 & 7A, Bombay Exhibition Centre, WEH, Goregaon (E), Mumbai Around The World - In 11 Countries Taking Place Every Year

Machine Tools Machine Tools Accessories Automation & Robotics Tooling Systems Hydraulic & Pneumatic Pumps & Valves Fastner & Hardware Gears, Motors & Drives Electronics & Electricals Material Handling & Storage IT Enabled Services Testing & Measuring Power Tools & Hand Tools Welding Equipment & Consumables Newly Launched Products & SPMs

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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

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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

Mitutoyo Formtracer SV-C3200 Dual-purpose measurement and powerful analysis of surface roughness and contour combined with high accuracy, high drive speed and simplified CNC measurement Mitutoyo Formtracer SV-C3200 is designed to provide high accuracy and fast drives with time-saving features for increased throughput. The SV-C3200 employs a detector arm held by a magnet to expand the measurement range in the Z1 axis by 10 mm. This arm design also helps prevent interference with the workpiece to help avoid stylus damage. A precision arc-scale built into the Z1 axis (detector) allows the arc trajectory of the stylus tips to be read directly, thus minimizing error. The measuring system incorporates Mitutoyo’s ABS (Absolute) scale on the Z2-axis (column), which is designed to eliminate the need to reset the origin when taking repeated measurements. Formtracer SV-C3200 form measuring system works with Mitutoyo FORMTRACEPAK analysis software. Available in 15 language views, FORMTRACEPAK offers total support for measurement system control and comprehensive measurement analysis as well as generation of inspection reports. Additionally, this machine supports USB communications including output to measurement data applications such as MeasurLink, Mitutoyo’s proprietary statistical-processing and process-control program which performs statistical analysis and provides real-time display of measurement results for SPC applications.

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

• Measuring range: o X axis: 100 – 200mm o Z1 axis (detector unit): 800μm / 80μm / 8μm • Resolution o X axis: 0.05μm o Z1 axis (detector unit): 0.01μm (800μm range)/0.001μm (80μm range)/0.0001μm (8μm range) • Measuring speed: 0.02-5mm/s.

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.

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PRODUCTS SHOWCASE

Series Expansion – New Chip Breakers Added to MVX Indexable Insert Drill Series Mitsubishi Materials Corporation, Advanced Materials & Tools Company (President - Fumio Tsurumaki, Headquarters: 1-3-2 Otemachi, Chiyoda-ku, Tokyo) has added new inserts with UH breaker and UN chip breakers for the MVX indexable drill series. The existing MVX drill provides excellent economy due to the 4-corner insert design and achieves a high cutting performance as well as long tool life. This is due to the optimum positioning of the outer and inner inserts on the drill body. MVX has also received a favourable reception in the market place for deep hole drilling due to the availability of an L/D=6 version with the same high rigidity body as the standard length version. The new UH breaker, a strong cutting edge type with high fracture resistance provides longer tool life when drilling steels, high hardened steels and cast iron. Additionally the new UN breaker for aluminium alloys has been added to the range.

Features of the UH breaker and UN breaker For Product Enquiry Contact MMC Hardmetal India Pvt. Ltd. R.O.: 4th Floor, Nirmal Plaza, Survey No. 148, Hissa No. 4A/4B, Paud Road, Kothrud, Pune - 411 038, Maharashtra, India. Tel : +91 20 6520 8430, 2539 6824, Cell : +91 9890595858 E-mail: mayur.kulkarni@mmci.co.in Web: www.mitsubishicarbide.com

1. The new UH breaker, a strong cutting edge type for the inner insert position provides enhanced edge strength due to the negative geometry and wide land width. The PVD coated carbide grade DP8020 gives additional toughness and improved fracture resistance and is ideal for drilling of steels, hardened steels less than 45 HRC and cast iron. 2. The new UN breaker for aluminium alloy machining delivers substantially better welding resistance due to a sharp ground cutting edge and a polished rake face.

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

Following are some of its unique features:

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

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• • • • • • •

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

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

PRODUCTS SHOWCASE www.mtwmag.com

PANTHER Series Drills Indian Tool Manufacturers (ITM) – A division of Birla Precision Technologies Ltd., is now launching Panther - Drills, a new series of Superior quality drills. Panther series of drills are made out of finest grades of HSS premium materials. These drills are produced from our latest CNC Machines, with unique geometry to give better accuracy holes and best performance. These drills are developed to machine hardened steel materials like Stainless Steel, Nickel chromium Steel, Forged Steel, etc.

Advantages: • • • • •

Made out of Premium grade Steel - suitable for tougher work Materials Better rigidity gives longer life Special Point to reduce thrust force while drilling Wider flutes for optimum chip evacuation resulting increased Tool life Surface treated for maximum wear resistance

Size Range: • Panther Drills are manufactured in Metric series as per IS 5101 & Inch series as per BS 328 • Metric size: 3.0 mm to 13.0 mm • Inch Series: 1/8” to ½”

Applications: • • • • For Product Enquiry Contact Indian Tool Manufacturers (Division) Birla Precision Technologies Limited Email: itmth@indiantool.com

Panther Drills are suitable to drill on : Stainless Steel Forged Steel Nickel chromium steels and for tougher applications.

PANTHER Series of products are result of extensive study and continuous efforts put in by our Research and Development team, which has resulted in Superior Quality products which are better than every product in it’s category.

High efficient, more productive Rotary Table Model URX series UCAM added a new Rotary Table in its product portfolio, namely URX Series. This New series of Rotary Tables are having Higher Clamping Torque & better aesthetic view. Higher clamping torque allows the machine to work with higher cutting forces which in turn enhances the productivity of machine. Also it allows the user to go for a smaller size rotary table for bigger jobs thus reducing the overall cost. With its newly developed, FRP sheet guard, there is no doubt that it can’t miss one’s attention. For Product Enquiry Contact UCAM Pvt. Ltd. A-11 / 12, 1st Stage, 1st Cross, Peenya Industrial Area, Bangalore - 560058, INDIA Tel: +91 80 40744777, Fax: +91 80 40744711 Email: sales@ucamind.com Website: www.ucamind.com

Features: • • • • •

Pneumatic / Hydraulic Clamping Pre Loaded Axial Radial Roller Bearing Gear Mechanism – Motor to Worm Shaft Dual Lead Worm Gear set Vertical / Horizontal Mounting.

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PRODUCTS SHOWCASE

Double Disk Grinding Machine DUPLEX GRINDER WITH VERTICAL SPINDLE (DDV)

For Product Enquiry Contact Alex Machine Tools Pvt. Ltd. 8, Gaiwadi Industrial Estate, S. V. Road, Goregaon (W), Mumbai - 400 062, India. Tel.: 011-91-22-2874 3226 / 2874 3744 Fax: 011-91-22-2875 7319 E-mail: amt@vsnl.com Web: www.alexmachinetools.com

• This series is designed specifically for thin components orto suit automation in work feeding. • Optimum loading systems to suit customer need. • Sturdy forged spindle supported by precision angular contact bearings provides accurate finishing even under heavy duty loads. • Robust spindle drive design is through a splined sleeve and precision belt transmission to eliminate spindle deflection during grinding. • Accurate positioning of grinding wheels with zero backlash through a precision ball screw, anti friction slide and digital control. • Optimum entry angle for maximum accuracy through effective tilting of upper head with lower head in 2 directions. • Ample coolant supply via rotary union through two spindles. • Swing arm wheel dresser is hydraulically operated. • All controls are within easy reach of the operator. • Optional CMC Controls for Fully Automatic Grinding Cycle including dressing and compensation. • Optional Auto loading & unloading arrangement. • Optional Auto gauging and compensation provision.

Application Piston Rings, Circlips, Washers, Valve Plates, Pump End Cover, Gerotor, Bearing Rollers, Carbon Seals, etc.

The rich world of linear actuators

For Product Enquiry Contact Elesa and Ganter India Pvt. Ltd A-54, Sector -83, Noida - 201305 (U.P.) INDIA Tel. +91 120 472 6666, Fax +91 120 472 6600 Email: info@elesaganter-india.com marketing@elesaganter india.com Website: www.elesa-ganter.in

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Whenever ultimate distortion resistance and flexural strength are required from linear actuators when they move and position large masses in any installation position, linear actuators with dual support are the first choice. With the GN 491 and GN 492 double tube linear actuators, Elesa+Ganter offers the appropriate standard parts with a guide system consisting of two parallel tubes which allow different configurations and can therefore be adapted to highly specific requirements. While the GN 491 double tube linear actuator features a compact slider size, the GN 492 works with a double slider carrying a large adapter plate. In both models, the central trapezoidal thread spindle rising left or right runs on ball bearings and is mainly intended for manual adjustment using a handwheel, but can also be motor-driven via the journal if the appropriate lubrication is used. With a stroke along he chromed, low-maintenance steel tube guides within the standard range from 100 to 300 mm, the rolled steel spindle allows the guide nut - and therefore the slider - to be positioned with ultimate precision to a stroke of 0.2 mm / 300 mm. The unit is installed via the numerous fixing options including through and/or thread bores at the end pieces and at the slider. The specially designed flat recess of the through bores optionally take hexagonal screw heads or nuts, as well as the round heads of cylinder head screws. Other double tube linear actuators are available on request, for example with special slider sizes, with several symmetrically opposing sliders or sliders running separately and with central support. This means that Elesa+Ganter has the matching component for virtually all applications - and as always in ultimate quality and delivered the next day.

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WOHLHAUPTER / ALLIED MACHINE & ENGINEERING COMPANY

INSIDE FRONT COVER

ELESA AND GANTER INDIA PVT. LTD.

ELGI EQUIPMENTS LTD.

EMAG INDIA PVT. LTD.

ENGIMACH - 2017

109

MMC HARDMETAL INDIA PVT. LTD.

EPPINGER TOOLING ASIA PVT. LTD.

FIBRO INDIA PRECISION PRODUCTS PVT. LTD.

RAVISON'S CORPORATION

SAHAJANAND LASER TECHNOLOGY LTD.

FATTY TUNA INDIA PVT. LTD.

69, 97

ELECTROTHERM (INDIA) LTD.

NICKUNJ EXIMP ENTP P LTD

RAVIK ENGINEERS PVT. LTD.

HOSABETTU HEAVY MACHINERY LLP

KUKA ROBOTICS INDIA PVT. LTD.

RATNAPARKHI ELECTRONICS IND. PVT. LTD.

HEIDENHAIN OPTICS & ELECTRONICS INDIA PRAIVATE LIMITED

IMEX - 2017

B BIRLA PRECISION TECHNOLOGIES LIMITED

PG. NO.

QUAKER CHEMICAL INDIA PRIVATE LIMITED

Y YAMAZAKI MAZAK INDIA

32 - 33

YG CUTTING TOOLS CORPORATION PVT. LTD.

FRONT GATEFOLD

YOUNG BUHMWOO INDIA CO. PVT. LTD.

Z 23

ZOLLER INDIA PVT. LTD. JULY 2017

31 MACHINE TOOLS WORLD

115

Inside Story

Mr.

S. M. Sood Managing Director, Marposs India Pvt Ltd

My Lifeâ&#x20AC;&#x2122;s Goals Aim & Ambition: I aim to be always true to myself, my values and my morals and achieve whatever possible with self-efforts while being driven by hard work and determination. My ambition is to motivate people associated with me to develop mutual respect and be successfully happy in their personal and professional sphere.

Vision: I visualise my company as ever growing FAMILY in reaching pinnacle of success while following best practices. To contribute in same I aspire to put in my best efforts as employee, leader, mentor & guide for my colleagues.

Social Goal: I wish to give back to society and do my bit for the underprivileged. Child Care and Education is close to my heart.

Business Goal: Effect positive change with my experience and mentoring the starters in organisation. To Innovate and most importantly stand up to challenges and difficult aspects of the job to stimulate growth internally and externally.

My Leisure Choices Favourite Tourist Spot: Anywhere in Hills, where there is abundance of green and peace of nature. I also love to travel in Italy and enjoy the rich culture and rustic charm. Music I Like: Old Hindi and English Classics while being partial to Rafi and Cliff Richards. I also enjoy instrumental music. Sports I Love: I played cricket and football in my younger years and love following English Premier League, World Cup Football and Indian Cricket team.

Ask my Taste Buds Favorite food: Indian and Italian cuisine. Though my favourite is wifeâ&#x20AC;&#x2122;s home cooking, her baked cakes are simply irresistible. Favourite Drink: I like an occasional glass of red wine, and prefer something cool to drink.

In Awe of I Admire: My admiration goes to people who are good human beings and achievers in their own fields, be it work, art, sports or life as such. I also admire ordinary people in day to day life who go about living life like a mission. 116

MACHINE TOOLS WORLD JULY 2017

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

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