MACHINE TOOLS WORLD - MARCH 2018 by Divya Media Publications Pvt. Ltd.

Volume 03 No. 10 | March 2018 | ` 150

Pages 102 | RNI No. MAHENG/2015/64267

QUALITY CUTTING TOOLS

CEO CORNER Industry 4.0: The talk of the town Industry 4.0 is all about doing things differently — introducing automation and data exchange in manufacturing technologies. It includes cyber-physical systems, the Internet of Things, and cloud computing. The goal is the “smart factory” with cyber-physical systems capable of autonomously exchanging information, triggering actions, and controlling each other independently. This facilitates fundamental improvements to the industrial processes involved in manufacturing, engineering, material usage, asset performance and management, and supply chain and lifecycle management. Adopting an Industry 4.0 approach also provides the means to navigate change. Manufacturers are reinventing their business models to focus on value-added services, and/or entering new geographic markets or adjacent market segments. Today’s Industry 4.0-outfitted factories are empowered to drive productivity and keeps costs down while ensuring quality and consistency across manufacturing processes globally. The boundaries between production and management must disappear, and ERP, MES and other critical systems must form an integrated unit if businesses are to realize the growth opportunities presented by this new age of intelligent manufacturing. Evaluating the existing IT environment is the first step to understanding how ready — or unprepared — manufacturers are for Industry 4.0. Industry 4.0 may create disruptions in the labour market by eliminating some of the low-skilled and/or repetitive jobs, at the same time increasing the shortage of talented and highly-skilled workers. Developing Countries like India will have to rethink educational systems and encourage life-long learning in order to make human resources competitive and succeed in the fourth industrial revolution.

CEO

MACHINE TOOLS WORLD MARCH 2018

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 Shekhar D.

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

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) Kamlesh B. - 09819464242

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

Contents

Vol 3 Issue 10 | MARCH 2018

COVER STORY

Home grown technology leading the charge towards industry dominance: The saga of ELGi Equipments Ltd. Anvar Jay Varadaraj, Head – Marketing & Corporate Communications, ELGi Equipments Ltd.

BUSINESS NEWS

INSIGHT

UNION BUDGET 2018 INDUSTRY REACTS

Mastercam celebrates 35th anniversary

New Suction Cup from Schmalz Optimizes Sheet Metal Handling

Renishaw’s 5-axis measuring technology enables measurement without compromise

“The Budget has interesting schemes towards agriculture and rural development”

“No steps to boost exports”

“The demand for welding products will go up”

“The Machine Tools Industry did not gain anything special”

22 Head Office : Divya Media Publications Pvt. Ltd., 3rd Floor, Harmony Tower, N.S. Road, Thane-400 602. Maharashtra Tel: +91 22-25380574/75, Telefax: +91-22-25418254 E-mail: shekhar@divyamediaonline.com Website: www.mtwmag.com 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 MARCH 2018

NORDAC’s LINK FIELD DISTRIBUTION SYSTEM truly versatile

Allied Machine announces GEN3SYS XT Pro Line of Inserts and Holders

WALTER unveils two new HELITRONIC models

Most Authorized & Honorable Prize in European Machine Tool Market 2017 MM AWARD Grand Prize in MILLING Category

Machining Center for Impeller and Small-size Complex Shape Processing

Specifications

A-Axis

X-A

xis

Z-A

B-Axis

Ram Type Moving (X/Z-Axis)

Ã&#x2DC;200

mm Table Size

kg Workpiece Weight

40,000 (HSK-E40)

r/min Spindle Speed

EA No. of Tools

300/300/200

mm (X/Y/Z-Axis) Travel

50/50/50

m/min (X/Y/Z-Axis) Rapid Traverse

200/200

rpm (A/B-Axis) Rotary Table Speed

2G/2G/2G

G (X/Y/Z-Axis) Acc./Dec. Speed

SIEMENS 840D sl

CNC Controller

Rotary Tilting Table(A/B-Axis)

HYUNDAI WIA INDIA PVT. LTD. Address : #4/169 1st flr, LOTTE Bldg, Rajiv Gandhi Salai, (OMR), Kandanchavadi, Chennai - 600 096, Tamilnadu, India Office Tel. No. : (0)76049 03348, E-mail : sales@hyundai-wia.com

Contents

Vol 3 Issue 10 | MARCH 2018

TECH TRENDS

Laser Triangulation: Getting from point to line

COMPANY PROFILE

Automatic Guided Vehicle Future of Industrial Logistics

EWAG PROFILE LINE – high-precision, flexible 5-axis grinding centre

DMG MORI sharpens Die & Mold excellence

Shavo Technologies offers high-tech tailor made solutions

PRODUCTS SHOWCASE

76 95 G350T and G550T – Generation 2

72 96 Compact Rail Linear Guides:

Accusharp tells more about ‘Gundrilling’!

The ideal solution from Rollon for compensating misalignment and for environments with impurities

CASE STUDY

Elesa+Ganter tubular handles: standard or customised solutions with an ergonomic and original design

Another 12 meters Pipe rolling machine for the Russian Oil & Gas industry ready for delivery. Customer satisfaction guaranteed!

The new Gast 86/87R Series of oil-less rocking piston compressors and vacuum pumps

Welding Fume Extractor, King Extractor-II-MU 3

Steady Volt Servo Voltage Stabilizers

84 New Seco Solid-Carbide Cutting Tools Boost .... 10

MACHINE TOOLS WORLD MARCH 2018

Comfortable Speed Monitoring.

Editorial Board

Editorial Index A

Mr. Arun Mahajan General Manager

AMT- The Association For Manufacturing Technology

Mr. A.P. Jayanthram Consultant Grob Machine Tools India Pvt. Ltd.

Mr. GK Pillai Managing Director & CEO Walchandnagar Industries Ltd.

Accusharp

MAC Machine Tools

Ador Welding

and Automation

Allied Machine

Mastercam

Altair Engineering

Micro-Epsilon

ANCA

Asiamold 2018

Nord Drivesystems R

DMG MORI

Renishaw

DOLD Electric

Rollon India

Dormer Pramet

Mr. Arjun Prakash Managing Director Effica Automation Ltd.

Ms.Samina Khalid Marketing Manager

Renishaw Metrology Systems Ltd.

Mr. Rupesh Paparaju Director, Bettinelli Automation Components Pvt. Ltd.

Schmalz

Elesa and Ganter

Seco Tools

ELGi Equipments

Shavo Technologies

42,

EOS

96 Solitaire Machine

Faccin

GROB

Tools

Spraymet

United Grinding

HEIDENHAIN

30, 61

Unity Controls

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 MARCH 2018

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 EspaÃ±a 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

Mastercam celebrates 35th anniversary The year 2018 marks the 35th anniversary of CNC Software, Inc., developers of Mastercam CAD/CAM software. In 1983, two brothers, Mark and Jack Summers, came up with a new concept for programming CNC (ComputerNumerical-Control) machine tools. A third brother, Brian Summers, soon joined and together they developed a PC-based CAD/CAM software package that laid the foundation for what would be Mastercam, the world’s most widely used CAD/CAM software. * “It started out as a simple idea,” says Chairman Mark Summers. “I was a machinist. My brother was a mathematician. We combined our experience to put what was out of reach for most shops – NC programming software – right onto their desktops.” In the 35 years that fol-

lowed, they have advanced dozens of important new technologies for those shops, including “smart” toolpaths, hybrid machining, mill-turn, multiaxis, their proprietary Dynamic Motion technology, as well as basic packages for milling, turning, and wire EDM. They first called the software pro-

gram “Meghan,” named after Mark Summers’ eldest daughter, and then changed to “Mastercam” as a clearer descriptive of the software’s primary function. Today, Meghan is the CEO and Mastercam is the most widely used CAD/CAM software in the world, closing in on almost a quarter million installations at the

end of 2017. “Mastercam users help drive our innovation,” says CEO Meghan West. “We’re in constant contact with shops, machine tool builders, educators, tooling suppliers, and they all help us focus on what shops need the most now and in the future, so we can deliver.” “One of the biggest reasons for our success is our global dealer network – probably the largest and most experienced in the CAM industry,” continues West. “They are true partners with our customers, offering advice, training, and applications experience to Mastercam users around the world. We’re also extremely proud to be the number one CAD/ CAM program being taught by technology teachers in schools, colleges, and universities.”

Asiamold 2018 – Guangzhou Exhibition to open in March Asiamold – Guangzhou International Mould & Die Exhibition is ready to present some of the latest offerings from the mould, die casting and additive manufacturing markets. Running concurrently with SPS – Industrial Automation Fair Guangzhou (SIAF) from 4 – 6 March at the China Import and Export Fair Complex in Guangzhou, China, the two fairs will welcome 850 exhibitors from 20 countries and regions across 60,000 sqm of exhibition space. Highly regarded within the industry as an effective trading platform, the show attracts leading brands who are well prepared to present their latest innovations in mould making, die casting, metalworking,

MACHINE TOOLS WORLD MARCH 2018

3D printing and automation technologies. Some of the prominent brands confirmed for the 2018 edition include: Participating for the first time, Shenzhen Chenvo Technology specialises in high-end manufacturing industries such as precision moulds, precision metal manufacturing, product assembly, R & D and the manufacture of intelligent terminal cabinet products. The company’s wide-ranging product portfolio includes ATM machine cabinets, new energy sources, smart unmanned cabinets, medical devices and railway apparatus.

The Trusted Partner in Metal Forming Machines

PRODUCTIVITY REPEATABILITY AND AUTOMATION OF PIPELINES ROLLING PROCESS

BUSINESS NEWS

New Suction Cup from Schmalz Optimizes Sheet Metal Handling The new bell-shaped suction cup SAX from Schmalz is particularly well suited for quick handling of metal sheets and car body parts. It conforms perfectly to differing workpiece contours. The large stroke of the new suction cup SAX allows it to conform perfectly to complex workpiece shapes. This makes it particularly well suited for handling car body parts, for de-stacking metal blanks, and for loading and unloading CNC metal and laser cutting machines. The specially structured suction area gives the SAX great holding force and allows it to withstand very great lateral forces. Thus it handles oiled sheet metal particularly quickly. Thanks to its very flexible sealing lip, it can also reliably hold workpieces with rough surfaces. Schmalz constructs the SAX out of the wearresistant plastic Elastodur, whose service life is considerably longer than that of comparable materials. In addition, it resists the effects of

ozone and aggressive drawing oils. This single-piece suction cup with a vulcanized connection nipple made of reinforced plastic guarantees a firm seat at the tooling. Schmalz offers the SAX with various connection types. It is available in seven different sizes, with suction area diameters of 30, 40, 50, 60, 80, 100, and 115 mm. Schmalz is the market leader in vacuum automation and ergonomic handling solutions. Schmalz products are used all over the world, for example in applications in the logistics

industry, the automotive industry, the electronics sector or in furniture production. The wide range of products in the Vacuum Automation unit includes individual components such as suction cups and vacuum generators, as well as complete gripping systems and clamping solutions for holding workpieces, for example in CNC machining centers. The Handling Systems unit offers innovative handling solutions with vacuum lifters and crane systems for industrial and handicraft applications. With the Energy Storage unit, Schmalz has created a new pillar in the field of stationary energy storage. With comprehensive consulting, a focus on innovation and first-class quality, Schmalz offers its customers long-lasting benefits. Schmalz’s intelligent solutions make production and logistics processes more flexible and efficient, while also preparing them for the increasing trend toward digitalization.

Renishaw’s 5-axis measuring technology enables measurement without compromise Measurement is an essential part of manufacturing, used to control processes and verify products. However, measurement time is often viewed as non-productive, causing unwanted bottlenecks and putting pressure on manufacturers’ operating margins. Renishaw’s 5-axis measurement product range for co-ordinate measuring machines (CMMs) claims to be one of the biggest step-changes in measurement capability ever introduced in industrial metrology and goes a long way to overcoming these challenges. The need to retain accuracy has historically compromised the ultimate speed of the measuring process due to the characteristics of a CMM’s structure. The non linear motion of a Cartesian CMM induces accelerations and decelerations that twist and deflect the machine structure, and result in measurement errors that increase with speed and acceleration. CMM manufacturers work relentlessly

MACHINE TOOLS WORLD MARCH 2018

on software and machine improvements to overcome those limitations, but ultimately the physical nature of the CMM structure constrains further improvement. REVO® 5-axis systems approach this challenge from an entirely different perspective, minimising CMM accelerations whilst moving the stylus very rapidly over the component surface through the simultaneous control of the three machine and two probe head axes (X, Y, Z and A, B). Additionally, the REVO® system offers five different probe families, each specifically

designed to maximise the advantages of 5-axis motion and infinite positioning. The probes are automatically interchangeable and include tactile scanning, touch-trigger, surface finish and non-contact vision probes. All are used within a common co-ordinate reference frame and provide the choice of an optimum tool to measure multiple features all on a single CMM platform. Automotive is one sector benefitting from this technology with manufacturers finding unparalleled advantages in the expanded SFP2 surface finish measurement product range, offering operator independent data collection and the opportunity to eliminate dedicated surface finish equipment. By integrating automated roughness measurement and drastically reducing the number of probe styli required to measure complex parts, REVO® systems have a direct impact on powertrain manufacturing effectiveness.

Smart All Down the Line Efficient tool data handling with coordinated hardware and software solutions

Easily create a smart factory: with a combination of smart cabinets, presetting and measuring equipment, and TMS Tool Management Solutions by ZOLLER – connected by the z.One tool database. You’ll have direct access to storage locations, parts lists, and the tool assembly assistant software program. You can preset and measure complete and assembled tools on your ZOLLER device immediately, since data is already in the system. That’s how easy it is to get started with Industry 4.0 – at least with ZOLLER.

Experience networked production live – with the virtual reality app from ZOLLER. Download now!

BUSINESS NEWS

NORDAC’s LINK FIELD DISTRIBUTION SYSTEM truly versatile NORD DRIVESYSTEMS is one of the world’s leading manufacturers of drive technology for mechanical and electronic solutions. The range of products includes constant speed reducers, electric motors, industrial gear units, and motor starters and AC Vector drives for cabinet mount & distributed control. “In general, conveyor technology and intralogistics require drive control systems which can be simply installed and which are easily accessible during operation and of maintenance is required. The NORDAC LINK field

distribution system supplements the NORD DRIVESYSTEMS product range and provides customers with a drive control which can be flexibility installed close to the motor. System costs can be significantly reduced thanks to decentralised drive technology.” The system is freely configurable according to requirements and the application; is available as frequency inverters (up to 7.5 kW) and motor starts (up to 3 kW); can be commissioned fast due to simple operation, and has a simple and

reliable plug-in capability. The system is simple to maintain due to integrated maintenance switch and local manual control facility and can be integrated into all common bus system. It can be used in bottling Industry (Process Line Conveyors);

Intralogistics Segments (Baggage Conveyors ); automotive industry (Pallet Transfer); tyre industry (Trimming line conveyors, Storage conveyors); Food Industry (Packaging conveyors) and Intelligent Drivesystems, Worldwide Services.

EOS announces leadership movements and expansions in Asia-Pacific EOS, the world’s leading technology supplier in the field of industrial 3D printing of metals and polymers, announced three recent leadership appointments in Asia-Pacific as well as expansion of its regional footprint as part of the company’s bid to meet strong demand for the additive manufacturing (AM) sector. Dr. Adrian Keppler, CEO and Speaker of the Corporate Management at EOS GmbH, says: “Industry 4.0 has brought about tremendous opportunities for AM and great traction for the adoption of AM in Asia-Pacific. We are already seeing demands from our customers in industries such as aerospace, automotive, medical and fast-moving consumer goods, where excellence in technical precision and structural engineering are paramount.

MACHINE TOOLS WORLD MARCH 2018

Hence, we are extremely excited to expand our global footprint, especially in Asia-Pacific, and to broaden our leadership team to tap on this market demand.” Effectively November 2017, Jack Wu was appointed Sales Director of Asia-Pacific. Based in Singapore, Jack oversees the sales function and take on a key role to boost EOS’ customer portfolio for the region in key markets – Singapore, China, India, South Korea and Japan. In Japan, EOS has appointed Yasuaki Hashizume as General Manager to head its Japan office and oversee business operations in the country. Terrence Oh, Senior Vice President (Asia-Pacific) at EOS GmbH, added: “Our APAC customers are gradually transforming their businesses for the fourth industrial revolution

and we want to help accelerate that process by contributing more to their AM strategy and production. We also want to be there at every stage of the journey, from helping them set up their in-house AM capabilities to enabling them to deliver high quality products within a shorter time span or having eco-friendly spare parts produced. Through our in-house consultancy unit, Additive Minds, we hope to further strengthen our customers’ AM value proposition and ensure that they are at the forefront of implementing advanced technologies.”

1989, the independent company is pioneer and innovator for comprehensive solutions in additive manufacturing. Its product portfolio of EOS systems, materials, and process parameters gives customers crucial competitive advantages in terms of product quality and the long-term economic sustainability of their manufacturing processes. Furthermore, customers benefit from deep technical expertise in global service, applications engineering and consultancy.

About EOS EOS is the world’s leading technology supplier in the field of industrial 3D printing of metals and polymers. Formed in

For more information, Website: www.eos.info

BUSINESS NEWS

Allied Machine announces GEN3SYS XT Pro Line of Inserts and Holders Allied Machine & Engineering, a leading manufacturer of holemaking and finishing tooling systems, announces its new GEN3SYS® XT Pro line of high penetration drilling products. The product line features enhanced holders and inserts with three unique geometries, and two advanced coatings. Combining specific geometries and coatings to create the optimal solution for different machining materials, this next level of the GEN3SYS® high penetration drilling product line delivers top results. GEN3SYS XT Pro inserts have

been designed specifically for ISO material classes, making tool selection easy. They are offered for steels (class P), cast irons (class K), and non-ferrous materials (class N). The drill inserts come in diameters

ranging from 11 mm (.4331 inches) to 35 mm (1.378 inches), and are available in .1 mm (.004 inch) increments. The inserts designed specifically for steel and cast iron have new AM400 series coatings,

which provides increased wear resistance and tool life. Inserts for non-ferrous materials are coated with titanium nitride (TiN). Holders for the GEN3SYS XT Pro line are offered in depth-to-diameter ratios of 3xD, 5xD, 7xD, and a new 10xD. These newly designed holders feature an enhanced flute design that improves chip evacuation and an updated coolant configuration that increases flow and directs additional coolant to the cutting zone. The GEN3SYS XT Pro holders are available in both imperial and metric shank diameters.

Altair and DesignTech Systems to set up centre of excellence US-based Altair Engineering announced a collaborative effort with its partner in India, DesignTech Systems, and the Science and Technology Park, an institute supported by the Department of Science and Technology (DST), Government of India, to support the advancement of the Indian government’s Skill India Programme. The objective of this skill enhancement programme by the government is to enable a large number of Indian youth to take up industry-relevant product design skill training that will help them in securing a better livelihood. The agreement to establish an engineering Centre of Excellence (CoE) for research, innovation and skill building, is therefore expected to benefit a large community of students, academic institutes and the overall industry. Speaking on the occasion of

MACHINE TOOLS WORLD MARCH 2018

this technical collaboration, Dilip Band, President of Science and Technology Park, Pune, said, “This CoE is expected to complement the current courses undertaken by the state institutions and is aimed at bridging the gap between quality of vocational engineering skills of students and skill level expected of them by the industry.” Dr. Rajendra Jagdale, Director

General and CEO, Science and Technology Park (STP), said, “The CoE will promote startups in the design domain. We are collaborating with several prominent educational institutions in Maharashtra and other parts of India to set up these centres jointly.” Pavan Kumar, Vice-President South Asia and Managing Director,

Altair India, said, “These initiatives are designed to use technological solutions and resources to better align technical institutes with industry requirements – by getting diploma and graduate students who are industry-ready, and boost entrepreneurship in these budding engineers.” Speaking on the occasion, Vikas Khanvelkar, Chairman and Managing Director, DesignTech Systems, said, “In a globalised, technology-driven, evolving world of product design and innovation, Altair Engineering in collaboration with DesignTech Systems Ltd., intends to propose the Altair Centre of Excellence for research, innovation and skill-building with focus on enhancing student exposure to the best practices of design and engineering while enhancing the possibilities of their employment.”

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BUSINESS NEWS

WALTER unveils two new HELITRONIC models WALTER is unveiling two brand new HELITRONIC models at this year’s GrindTec industry trade show: the HELITRONIC POWER 400 grinding machine and the HELITRONIC POWER DIAMOND 400 grinding and eroding machine. WALTER’s latest machines feature a grinding wheel / electrode changer and extended traverse, and can now machine tools up to 380 mm in length, surpassing the previous limit of 280 mm. This is an increase of over 35%. But the two machines offer more than just longer workpiece lengths. WALTER engineers completely redesigned the HELITRONIC POWER and HELITRONIC POWER DIAMOND multi-functional machines. “The new HELITRONIC POWER 400 and HELITRONIC POWER DIAMOND 400 machines are more in line with our HELITRONIC VISION models. They’re basically two completely new machines”, says Torsten Wörner, product manager in the grinding department at WALTER. For example, the base of both machines was completely remodelled. The new, more rigid machine bed ensures even better damping behaviour which in turn facilitates greater precision and higher surface quality. The C-axis of the standard version of both new machines is

driven by a worm drive. A low-maintenance and extremely accurate torque motor is also available as an optional feature. The engineers also used the pneumatically driven steady rests and tailstocks from the HELITRONIC VISION series. This means that the steady rests and tailstocks are less prone to leaks, require less maintenance and are much cleaner. They also absorb less heat than components that use hydraulic oil, thus ensuring even greater precision. Like all “Two-in-one” machines from WALTER,

the new HELITRONIC POWER DIAMOND 400 also uses FINE PULSE TECHNOLOGY. “For over a year, this technology has been at the forefront when it comes to surface quality, cutting edge roughness and process stability of PCD tools,” says Siegfried Hegele, product manager in the eroding department at WALTER. Unlike the previous models, the HELITRONIC POWER DIAMOND 400 and HELITRONIC POWER 400 machines can be automated with a top loader for up to 500 tools, a robot loader for up to 7,500 tools or the robot loader 25.

Turn to Dormer with new 2018 catalog Featuring more than 540 product families over 640 pages, the new Dormer catalog is now available. Available in 20 languages, the comprehensive publication covers Dormer Pramet’s round tools assortment and features 50 new products since the last edition. Latest additions include the new Force X and Hydra carbide drills and a complete program of rotary burrs. Dormer’s range of threading tools has also expanded significantly with new Shark Line taps, forming taps, as well as a full range of thread milling cutters. The full collection of tools is grouped by product type; drills, taps, milling cutters, reamers,

MACHINE TOOLS WORLD MARCH 2018

countersinks, dies and parting off tools. Also, there are new sections specifically dedicated to thread milling cutters and rotary burrs, reflecting Dormer’s

expanding assortment. The popular Technical section is again included, providing advice and support information on a wide range of machining

applications. Meanwhile, a new icons and symbols bookmark will complement the new catalog as a quick reference guide and allow users to find frequently used pages more easily. Offering both versatile and material-specific cutting tools, Dormer Pramet’s rotary program provides a variety of options for a host of industry segments, such as die & mold, maintenance repair and overhaul (MRO) and general engineering. In total, more than 56,800 copies have been printed of the 2018 catalog and to request a hard copy contact your local Dormer Pramet sales office.

G-SERIES

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

Contact: GROB MACHINE TOOLS INDIA Pvt. Ltd. I Hyderabad, INDIA Phone: +91 40 4202-3336 I E-mail: info@in.grobgroup.com

01_MTW_Monthly_Magazine_190x250mm.indd 1

www.grobgroup.com

15.02.2018 10:20:47

BUSINESS NEWS

Renishaw launches enhanced probing system for CNC grinders Renishaw, a world-leading engineering technologies company, will launch the next generation of its MP250 strain gauge probing system for grinding machines at GrindTec 2018, Germany (14th – 17th March, hall 8, stand 8101). Building upon the highlyeffective and proven design of the original MP250 probe, the enhanced version features improved configurability options, allowing users to select ultrarobust or low latency operating modes – dependent on the application requirement. Comprising the updated MP250 strain gauge probe and the new HSI-C interface, the system provides a high-speed, highprecision, touch-trigger solution for determining component geometry. Equipped with RENGAGE™ technology, the system offers unbeatable 3D accuracy and

MACHINE TOOLS WORLD MARCH 2018

repeatability – enabling reliable on-machine measurement. The probe’s ultra-low trigger force helps to eliminate surface and form damage, making it ideal for inspecting delicate workpieces. Engineered for harsh environments, its small form factor and robust design make the probe ideal for tool and cutter grinding applications.

Application-focused configurations Enhancements to the MP250 probing system focus on improving performance by providing users with the flexibility to operate the probe in one of three modes: a highly vibrationresistant configuration; a lowlatency configuration – should a fast probe response be required; the default configuration – for general use. Using an M-code, users can temporarily set the probe to

the highly vibration-resistant configuration – extremely useful when moving around the machine volume at fast feedrates with long or heavy styli arrangements – before reverting to the low-latency configuration for remarkably accurate component measurement using small approach distances (or to the default configuration for

general usage).

Reduced installation time User configuration of the upgraded MP250 is made possible by a new machine interface, the HSI-C. Featuring a proprietary electronics housing, the HSI-C is easily fitted onto a DIN rail in the machine cabinet – requiring minimal fitment time & effort.

INSIGHT

UNION BUDGET 2018 INDUSTRY REACTS

“No steps to boost exports”

“The Budget has interesting schemes towards agriculture and rural development”

he budget has introduced some interesting schemes towards agriculture and rural development. They continue to support investments in infrastructure, which will support our portable compressor range. Many of our suppliers will benefit from the MSME tax reduction and perhaps the tax reduction will encourage capital expenditure, which could in turn support our industrial compressor range. Overall, while there are no explicit manufacturing boosters, we hope that the momentum from the last quarter will sustain through 2018.

MACHINE TOOLS WORLD MARCH 2018

Dr. Jairam Varadaraj, MD, ELGi Equipments Ltd.

Mr. Vikas Khanvelkar, Managing Director, DesignTech Systems Ltd.

verall budget is very rural focussed and has many schemes to support farmers and rural healthcare. It will not have much impact on urban population for them it is status quo. Increasing the eligibility for 25 % corporate tax from Rs 50 Crs to 250 Crs is a good move for MSME industries in that bracket. There are no special steps to grow the exports. How 15 % growth in exports will be achieved is not clear. Creating employment should have been one of the thrust factors, but except big outlay in infrastructure projects which will lead to large employment creation, no other measures are taken to make up the employment deficit from other sectors.

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INSIGHT

“The demand for welding products will go up” •

•

Mr. Satish Bhat, Managing Director, Ador Welding Ltd.

he Budget is focused on agricultural & rural development, with special emphasis on health, education and employment, while boosting growth prospects for MSMEs. Infrastructure development is the common thread in all these focus areas. For a while now, industry has been struggling with lower capacity utilization. Boosting Rural demand appears to be a step in the right direction. Rural Economy

The following measures are expected to boost rural incomes and thereby enhance rural spending: • Increase in MSP for kharif crops. • Nearly 30% growth in allocation for Institutional Farm Credit is also a huge positive for the sector. • Rural haats to be developed and upgraded into Gramin Agricultural Markets • Operation Green” launched to address price fluctuations of potato, tomato and onion • Two New Funds of Rs. 10,000 crore announced for Fisheries and Animal Husbandary sectors, Rs 1290 crore

MACHINE TOOLS WORLD MARCH 2018

•

for Re-structured National Bamboo Mission. Loans to Women Self Help Groups will increase to Rs.75,000 crore in 2019 from 42,500 crore last year. Higher targets for Ujjwala, Saubhagya and Swachh Mission to cater to lower and middle class in providing free LPG connections, electricity and toilets. Outlay on health, education and social protection will be 1.38 lakh crore. World’s largest Health Protection Scheme covering over 10 crore poor and vulnerable families launched with a family limit upto 5 lakh rupees for secondary and tertiary treatment. Tax Deductions to Farmer Producer companies

Industry Focus

• Rs 5.97 lakh crore allocation for infrastructure - Proposed spend on Railways, Airports and Bharat Mala. • Govt will contribute 12% of the wages of new employees in EPF in all sectors for next 3 years and Women contribution to EPF reduced to 8% for first 3 years • Proposal to extend reduced rate of 25% currently available for companies with turnover of less than 50 crore (in Financial Year 2015-16), to companies reporting turnover up to Rs. 250 crore in Financial Year 2016-17, to benefit MSMEs. • NITI Aayog to initiate a national programme on Artificial Intelligence (AI) and centres of excellence will be set up on robotics, AI, Internet of things, etc. Taxation

• Income Tax – Tax on Long Term

Capital Gains exceeding Rs 1 lakh at the rate of 10%, without allowing any indexation benefit. • Standard Deduction of Rs 40,000 in place of present exemption for transport allowance and reimbursement of miscellaneous medical expenses. 2.5 Crore salaried employees and pensioners to benefit. • Hike in deduction limit for health insurance premium and/or medical expenditure from Rs 30,000 to Rs 50,000 under section 80D for Senior Citizens and exemption of interest income on deposits with banks and post offices to be increased from Rs 10,000 to Rs. 50,000. These are some of the key measures and the Budget appears to be a wellbalanced plan to enhance the life of Indian Citizen. However, adhering to the fiscal discipline (Fiscal Deficit projected at 3.3% for 2018-19) will be a challenge as it is subject to the Divestment going through as planned and also subject to Oil price and Forex shocks. Overall the Budget will give an impetus to core industries like steel, cement and power which will be led by Infrastructure spend. As these core industries have better capacity utilization, there would be further interest in investments on capacity addition which today is few and sparse. The other industry which will grow and should be driving industrial growth is ‘Defence Sector’. Improvement in Rural economy will boost the prospects of automotive and white goods industry. The growth in core sectors should help the welding industry and as the investment interest in capacity addition rises, demand for welding products will only go up.

INSIGHT www.mtwmag.com

“The Machine Tools Industry did not gain anything special”

Mr. Ashok Sheth, Chairman, Solitaire Machine Tools Ltd.

he Budget was more focused on Agriculture and Infrastructure. However, the ripple effect of these sectors do help Machine Tools. The manufacture of tractors & implements would go up. The rural population’s disposable income would go up resulting in sales of more vehicles, household

appliances and consumer goods. All of these sectors do need more Machine Tools to meet added demand. The growth expected on Defense and Aerospace sector was not so impressive. Those sectors should have been given more weightage in the Budget, as they drive up demands of all industrial sectors and has high potential for job creation. The ‘Make in India’ would become a reality when large number of youth, especially skilled and semi-skilled are employed in the manufacturing industry. The Budget was a bit of a disappointment when it came to middle Income salaried urban and semiurban population. Growth will be there basically due to the size of the economy and momentum gained over the years in moving forward. This Budget’s focus on Infrastructure would help certain sectors to grow fast and overall effect would be good for the country. The Industrial and Farm sector

loan defaults and its effect to banks would cast shadow on the growth front. Machine Tool industry in particular did not gain anything special. The reduction in Corporate tax to 25 % for turnover up to 250 Crores, would benefit some of the major machine tool manufacturers in the country. The Government’s decision to have only Electric Vehicles from 2030 and reduced GST for electric vehicles is a welcome sign. However, the Government must set a large fund to help in R & D efforts of industry to make this feasible. The future of entire auto ancillary industry remains in the dark as the concept of manufacturing vehicle will change. Several auto ancillary industries are already concerned about expansion in view of what future holds for their current plant and machinery. Investment on high end machines is being avoided as payback periods are long.

MARCH 2018

MACHINE TOOLS WORLD

COVER STORY

Home grown technology leading the charge towards industry dominance: The saga of ELGi Equipments Ltd.

Anvar Jay Varadaraj, Head – Marketing & Corporate Communications, ELGi Equipments Ltd.

MACHINE TOOLS WORLD MARCH 2018

The home grown ELGi Equipments Limited is today the 7th largest manufacturer of air compressors in the world. The company with a broad line of innovative and technologically superior compressed air systems has earned the worldwide distinction of having designed sustainable solutions that help companies achieve their productivity goals and keep the cost of ownership low. The Indian MNC’s ambition to seize the No.2 position in the world by 2027 is not without substance. It has the technology, products and the people to achieve this, according to Anvar Jay Varadaraj, Head – Marketing & Corporate Communications at ELGi. The foundation of the company’s aspiration is also based on the fact that it is one of the three global players with the full range of compressed air systems, discovers P.K. Balasubbramaniian in an interview. Excerpts:

COVER STORY www.mtwmag.com

Q. ELGi is an Indian MNC in Air Compressors. What’s your standing today and how do you plan to push your global ranking to a notch above? ELGi is currently the seventh largest air compressor manufacturer in the world. Our ambition is to be number two by 2027. Amongst the global players, we are one of three companies with the full range of products, which is the foundation for our aspirations. We believe that reliable products with industry leading energy efficiency will be critical to our growth. We have had a strong start in quality conscious markets such as Europe and the USA and we believe that we will grow steadily as more customers and distributors experience our products.

Q. What are your strategies to accelerate your growth? As we grow to number two, we believe 30% of our growth will be fueled by organic growth in markets, while 70% will come from inorganic avenues such as acquisitions. We will focus on “access to market” acquisitions such as distributors.

Q. How do you propose to step up your infrastructure and resources to achieve the goal you have set for yourselves? Our current infrastructure will hold us well for sales increases over the next five years. However, as we grow sales in key markets such as the USA, we will consider on-site manufacturing to improve our service to our customers and distributors. To this end, we have projects underway to envision the ideal ELGi factory in the USA taking into account factors such as

higher labour costs.

Q. What’s your present range of manufacture? Any new additions in the anvil as a result of your ¬¬rigorous R & D? ELGi currently offers the full range of compressed air solutions and services. For products, we have both lubricated and oil free reciprocating compressors. Starting from 1 HP and supporting applications such as small scale manufacturing and auto workshops, our lubricated reciprocating compressors offer decades of reliable operations. Our oil free reciprocating compressors support clean air sensitive applications such as pharmaceutical manufacture and textiles. Our oil lubricated screw compressors support a vast array of industries starting from 7 KW with the aim of providing the lowest ownership cost experience, which includes upfront price, energy consumption, and maintenance. Our screw compressor range also includes oil-free machines which are built around our proprietary oil free Airend design and produce class zero air for large scale pharmaceutical manufacture and textiles. Our screw compressor range extends to portable and skid compressors. Portable compressors are either powered by an electric or diesel motor and are critical for applications such as mining and road construction. Our skid compressors, mated to diesel engines, are used for water well applications. Finally, we have our centrifugal compressor range that supports large capacity air requirements for industries such as power, textiles, and cement.

Q. As a trendsetter, what are the technological innovations you have showcased recently? As our IOT initiative, we have launched Air Alert, a communication device embedded in our screw compressor range to transmit critical compressor to ELGi. We will use algorithms to continuously monitor these machines to provide failure prevention, proactive maintenance, and quality improvement. With Air Alert, customers can rest assured that their ELGi machines are under constant surveillance. By the end of the calendar year 2017, we will have 500 machines fitted with Air Alert and by the middle of 2018, all of our machines will have Air Alert as standard and at no additional cost.

Q. What’s your level of success in producing energy efficient compressors of superlative quality and performance? Our technology roadmap considers energy efficiency as a key driver. We initially aimed to match the best in terms of quality and energy consumption. We are proud to note that we are amongst the most efficient and most reliable machines in the industry. Our success in the USA, for example, is testament to our products’ quality and reliability. Our current goal is to be unequivocally the best in terms of quality and energy consumption, both critical parameters for an Indian brand competing with European brands.

Q. How would you summarize your major strengths, capabilities and resourcefulness? We live by the mantra that the customer is

A reflection of world-class manufacturing: ELGi’s ultra-modern production facility.

MARCH 2018

MACHINE TOOLS WORLD

COVER STORY always right. This mantra is our strength as it has instilled values amongst our team where no one tolerates compromises to the customer. If customer- centricity was not central, then our products and technology won’t count for much.

Q. What are the calculative efforts you make to improve your brand value? We aim to be thought leaders in compressed air. To this end, we’ve invested in platforms such as Linkedin, Facebook, and our blog (The Compressed Air Journal) that will allow us to create and share meaningful stories about ELGi.

Q. What’s your customer base? And how do you delight your customer offering tangible benefits and lasting values? Any operation that uses compressed air is our potential customer. We delight our customer by offering the lowest ownership cost experience in the world, bar none.

Q. What’s exciting at ELGI today? Our aspiration to be number two in the world energizes the whole company. We believe we have the technology, the products, and the people to achieve this.

“know why” over decades of investment into our team and our R&D function. We are proud today to have engineers with us who have grown from campus developing their own world class designs and producing industry leading designs.

Q. Is ELGI a classic example of eminent Indian engineering that makes India proud?

Q. You are quite visible on the CSR front. Could you throw some light on your recent initiatives and the results?

While this is a work in progress, ELGi is a good example of home grown technology leading the charge towards dominance in an industry. Today, we have “know why” on compressed air technology, which will allow us to develop the compressed air products of the future. We’ve built this

We would like to highlight two initiatives. First, we have a vocational training program at ELGi that has been designed around German vocational training principles. We identify high performing students of limited means from neighboring towns and villages who have

ELGi’s sprawling manufacturing facilities at Coimbatore

Chiseling out products with an uncanny eye for quality and reliability: ELGi’s air end production bay

MACHINE TOOLS WORLD MARCH 2018

completed the tenth standard and enroll them into a three year program with the goal of placing them in different areas of air compressor manufacture. By doing so, we guarantee that our labour talent is aligned to our expectations of quality and character, while offering these students an opportunity to cement their careers. So far, we have placed more than one hundred and ninety students. Second, we run the ELGi school which aspires to provide a best in class science and math education for children from destitute backgrounds. The school enrolls 1400 students and we aspire to build residential facilities with the aim of inducting more students from orphanages.

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COMPANY PROFILE

Shavo Technologies offers high-tech tailor made solutions

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

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

Applied gas delivery systems

MACHINE TOOLS WORLD MARCH 2018

solutions and turnkey capability in an effort to keep offering better value by leveraging the technologies we provide,” says Mr. Rushil Shah. All its principals have specific technologies that would be classified ‘cutting edge’ considering the fact that all of them are world leaders in their fields. Following are brief details of their principals and business areas: TESCOM is a recognized leader in the manufacture of high-pressure regulators up to 20,000 psig designed to work with all types of fluids, both corrosive. Tescom range covers over 70 standard models of high-pressure regulators to meet almost any requirement. HAM-LET specializes in the design, development and production of high quality instrumentation valves and fittings in a wide variety of materials for high, pressure, temperature and vacuum applications. These products are used in diverse industries like petrochemical, semiconductor, energy, food, biotechnology, pharmaceutical, defense, pulp & paper and mining. CLASSIC FILTERS brings you filter elements to filter housings to complete filter systems for almost any function. It delivers some of the most robust high quality, coalescing filters and particulate filters in the world. In order to manufacture high tech devices such as semiconductor devices, flat panel displays and even photo voltaic or solar cells, precise fluid control is a must. HORIBA is the established world leader in offering a full line-up of gas, liquid, and vapor delivery products. Applied Energy System Inc. is one of the world leaders in the field of ultra high purity gas delivery systems like gas cabinets and panel for solar, semiconductor, nano technology and other high purity industries. Gas specializes in design and

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COMPANY PROFILE

High quality instrumentation valves High pressure regulators

manufacture of air moving products including vacuum pumps, compressors, air motors, gear motors, vacuum generators and regenerative blowers. “As a matter of fact, our journey of working with high technology industries started with Gast which today remains

one of the world leaders in air motors and fractional horse pumps,” reveals Mr. Shah. Meech’s forte is industrial electrostatics. With a standing of over 40 years, Meech has developed a wide range of products like ionizing bars, hand-held ionizing air curtains, etc.

Electrostatics for effective static neutralization

MACHINE TOOLS WORLD MARCH 2018

for effective static neutralization and dust removal. With the experience gained from more than 200 successful web cleaning installations, Meech can offer both non-contact and contact web cleaning systems. ITT Enidine is again a world leader in energy absorption and vibration isolation products, providing solutions to a wide range of industrial markets. ITT Corporation is a high-technology engineering and manufacturing company operating on all seven continents in three vital markets viz. water & fluid management, global defense & security, and motion & flow control. Shavo feels fortunate to work with some of India’s top companies and institutions like Reliance, Tata’s,, Biocon, GE, Department of Space, Ministry of Defense and many more. It has in excess of 1000 live accounts. The company has a full service capability at its Pune office and is in the process of building a world-class service center in its Bangalore factory. “Our service support is the key pillar of the value we provide,” says Mr. Shah. – P.K. Balasubbramaniian

For more information Web: www.shavogroup.com

TECH TRENDS

HEIDENHAIN Encoders for industrial robots Significant accuracy improvement at the tool center point Speed, power and durability are key characteristics of industrial robots. These robots are typically used in applications such as welding or in lifting heavy components for vehicle assembly. Yet despite advanced calibration methods, the position accuracy of industrial robots has been inadequate for certain tasks. This is now changing thanks in part to highly accurate, output-side encoders from HEIDENHAIN and AMO.

he main driver behind this development has been the aerospace industry because it must perform highly accurate machining operations on very large components. Machine tools would achieve the required level of accuracy with ease but are either too inflexible or too expensive as special-purpose machines for the job sites and working spaces involved. A robot, however, can easily reach any position on a very large component, such as the fuselage of an aircraft, and can perform tasks on it such as drilling and milling.

• In order to achieve the desired level of maneuverability, robots with serial kinematics are required, such as articulated robots with six axes. • Each one of these axes is driven by a servo motor with a gear train. Zero position error, backlash, and joint elasticities are the main sources of inaccuracy. • Applied forces and dynamic effects during the machining process affect the rigidity of the robot’s mechanics and negatively influence the absolute position accuracy.

Accuracy is impaired by many factors For these kinds of applications, however, the tool center point (i.e., the tool at the end of the robot’s arm) must be positioned and guided with sufficient accuracy. This is where the classic industrial robot runs up against its limits. Deviations result from a variety of factors:

Thanks to advanced calibration methods, it is already possible to move a tool center point to a certain position repeatedly to within several hundredths of a millimeter. Depending on the manufacturer, the repeatability of articulated robots as per ISO 9283 is ±0.1 mm or better. However, when compared with

Figure 1: Classic HEIDENHAIN rotary encoder for motor feedback

MACHINE TOOLS WORLD MARCH 2018

repeatability, the absolute position accuracy that can be achieved within the robot’s coordinate system is worse by a factor of ten. Depending on their design, maximum range, and maximum load capacity, articulated robots currently achieve an absolute position accuracy of ±1 mm. This is insufficient for meeting the accuracy requirements of industries such as the aerospace sector. Yet robot manufacturers have been responding to this problem. Step 1: highly dynamic motor control Classic rotary encoders continue to provide the servo motor feedback at the robot’s axes. Because servo motors require high control dynamics, the robust inductive rotary encoders from HEIDENHAIN, such as those of the ECI 1100 and 1300 series, or multiturn models of the EQI 110 and 1300 series, are ideal for this type of application. These encoders deliver high control quality and system accuracy, and they are resistant to strong vibrations. Since these encoders feature a purely serial EnDat interface, even applications exposed to strong electromagnetic interference do not impair data transfer quality or safety. These inductive rotary encoders support safety integrity level SIL 2, category 3 PL d. They can even attain SIL 3, or category 4 PL e, if additional measures are taken on the control. These encoders also provided the added safety advantage of mechanical fault exclusion against the loosening of the shaft and stator connection. With this safety package, these inductive rotary encoders can also be used in systems designed for human-robot collaboration.

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

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AMERICAN RIGIDITY

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

TECH TRENDS Step 2: secondary encoders for highly accurate position measurement Robotics manufacturers can significantly improve the absolute position accuracy of their robots by using additional, high-accuracy angle encoders or rotary encoders at every robot axis. These socalled secondary encoders, which are

Figure 2: Improvement of the absolute position accuracy through the use of socalled secondary encoders on every axis

Figure 3: High-accuracy HEIDENHAIN and AMO encoders for absolute position measurement on robots

mounted after each gear train, capture the actual position of every robot joint. This allows the encoders to account for zero position error and backlash. The retroactive forces on each axis resulting from the machining task are measured as well. All of this results in a 70 to 80 percent improvement of the absolute position accuracy at the tool center point. Modular angle encoders, such as the HEIDENHAIN ECA 4000 with optical scanning, the HEIDENHAIN ECI 4000 rotary encoder with inductive scanning, and the AMO WMR angle encoder, are well-suited for these applications. Thanks to their modular design with a scale drum or scale tape and a separate scanning unit, these encoders are well suited for large hollow-shaft diameters and for the challenging installation requirements often encountered in robots due to space constraints. The signal quality of these secondary encoders is considerably better than that of the rotary encoders on the servo motor, meaning that the returned position values are significantly more accurate—even for highly dynamic movements. Step 3: accurate position measurement for movable robots In order to reach all of the machining positions on very large or long components, such as an aircraft fuselage or for manufacturing large composite fiber components, robots can be moved along the length of the component on linear axes. For the highly accurate

ECA 4000

ECI 4000

WMR

Scanning principle

Absolute, Optical

Absolute, Inductive

Incremental, inductive

Inside diameter

70 mm to 512 mm

90 mm / 180 mm 60 mm to 10 000 mm

Resolution

29 bits

20 bits

Depends on the subsequent electronics

System accuracy

±2“

±25“ / ±40“

±3“ per meter of arc length

Resistance to contamination

Mounting tolerances

Table 1: Comparison of the most important specifications for typical secondary encoders

MACHINE TOOLS WORLD MARCH 2018

positioning of robots with a linear drive, enclosed linear encoders from HEIDENHAIN are available in lengths of up to 30 m. Position measurement from a linear encoder compensates for thermal errors and other factors that influence the feed mechanisms. These factors cannot be captured by means of conventional position detection methods based on the pitch of the recirculating ball screw and the angular position of the rotary encoder on the motor.

Figure 4 : HEIDENHAIN linear encoders

Conclusion: highly-accurate position measurement improves accuracy at the tool center point The use of secondary encoders on all of a robot’s axes, as well as the use of linear encoders for positioning the robot relative to the workpiece, enables a level of accuracy at the tool center point that allows appropriately equipped industrial robots to perform positionally accurate machining and handling tasks on components. Angle and linear encoders from HEIDENHAIN and AMO offer not only the required system accuracy but also the necessary flexibility for installation in complex and compact robot mechanisms. The suitability of these encoders for safety-related applications also makes it possible to implement human-robot collaboration systems.

For more information Web: www.heidenhain.com

TECH TRENDS

Ceramic coatings for refurbishing machine tool parts

achine Tool Industry has undergone major developments in providing enhanced service life to spindles, arbors, bearings, etc. Ceramic Coatings by Plasma Spray have been in use in many industries since 1960. Since last decade, this process and ceramic coatings are being used to provide surfaces to seal areas of spindles, contact faces of arbors and electrical and heat insulation to bearings. Apart from OEM level coatings, many user industries are using ceramic coating for refurbishing of spindles and other machine tool parts. Typical Spray Materials used with Plasma Spray Metals and its alloys: Steels, Ni alloys, Co alloys, Moy, bronze, copper, Babbit, etc. Ceramics: Chromium Oxide, Aluminium Oxide, Al Oxide + TiO2, ZrO2, etc. Carbides: Tungsten carbide, Cromium carbide, TiC Hardness range of coatings: From SOFT 60Rb (Bronze) to HARD 70 Rc (ungsten carbide) Benefits of Plasma Sprayed Ceramic over Hard Chrome Environmental: Less hazardous as there

MACHINE TOOLS WORLD MARCH 2018

is no Hexavalent chrome involved dust disposal; easier than bath liquid. Performance: 3-4 Times more wear resistant than Hard-chrome; Micro porosity holds lubrication; Selective area coating is possible; Higher thickness up to 300 microns per side is possible. Limitations: Ceramics are brittle and are to be handled carefully. The process is not as widely available as hard-chrome. Spraymet Surface Technologies Bangalore-based Spraymet Surface Technologies Pvt. Ltd., headed by Mr. P.T. Bindagi, Technical Director and a veteran metallurgist, is engaged in thermal spray, ENP plating and weld surfacing. While their main plant is in Bangalore, the second plant is located in Pune, to stay closer to its customers especially from the automobile sector which is demanding technical excellence, proximity and

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

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

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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Angle Encoders

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Contouring Controls

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Rotary Encoders

TECH TRENDS

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

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

MACHINE TOOLS WORLD MARCH 2018

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

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

Diamond Roll Dresser

MEASUREMENT ERROR

MEASUREMENT PRECISION

The non-contact Mida ML75P laser tool pre-setting and verification system is the key to maintaining the micrometric accuracy required by the most demanding machining applications, as in the aerospace field. You get consistent quality, less waste and more profit. Marposs means precision.

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TECH TRENDS

Linear Guideway

Servo Regulating Wheel Drive

to reduce all the above costs to an optimum level. a. Power Cost: The maximum power consuming motor is the grinding wheel motor. We procure the motor such that during idling time of grinder in each cycle it would draw very low current, while providing full torque during the grinding process. Such motors have rating

MACHINE TOOLS WORLD MARCH 2018

of Eff 1 or better. The other options include soft start for grinding wheel motor or Variable Frequency Drive for regulating and grinding wheel motor. These options avoid peak current required for start-up of the motor. b. Employees Cost: Machine automation is designed in such a way that the operator can run more than one machine at a time. In mass production plants, the focus is to have one skilled person to look after the setting and inspection of finished components for all grinders. Loading, unloading and other routine operations are done by unskilled employees. CNC options also reduce the operator intervention to a large extent and thereby reduce the cost. At the time when customer sends the plant layout, we give suggestions and inputs to reduce material handling and make it ergonomically convenient in order to reduce operator fatigue. Variable Frequency Drive is installed to achieve Constant Surface Speed for Grinding Wheel. This helps in reducing the dressing frequency even when the wheel diameter is reduced.

Hence, the grinding wheel is used to its optimum level. c. The other consumables like oil, coolant, diamonds and wheels are selected with the help of various manufacturersâ&#x20AC;&#x2122; input and expertise, to suit each application. 4. The increase in fuel prices and depreciation of Indian currency has put a lot of burden on manufacturers to improve the fuel efficiency of vehicles. This calls for more close tolerance in manufacturing parts. Quality Parameters are a combination of Size Tolerance, Roundness, Cylindricity and Surface Finish. We use Precision Linear Guideways to achieve practically friction free movement. This enables the slide to move with high accuracy, as close as 0.25 microns and helps in maintaining size in close tolerance. To achieve roundness in 1 to less than 1 micron, it is necessary to have rigid spindles and vibration free grinding. We mount Automatic Wheel balancers, which balance wheel with vibration level less than 1 micron. This also helps improve Cylindricity. Coolant supply while dressing the wheel has to be forced at the point of contact of diamond and wheel. Proper forced coolant supply helps to dress well, which in turn helps in improving surface finish on component. Coolant supply during grinding is conventionally done by free flow of coolant on the part. Due to air turbulence because of wheel rotation, most of the coolant does not reach the actual grinding area. With redesigned nozzles and flapper to stop air turbulence, the coolant now reaches grinding hot spot to almost 90% level. The overheating of parts and burning marks are reduced and surface finish improved. The above are some of the innovations & adaptations incorporated in the machine to meet the demand of the industry for better & greener tomorrow.

TECH TRENDS

Laser Triangulation: Getting from point to line Optical measurement techniques play an essential role in the increasing automation of manufacturing and inspection processes. Most modern laser triangulation technology is responsible for fast, high precision and reliable measurements of manufactured components and their measuring points. Measurement data is generally available in real time and so can be used to automatically correct and control the production process.

ptimised processes improve product quality, reduce raw materials and energy, which minimises production costs. With its wide range of precision, high speed optical displacement and distance measurement sensors, for many years Micro-Epsilon has held a leading position in the market for non-contact measurement technology. The triangulation principle involves the measurement of distance on a wide range of material surfaces where different measurement techniques are employed: the measurement of displacement, distance and position using a laser point, and profile or gap measurement using a laser line. Regardless of how different these techniques are, they are united by their high precision, high speed and reliability. Laser point sensors The laser triangulation principle is based on a simple geometric relation. A laser diode transmits the laser beam onto the measurement object. A lens focuses the reflected rays onto a CCD/CMOS array. The distance to the measurement object can be determined by the three-point relationship be-tween the laser diode, the measuring point on the target object, and the pro-jection on the CCD array. The measurement resolution can achieve a frac-tion of a micrometre. As well as analogue interfaces, digital interfaces are also available for direct connection with the existing environment. Sensors with digital interfaces are configured via an external PC.

MACHINE TOOLS WORLD MARCH 2018

optoNCDT 1320/1420 laser sensors convince due to their unique conception & design and have therefore even been awarded with the Red Dot Award Industrial Design 2016.

Laser-based optical displacement sensors measure from a large distance to the target using a very small spot which enables measurements on the very small parts. The large measurement distance in turn enables measurements to be taken against difficult target surfaces such as hot metals. The non-contact principle enables wear-free measurements as the sensors are not subject to any physical contact with the target. Furthermore, the laser triangu-lation principle is ideal for very fast measurements with high accuracy and resolution. One example that requires fast, high precision measurements in a minimum design envelope are automated pickand-place machines. Here the laser point sensors demonstrate their

advantages when it comes to quality control of tiny components as these must be positioned the correct side up, at the correct location and at the correct height. Other challenges include the in-spection of even smaller IC pins of a component in order to check that they are positioned at precisely the correct distance from the circuit board. These pins later enable connection to the circuit board. In order to guarantee proper soldering, the distance between both components must not be too high. The so-called â&#x20AC;&#x2DC;coplanarityâ&#x20AC;&#x2122; indicates if all the pins are arranged in line with each other and is therefore considered to be the critical factor that must be in-spected using high precision measurement technology. The component is guided

TECH TRENDS over a triangulation displacement sensor whose laser beam scans the pins. After calculation of the distance values, the sensor arrives at a decision on whether the component should be placed or removed. The requirements on the measurement technology are enormous; not only because the parts are extremely small, but also primarily due to the rapid change from shiny to matt surfaces. The pins consist of a shiny metal, whereas the circuit board presents a matt surface. Therefore, the receiver element in the sensor is at frequent intervals alternately exposed to strong and then weak reflections â&#x20AC;&#x201C; a task that the optoNCDT 1420 laser sensors are optimised to perform. The Auto Target Compensation (ATC) feature provides fast control of different reflections and enables a smooth signal frequency of the distance signal. With the optoNCDT 1320/1420 laser sensors, Micro-Epsilon sets new standards in laser triangulation in terms of functionality and design which has re-cently been awarded with the Red Dot Award Industrial Design 2016. Since 1954, the â&#x20AC;&#x153;Red Dotâ&#x20AC;? award has been a globally acknowledged seal of quality. These laser sensors stand out due to their perfect and unique combination of various characteristics. The extremely small laser spot size, which is focused through an optical system to a very small diameter, enables the measure-ment of extremely fine details. Their compact design without external control-ler

The optoNCDT 1320/1420 laser point sensors measure smallest details, for example when inspecting the coplanarity of IC pins in pick-and-place ma-chines.

MACHINE TOOLS WORLD MARCH 2018

Production control of smartphones, laptops and tablets using laser line triangulation.

enables their installation in restricted space and even the integrated evaluation electronics is space-saving and simplifies cabling. Furthermore, the ex-cellent price/performance ratio and the innovative web interface, which sim-plifies sensor set up by providing predefined set ups for different surfaces (e.g. circuit boards). As well as in the electronics production, the laser sensors are also applied in the packaging industry, wood processing, logistics, medi-cal engineering, laser engraving equipment and quality assurance. Laser line triangulation As well as for the inspection of onedimensional quantities, there is a demand for the multi-dimensional quality control in industrial production. Laser profile scanners are increasingly used for profile and contour measurement applica-tions. Their operating principle is based on the laser triangulation technique for two-dimensional profile detection. They detect, measure and evaluate the profiles on different object surfaces. By using special lenses, a laser beam is enlarged to form a static laser line instead of a point and is projected onto the target surface. An optical system projects the diffusely reflected light of this laser line onto a highly sensitive sensor matrix. In addition to distance infor-mation

The scanCONTROL 29xx-10/BL stands for precise laser line triangulation measurements of tiny objects.

(z-axis), the controller also uses this camera image to calculate the position along the laser line (x-axis). These measured values are then output in a two-dimensional coordinate system that is fixed with respect to the sen-sor. In the case of moving objects or a traversing sensor, it is therefore possi-ble to obtain 3D measurement values. Laser scanners are equipped with an integrated, highly sensitive receiving matrix that enables measurements on almost all industrial materials, largely independent of the surface reflexion. The inspection of adhesive beading in smartphone housing is a typical appli-cation. A particular challenge here is the very fine contours inside the smartphone and extremely thin, partially semi-transparent adhesive beading. Here, absolute reliability and 100 per cent control of the completeness of the beading, the height and width

TECH TRENDS provide twice the resolution of previous laser scanners with a 25mm measuring range. These special characteristics enable these laser scanners to detect even smallest parts with highest precision. Therefore, reliable quality control involving the monitoring of individual production steps is necessary. The combination of compact scanner, integral controller and different interfaces makes this laser profile scanner highly suit-able for inline applications and for dynamic production control.

In the C-frame, the sensors are mounted fixed on an upper and a lower arm for differential thickness measurement. The frame is moved as a unit to reach the measurement position.

of the applied adhesive are required. This also applies to the logos on tablets and laptops: grooves are milled into the alumin-ium housing, in which the logo elements are glued afterwards. The latter must be flush with the housing. Haptics (i.e. touch sensation) is a critical factor, as the customer would immediately feel any protruding logo or depression. Using laser line scanners, these depressions are measured in order to determine the planarity as well as the depth. The parts being glued are also measured in order to

MACHINE TOOLS WORLD MARCH 2018

ensure a perfect fit. Laser profile scanners operate with a red or more recently a blue laser line. From the very early days, these optical standard sensors used a red laser light as the receiving element as this had the highest sensitivity. With a lot of applications, the laser profile scanner using a red laser line provides precise results. However, when detecting red-hot glowing, transparent or organic ob-jects, the red laser has limitations. MicroEpsilon has revolutionised this technology and presented some years ago a world first: the Blue Laser Technolo-gy in the form of laser point sensors. Unlike the red laser, the blue laser light does not penetrate the measurement object and projects a sharp line. There-fore, red-hot glowing and organic objects can be measured reliably and with high precision. The scanCONTROL 29xx-10/BL sets a new standard in terms of profile resolution. Equipped with Micro-Epsilonâ&#x20AC;&#x2122;s innovative Blue Laser technology, the new model provides an effective measuring range of just 10mm with a profile resolution of 1280 points. This results in a point distance of just 7.8Âľm, which enables the laser profile scanner to

Measurement and inspection systems using laser triangulation Triangulation sensors are also used in measurement systems e.g. for thickness measurement of metals. The principle of dimensional, geometric thick-ness measurement includes one optical distance sensor on each side of the material. Thickness measurement using laser point sensors is based on one point respectively, whereas in thickness measurements using laser profile sensors, the entire laser line is processed. For thickness measurement during production, the difference between the sum of the distance signals and the value of the operating range is determined. Both laser lines must be projected congruently onto the top side and the rear side of the material in order to achieve an accurate thickness measurement. The right choice With its high precision, measurement speed, compact size and fast data pro-cessing, non-contact measurement technology offers many benefits. The user can choose from different measurement systems. Each principle comes with its own particular advantages and limitations that all need to be carefully considered. As demanding applications require e.g. higher resolution, robust-ness, temperature stability, linearity or special mounting and installation condi-tions, Micro-Epsilon offers special solutions and custom designs that are adapted to the customerâ&#x20AC;&#x2122;s specifications.

TECH TRENDS www.mtwmag.com

EWAG PROFILE LINE â&#x20AC;&#x201C; high-precision, flexible 5-axis grinding centre The new PROFILE LINE from EWAG is a solution for efficient and flexible machining of indexable carbide inserts

he new PROFILE LINE from EWAG is a solution for efficient and flexible machining of indexable carbide inserts. The machine is built in close partnership with sister company Walter Maschinenbau GmbH and enhanced with Ewag AGâ&#x20AC;&#x2122;s tooling and software expertise. This partnership has produced an extremely efficient grinding centre for advanced grinding of highly complex interchangeable insert geometries, including interfaces. The innovative technology of the PROFILE LINE has set new standards of production efficiency for these applications. For example, an intelligently integrated 6-station changer for grinding wheel sets and coolant supply manifolds ensures optimum wheel selection, thereby maximising the machining volume for sintered blanks. Another outstanding feature for autonomous multi-shift operation is the intelligently integrated, flexible automation with a 6-axis Fanuc robot. Customer-specific pallets can be

accommodated in the user-friendly robot cell. A high-resolution CCD-HD vision system is available for loading grid pallets using magnetic grippers. Cleaning, reclamping and centring stations can also be integrated and adapted to the customerspecific product range. Perfect software is required to create perfect geometries of interchangeable inserts on the machine. But the PROFILE LINE offers even more by combining ProGrind software from EWAG with HELITRONIC TOOL STUDIO from WALTER. The machine is totally

unprecedented thanks to this unique combination of expertise and know-how from the two machine tool manufacturers. This dramatically expands the range of applications for an extremely wide variety of interchangeable inserts. In drilling or milling applications, even complex geometries can be ground in one set-up thanks to the ultra-precise interfaces of the indexable inserts. This boosts precision and productivity enormously. Furthermore, the FANUC control unit ensures maximum reliability, availability and ease of use for the user.

MARCH 2018

MACHINE TOOLS WORLD

TECH TRENDS

Automatic Guided Vehicle Future of Industrial Logistics Srihari S, DGM – Operations, CNC India

n the quest to reduce cost of manufacturing, the industry began to automate a lot of operations and one such operation is the movement of material. Automatic Guided Vehicles (AGVs) became the unanimous answer for manufacturers to transport materials seamlessly. AGVs are designed for performing operations with quick turnaround time, repeatability and accuracy. An AGV is a portable device that follows a specified path using specific markers using vision system/ laser tracking / magnetic tracking or advanced navigation systems. Today, they are widely used in the industry for: • Repetitive movement of materials over a distance • Regular delivery of stable loads • Processes where tracking material is important • Movement of hazardous material. AGVs can be broadly classified into Cart Type, Tow type and Powered Deck Type based on material movement. They can also be classified based on navigation method such as, Magnetic Type, Laser Type etc. AGVs consist of 4 major systems: Navigation, Steering Control, Collision Detection System and Power Backup. Navigation To help AGVs navigate, two things need to take place – Navigation and Steering Control. An AGV normally consists of navigation system, steering controller, power back and safety system. It has various sensors including a laser system or a GPS system for navigation. Navigation in general is thru laser or magnetic strips. They have a set of scanners which ensure the path of the AGV is maintained throughout. Advanced development in scanner and “localized GPS” have made navigation easier. Field scanners are provided at

various locations to understand dynamic movement of the “obstructions” such as machines, racks, temporary walls etc. Intelligence is built in to AGVs to decide an optimal path based on given traffic and obstruction. AGVs can be programmed with the destinations, loading and unloading of objects. They follow the path and communicate with the loading and unloading equipment. Steering control is achieved thru differential speed mechanism where 2 independent motors are mounted which rotate at different speed to achieve turning or straight movement. The movement is controlled by PLC based navigation system. The major challenge with AGVs is power supply. They carry the power system on their back wherein battery swapping is the usual method to keep the AGV running. However, wireless charging is becoming a common feature and charging points are provided at every load / unload station thus, enabling charging at every station. Assured Safety Collision detection system is a major safety requirement in AGV. Normally front mounted scanners like ‘radars’ are provided to detect objects on the path. AGVs are equipped with bumper mounted sensors for detection of physical collision. Additionally, safe zones are created by field mounted scanners along the path wherein, each AGV will have a transmitter and receiver. As the AGV enters a zone, they receive signals confirming “clear” to enter and pass. These features have made AGVs collision free to a large extent.

MACHINE TOOLS WORLD MARCH 2018

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TECH TRENDS

Accusharp tells more about

‘Gundrilling’!

ince 1999, Accusharp is in the activity of manufacturing metal cutting ‘Round Tools’ like Carbide and H.S.S. drills, end-mills, reamers, cutters, burrs, form tools, step drills, etc. As a matter of fact, it is difficult to drill a straight and accurate dimensional hole of a depth more than about five times the diameter using a standard twist drill. However, using a ‘Gundrill’ one can make a ‘Deep’ hole of much longer depth; even 200 times the drill diameter. Not only it drills 200 times deep, but also with the precision tolerance of hole size, roundness, straightness, concentricity and surface finish in one pass. As it can cut small diameter and long length holes, the Gundrill can be also suitable for very deep hole drilling to machine parts as up to a 200:1 ratio for drill depth to drill diameter. This typical drill was initially developed 100 years back, to drill Gun barrels having 5.56 mm (0.223 inch) bore caliber barrel of rifles with 508 mm (20 inches) length, - nearly 100 times the diameter of the bore. The Gundrill was developed to drill such long, straight holes of high accuracy dimensional requirements. And since then, this type of drill is known as ‘Gundrill’, even if subsequently it is being used for other industry requirements and applications. Because of the high capabilities of this innovative ‘Deep Hole Drilling Concept’, it was but natural, that various industrial sectors got attracted to assess its appropriate extended use for their metal cutting applications. And since then it became widely popular in other industry sectors, as well. Gundrilling is an ideal solution for most

MACHINE TOOLS WORLD MARCH 2018

of the deep and high precision drilling projects. This operation produces deep holes with precision, high surface finish, and can maintain repeatability of the process. Looking at the present increasing need from various industry sectors, those who are in metal cutting, Accusharp, this year, decided to make ‘Gundrills’ to meet the industry requirements. More about ‘Gundrill’ for Deep-Hole Drilling: Gundrills can make holes of exact specified size, with precision tolerances, produce burr-free holes. It can also be used with special formed shapes in blind holes for bottom forming with a minimum of machine revisions. Gundrilling can be done on CNC machining centers, lathes and milling machines with relatively small investment. The process can be made affordable even for small shops with their various production requirements. Gundrill Construction: Gundrills consist of three elements: 1) a carbide tip, 2) a heat treated alloy steel shank, and 3) a steel driver -Typically silver brazed together and ground as one precision unit.

Carbide Tip: This is the real cutting portion of Gundrill, made of special grade of Tungsten Carbide. Tip guides the drill through the work piece and cuts the hole of precision dimensional properties. The drill-point, or nose geometry has two basic angles which may vary according to the work material and process parameters. These angles balance cutting forces on the bearing bush to keep the drill concentric. The tip diameter is slightly larger than the shank diameter, so that the shank can rotate freely without touching the hole. A round, kidney-shaped, or two round holes through the tip are provided through which high pressure coolant passes continuously during the drilling operation.

Gundrill Tip can be resharpened several times to extend their life.

Shank: The shank is made of special alloy steel tubing with a110° -120° Vee-flute. Coolant is pumped in to the driver through the centre of the shank towards the tip, there from it is flushed back along the shank’s flute. The shank has to maintain Gundrill

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TECH TRENDS alignment; and therefore it should be strong enough to absorb cutting torque and thrust. If the shank is too stiff it may misalign the entire tool set up. However, if the shank is more flexible, it may sag at high RPMs. Driver: Driver is a cylindrical piece located at the other end of the Shank. It is made of special alloy steel, and dimensionally according to industry standards. Driver has a concentric hole through its length for coolant to pass through in to the Shank. This also has an undercut or flat section for the set screw, which holds in the spindle bore. Two Flute Gundrills, with special nose geometry, are used for non-ferrous materials and allow for up to 80% increase in feed rates. The Working Principle of Gun Drilling Process: Long length of the Gundrill Shank is externally supported by bushes or bearings to avoid vibrations and to maintain the linearity, roundness precision and desired surface finish of the drilling operation. High pressure coolant, assuring sufficient flow rate, is pumped in to the Gundrill towards the cutting edge of the Carbide Tip, through the V- shaped fluted tubular shank. The coolant, this way reaches the machining zone. Thereby it cools and lubricates the

cutting edges of the Tip and also the Shank supporting bearing area. The coolant flow also serves to pick up chips formed at the cutting edges and to transport them into the Chip Box, through the V-flute. Gun Drilling diameters have normal range between 1mm to max. 50 mm. Depth to Diameter Ratios vary according to the type of the drill and process being used. Ratio

Cutting Tool & Process

5:1

Using common twist drills

10:1

Using high performance twist drills with through coolant

20:1

Using special deep hole drills with through coolant

100:1

Using Gundrills on dedicated Gundrilling machine

200:1

Using Gundrilling on high performance Gundrilling machine

300:1

Using Special nose geometry Gundrills in proprietary processes.

What are the advantages of Gundrilling process? • Gundrilling is a single pass complete operation, which does not call for any subsequent operations, like reaming, honing, de-burring after its initial pass. • Constant flow of pressurised coolant not only transports chips into a chip box, but also keeps the cutting area and tool edges cool. Thereby increases tool-life considerably.

Application of Gundrills in Industry Sectors: Mould-Industry, Aerospace, Automobile, Machine Tools, Paper Industry, Defence, Mining Tools, etc. Gundrills practically can be used in any industry wherein close tolerance long length holes need to be drilled in metal components. For Example: • Die & Moulds • Water lines • Heat exchanger tube sheets • Machine Tools, Oil Holes, Fixtures • Turbo Blades • Paper Rolls, etc

On the occasion of IMTEX 2017, Accusharp has introduced ‘Gundrill’, as its ‘New Product’. A wide range of diameters between 3 and 32 mm is on the production programme, and Gundrills from this range were displayed in the IMTEX stall. One Gundrill of dia. 32 mm having length of 1 meter was specially displayed; which became a point of attraction for many customers and visitors at the IMTEX stall. In a short span of time from the launching of this new product, Accusharp has received encouraging response from a number of customers for their requirements of various sized Gundrills.

Accusharp Gundrills

‘Cut Fast & Cut Cost’!

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TECH TRENDS

DMG MORI sharpens Die & Mold excellence In the Die & Mold Excellence Center, DMG MORI has been bundling decades of experience in die and mold making with a forward-looking product portfolio and the design of individual manufacturing solutions with continuous process chains. With the DMU 200 Gantry and DMU 340 Gantry, DMG MORI presents two world premieres for large component machining for die and mold making at the EMO 2017.

ie and mold making are among the core competences of DMG MORI. With far-reaching effects, as Markus Piber, Managing Director of DECKEL MAHO Pfronten GmbH, says: “Great importance has been placed on die and mold applications at DMG MORI for decades, which on the one hand has resulted in our enormous experience in this field and on the other has given and continues to give rise to path-breaking technologies.” The demands on precision, long-term accuracy and surface quality has transformed die and mold making into one of the most challenging manufacturing areas. “These demands are met by high-precision and dynamic machining centres”, adds Markus Rehm, Managing Director of DECKEL MAHO Seebach GmbH. DMG MORI concentrates their experience and skill in die and mold making in the DMG MORI Die & Mold Excellence Center. The developers there implement cross-sector and unique processes – from

MACHINE TOOLS WORLD MARCH 2018

programming through milling strategies up to the selection of holders, dies and die clamping as well as automation solutions. Markus Piber comments on the work method: “We involve our customers in the projects at a very early stage to enable us to learn from one another and achieve optimal production solutions.”

Full-liners in die and mold making DMG MORI’s large product portfolio makes the machine tool manufacturer the right partner for every die and mold application. It starts with 3-axis machining on the powerful vertical machining centres from the DMC V series, which already set the standard with the speedMASTER® with its 20,000 rpm spindle, an innovative cooling concept and direct path measuring systems that achieves the precision demanded. The vertical machines from the NVX series expand on this with their excellent stability and damping with slideways in all axes. The speedMASTER® spindle with integrated cooling reaches a rotational speed of 15,000 rpm. The 5-axis machining centres from DMG MORI master the most complex geometries. The range of products extends from the universal DMU monoBLOCK series with swivel rotary table, maximum automation options and up to 2,000-kg table loading capacity through the dynamic DMU eVo linear models with rapid traversing speeds of up to 80 m/min up to high-speed milling on the HSC 20 linear and their big sister machines. Speeds of up to 60.000 rpm here guarantee the optimal surface quality that is demanded in die and mold making. “As a single-source provider, we provide services for the entire range of components used in the industry – from the smallest electrodes up to XXL compoDMG MORI’s gantry series extends from the DMU 600 P in the XXL area to the DMU 210 P little sister machine.

TECH TRENDS The LASERTEC Shape technology makes it possible to perform laser texturing of geometrically defined surfaces.

The DMU P series enables productive 5-axis simultaneous machining of complex shapes and tools.

With speeds of up to 60.000 rpm HSC machining guarantees the very best surface quality.

nents”, notes Markus Piber. This is why the successful DMU 600 G linear is primarily installed for large part machining in the area of die and mold making. With the DMU 340 Gantry, the XXL machines gain a little sister model just in time for the EMO, which effectively extends the product palette here to cover a whole range of different sizes of components. Its work area measures 3,400 x 2,800 x 1,250 mm with expansion options of up to 6,000 mm in the X-axis and 1,500 mm in the Z-axis. Thanks to the gantry design, the DMU 340 Gantry also offers a compact footprint. With the DMU 200 Gantry, DMG MORI will round off the Gantry series at the EMO. 5-axis machining with up to 30,000 rpm and optional ULTRASONIC or LASERTEC technology integration will

MACHINE TOOLS WORLD MARCH 2018

also enable complex components up to a weight of 10,000 kg made of aluminium or composites to be economically machined. “Especially the ratio of the large working space of 2 x 2 m to the installation area of less than 24 m² has also impressed our customers”, explains Markus Rehm, Managing Director of DECKEL MAHO Seebach. The XXL portfolio also includes the DMU 600 P for workpieces up to 3,000 x 6,000 mm and 40,000 kg. But also the smaller DMU 210 P and DMU 340 P, in the 3-axis as well as the 5-axis models enjoy great popularity in the car industry for the production of fittings. DMG MORI round off their range of products for die and mold applications with the machining centres from the DMU monoBLOCK and DMU duoBLOCK series. The DMU 125 monoBLOCK with space for workpieces up to 1,600 mm long and up to 6,000 kg in weight in the 3-axis variant is thus a popular model positioned between the smaller machining centres and the large gantry models. Markus Piber comments on DMG MORI’s advanced technologies: “We have set new standards in the mold-making sector with the innovative LASERTEC Shape technology.” The laser texturing of geometrically defined surfaces is more environmentally friendly than etching and offers enormous design freedom in addition to the highest repeat accuracy. “Also here we are able to accommodate all the relevant component sizes with the LASERTEC 45 Shape to LASERTEC 210 Shape range.”

The future of die and mold making “The highly-accurate machines are naturally a decisive factor for competing on a global scale”, understands Markus Piber. Intelligent automation solutions and innovative technology cycles are also just as important: “And the Die & Mold Excellence Center allows us to complement the entire integrated production process.” Pallet changers, pallet rotary storage and linear pallet pools are the bread and butter of automation. But features to support the process are also in high demand like never before. This includes immediate tool measurement in the work area or DMG MORI technology cycles such as the Application Tuning Cycle (ATC). This adjusts the feed rate of the respective table load, reduces processing time and maximises the component quality. DMG MORI paves the way into the digital future of die and mold making with CELOS. Aided by CELOS APPs, the integrated user interface installed in all new high-tech machines simplifies integrated management, documentation and visualization of order, process and machine data. In the area of die and molds, Markus Piber has a clear goal: “Our product and performance range offers the customer maximum flexibility and provides them with the capability to keep pace with the innovation speed of their customers.”

TECH TRENDS

Compact Rail Linear Guides: The ideal solution from Rollon for compensating misalignment and for environments with impurities

ompact Rail stands out in the extensive range of solutions for linear motion from Rollon, an international group based in Vimercate (MB-Italy) and present in India with a branch in Bangalore. Compact Rail is a system created by using linear rails in cold drawn steel with induction hardened and ground raceways and ball bearing sliders, the result of excellent know-how gained in over 40 years of experience. These products are known for their reliability, and for the several ways in which they can be customized. The linear rails are fitted with ball bearing sliders, also made of hardened steel. Compact Rail has compact dimensions, and is silent and fast (up to 9 m/sec). It is easy and convenient to install on all surfaces, even if rough, thanks to its capability to deal with misalignment of up to 4 mm. Compact Rail offers several advantages and proves to be the best choice in comparison with other types of rails, like recirculating ball guides, if it is necessary to manage an imprecise or irregular structure. These rails from Rollon are perfect in particular for long strokes, but also when the rail is mounted in environments with impurities or debris, or for outdoor applications (for example, in special vehicles, trains, and platforms for

Rollonâ&#x20AC;&#x2122;s Compact Rail system is inherently tolerant of misalignment, thanks to a rail geometry that can absorb alignment errors in one or two axes.

disabled users). The use of ball bearings keeps sliding quality at the optimal level, even with dirt residue, while Rollonâ&#x20AC;&#x2122;s surface treatments guarantee resistance to weather and corrosion. In several types of applications involving linear movement inside industrial machines (such as lateral sliding protection guards or the movement of control panels) or in cutting machines, wood and ceramics working machines, and the packaging sector, Compact Rail is more and more often the best choice as opposed to rails with recirculating ball. Savings Ensured with Compact Rail It compensates for misalignment without additional processes and it lengthens life span. Compact Rail can compensate for

MACHINE TOOLS WORLD MARCH 2018

misalignment in a range of up to 4 mm, no other processes are required and there is no need to even add bases to guarantee perfect efficiency of the linear motion. This lowers the comprehensive cost considerably. Rails with recirculating balls, on the contrary, are extremely precise and require an alignment in the range of tenths of millimeters. In case of misalignment, the stress generated increases the load up to double the actual load, which reduces the systemâ&#x20AC;&#x2122;s lifespan to one eighth of what it should be, and causes a difficult situation of instability. Dirt is no problem Compact Rail, thanks to its bearings, works without problems even in contaminated environments or in presence of debris. No specific protections are required, unlike rails with recirculating balls.

TECH TRENDS

The Compact Rail system offers three different rail profiles, which can be combined to compensate for different types of misalignment.

Easy, fast assembly Thanks again to self-alignment capacity, even assembling the rails is easier and quicker: rails with recirculating balls require twice the time to mount. Other Advantages of Rollon Rails Low noise Compact Rail operates silently, thanks to its ground raceways, while rails with recirculating balls require specific spacers to reduce noise, but their operation becomes problematic if dirt is present. Simple effective lubrication Rollon guides, unlike with rails with recirculating balls, can manage lubricants in low and high temperatures, without derailing in freezing temperatures or reductions in sliding performance. Standard and customized surface treatments Rollon provides electrolytic galvanizing as a standard treatment for protection against corrosion, in case of use indoors. On request from clients, the anti-corrosion treatment RollonAloy is available, which strengthens resistance to weather in case of outdoor applications, and rails with chemical nickel plating are able to resist to corrosion caused by chemical substances. Sidebar: RollonAloy anti-corrosion treatment: 720 hours in saline mist, in compliance with standard ISO 9227 The Rollon R&D department is specialized in researching surface

MACHINE TOOLS WORLD MARCH 2018

treatments to guarantee maximum resistance of components to corrosion: RollonAloy was created from this research. It is a particularly effective formula for contrasting humidity, exposure to weather and drastic temperature differences. Treated components resist up to 720 hours in saline mist (test done according to the ISO 9227 standard). This makes them particularly suitable for outdoor applications such as for special vehicles or train underfloors (for instance, extracting the battery housing) and fire-fighting or air-conditioning plants. The various test phases Inside a test chamber, the samples are covered in a (5%) sodium chloride solution with a pH of 6.5 (at a temperature of 35 Â°C) by a misting nozzle. The evaluation is done at preset time intervals The quality of the surface protection is measured based on the test time and the integrity conditions. Market demands can vary greatly, depending on the type of application and the working environment: for this reason Rollon also offers other types of surface treatments, such as electrolytic galvanizing and chemical nickel plating, always in conformity to current international standards. Sidebar: Rollon: constant linear evolution since 1975! Rollon, an international group based in Vimercate (MB-Italy), has a thriving

Axial Parallelism Error

research and development department and has recently finalized strategic acquisitions (five in the last six years). The company can offer a range of mechanical solutions based on integrated, highly customizable product lines, which are among the most complete on the market. Rollon is the ideal technological partner for companies operating in the industrial automation sector. Rollon is present in 10 countries, with around 570 employees: their constant investments have brought about significant growth in turnover, 70% in the last three years, which peaked at 94 million Euro in 2017.

For more information: Rollon India Pvt. Ltd. Email: info@rollonindia.in Website: www.rollonindia.in

TECH TRENDS

G350T and G550T – Generation 2 5-axis universal machining centers from GROB

he G350T, G550T and G750T 5axis universal machining centers pro vide cus tomers in the machining industry almost limitless options for milling and turning workpieces from various materials. Three linear and two rotary axes enable five sided machining with fiveaxis simultaneous interpolation. With a swivel range of 225° on the A‘axis and 360° on the B‘axis, they provide opti mum flexibility in terms of positioning. Their drive concept is based on two symmetrically located ball screws and weight compensation with the G550T/ G750T in the Y‘axis and dynamic, wear free torque motors in the A’ and B’axis. Further benefits include the optimum position of the operating point (TCP) for extremely high rigidity, the longest Z axis travel for this machine class and the fact that the maximum workpiece size can be machined in the workspace with maximum tool length. G1050 large-scale machining center The G800 has been known as a machine concept for specific customer requirements in the system machine sector since as far back as the GROB inhouse exhibition in 2015. The G1050 now introduces the concept as a standard

MACHINE TOOLS WORLD MARCH 2018

GROB design for the universal machine market. With its innovative axis concept and ideal pallet size, the G1050 largescale machining concept provides customers in the universal machining sector with versatile applications across a wide range of industries. The 4 or 5axis modular system makes it ideal for adapting to specific customer requirements. The palette size of 800 x 800 mm to 1,000 x 1,250 mm is particularly suited to machining large components such as engine parts and rear axle covers for utility vehicles – and even whole axle brack ets. This means that components can be machined up to an interference diameter of 1,600 mm and a height of 1,500 mm. Steeply inclined chip conveyors in the machine work area are best for chip evacuation – even for dry machining. Precisiontimed toolchange alarm for tool weights up to 50 kg ensures excellent chiptochip times. Due to its generous guideway distances, the machine delivers amazing rigidity, even with extralong tools up to 850 mm. Plenty of equipment features for great flexibility Customers can choose from a wide range of GROB motor spindles developed

and manufactured inhouse – ensuring optimum process design and the right spindle for their specific requirements. GROB spindles have the shortest run up times and are easy to access and maintain. They are suited to all common cooling lubricants, giving them universal usability – with excellent mechanical features and extreme durability. GROB largescale machining centers give customers the choice of the latest marketleading CNC control systems, achieving better productivity. Setup can occur simultaneously to the tool being machined thanks to the dual palletchange system. GROB also offers additional software options to suit customer specifications, meaning that the large scale machining center can be adapted to specific customer requirements. The G1050 machine concept provides excellent process reliability, cost efficiency and durability. With the new pivoting milling head on the 5axis version, the G1050 can switch from horizontal to vertical machining mode in seconds. This makes the G1050 ideal for universal machine manufacturing, the aircraft industry, moldmaking and power engineering in the universal machining sector, too.

CASE STUDY

Another 12 meters Pipe rolling machine for the Russian Oil & Gas industry ready for delivery. Customer satisfaction guaranteed!

ipes production technology is an area of such complexity that only companies with many years of experience and high technology background can safely and reliably work in and deliver machines suitable for the most challenging projects. Faccin SpA has many years of experience in the design and manufacturing of special machines, standard and customized, for the production of pipes. Using the latest technology, the company follows from its 60.000 sqm facility in Visano, Italy, the construction of the machinery at every stage, from receipt of the order to design by the in-house engineering department, from construction of electro-welded structures to machining of structures and forged rolls up to assembly, shipping, installation and training. In order to meet specific production requirements for the Russian Oil & Gas industry, Faccin has just finished another HAV-2P, a NC-controlled highperformance pipe mill bending rolls able to support the production of pipes delivering productivity, repeatability and automation of the entire process. These pipe production bending rolls are constructed with extremely sturdy electro-welded structures and are fitted with three rolls in thermally treated steel alloys. The rolls of the special HAV-2P bending rolls are moved independently – the top roll moves vertically, the lower rolls move horizontally – and allow the power of the machine to be fully exploited, depending on the various thicknesses to be rolled. To offer high performance in the production of long pipes with relatively small diameters the lower rolls of

MACHINE TOOLS WORLD MARCH 2018

the HAV-2P bending rolls are supported by backups for their entire length. The top roll is preloaded to compensate for the flexion during plate bending and may be replaced quickly to extend the range of diameters and thicknesses that can be obtained by rolling. HAV-2P long bending rolls are designed for rolling plates generally from 5 to 45 mm thick, ideal for producing pipes up to 18m long and diameters from 15in to over 60in, complying with technical specifications, tolerances and quality of the API standards. For further increase the production speed and automation, Faccin proposes in addition to the HAV-2P pipe mill bending roll, an accurate postbending machine that prepares the pipe for welding and a series of outboard motorized guide rollers that control the movement of the pipe from the HAV2P to the post-bending machine and successive working stations. For specific customer projects, Faccin’s professional engineering and R&D department designs and produces customized solutions that effectively suit the requirements of the most exigent pipes producers.

Faccin is one of the world leaders, with more than 50 years’ experience, in the design, manufacturing and commercialization of plate bending rolls, profile bending machines, dished head machinery and special machines including ship frame bending rolls and presses, plate straightening machines. With a technologically advanced production and certified ISO 9001: 2008, Faccin is the largest production facility in the world of bending systems and plate bending machines. Through an extensive network of subsidiaries, Faccin provides thorough sales and after-sales service worldwide.

Do not miss the opportunity to

to see this giant before it leaves our factory & learn about our technology for pipelines production! Learn more about us and discover our latest developments by visiting our website www.faccin.com Watch Our Corporate Video

Linear solutions global provider.

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

Linear Line

Actuator Line

Telescopic Line

Actuator System Line

Rollon is a global provider of linear motion solutions for several industrial sectors, such as: industrial machines, railway, automation, packaging and logistics, aerospace.

CASE STUDY

ANCA’s MX5 and TX7 helps Aayudh Tools increase productivity by 30% Aayudh Tools based in Aurangabad, India achieves high accuracy and repeatability and a web centrality controlled within 10 microns

ituated at the manufacturing hub of western India Aurangabad in Maharashtra, Aayudh Tools has been engaged in cutting tool manufacturing since 1990. Driven by a passionate and experienced professional Hemant Dadhe, the company has carved a niche for itself in the competitive Indian cutting tool market with its tailor made solutions and highly reliable tools. After working with companies like TATA Motors (then TELCO) and Sandvik, Hemant Dadhe, started Aayudh Tools with a vision to become the most trusted cutting tool supplier in the domestic market. “We started manufacturing HSS tools in 1990; from 1995 onwards the group progressed further by manufacturing Brazed Carbide Cutting tools. In 2003, we started manufacturing Solid Carbide Cutting Tools to cater to the growing needs of the manufacturing industry,” says Hemant Dadhe, Founder & Director, Aayudh Tools. Indian manufacturing industry was scaling new heights and witnessed huge demand from automotive and

MACHINE TOOLS WORLD MARCH 2018

infrastructure sectors. It also prompted several global OEMs to set shop in India. As the FDI was increasing in the country, the demand for high precision tools was also in constant demand. “During 2009-10 we were catering to some global automotive OEMs and their expectations from the cutting tool supplier were very high. We wanted to give our best but finding the right machine was increasingly becoming a challenge. There was a requirement for

a machine that could provide us high repeatability and micron level accuracy, which our then set up was not able to meet. That is when we came across ANCA and made our first ANCA Purchase, TX7, a high-end CNC grinding machine,” adds Hemant. Talking about the benefits of ANCA machine, Hemant says, “ANCA helped us to achieve the much needed webcentrality. It means at the center point of the tool there is a kind of web which

Taming power quality is now child's play

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

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

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

Our Allied Products: n

Active Harmonic Filters K-Rated Transformers Light Energy Management Systems

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

The power quality & energy experts

D-137, TTC MIDC Industrial Area, Nerul, 405, Sapphire Arcade, 42 M.G. Road, Ghatkopar (E),400 Mumbai 400 077, India Navi Mumbai 706, INDIA +91-22-2501 3832 +91-22-2761 1872/ 33 / 4612 sales@unitycontrols.in www.unitycontrols.in

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

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UNITY CONTROLS PVT. LTD

CASE STUDY

is maintained at about 0.1 mm. The centrality of that web compared to X & Y-axis needs to be controlled within 10 microns. When it’s controlled at the said parameter, the performance of the tool improves. This was something we were not able to achieve earlier. ANCA was able to deliver us the perfect geometry.” One of the most important aspects when it comes to cutting tool business is repeatability of the performance, i.e. the first tool and the last tool should have the same kind of accuracy with exactly the same geometries. “It might seem there is hardly any difference between the finish of midrange machine and high-end machine, but the difference can be seen in the micron level. ANCA machines helped us to achieve high accuracy and repeatability. The minute difference in the geometries improves the lives of the tool and reliability, which is very important for us,” he adds. Aayudh Tools boasts of about 350 customers and manufactures tools as per the customer’s demand. The company has developed over 40,000 varieties of tools to date. Their long list of happy customers includes large domestic and foreign automotive OEMs. 82

MACHINE TOOLS WORLD MARCH 2018

Improved productivity

With the help of ANCA’s MX5 and TX7, Aayudh Tools have increased productivity by about 30% and looking to enter new and challenging sectors like aerospace. “The software team at ANCA is very experienced and has always helped us in design activities. Their open ended software is helpful in designing new tools especially for companies like us who makes only customized tools. Our suggestions were also implemented in the next version. We couldn’t be happier,” he adds.

ANCA control system is also equipped with CAM feature, which can be used to export data into Unigraphis. It helps to make the necessary changes in the design of the tools. ANCA is also trying to develop post processor that will allow 3D model geometry to create CAM programme in the machine itself. Says Hemant, “As the government of India has taken several initiatives to promote Electric Vehicles, we are aware that there will be a significant drop in the demand for machining activities in the automotive industry. At the same time, we see great opportunity for die mould and aerospace industry in the country and we are prepared to face the change in demand.” Backed by technologies from ANCA, Aayudh Tools is well-equipped to serve the challenging aerospace and die mould industry. “Since 2011, the market was stagnant and there were too many players. This made us focus on the development of new tools and geometries and invest in right technologies. Investment in right technologies like, ANCA helped us stay ahead of the competition,” concludes Hemant.

CASE STUDY

New Seco Solid-Carbide Cutting Tools Boost Knee Implant Machining Speeds The new Jabro medical range of solid-carbide cutting tools combines different machining strategies such as high-speed machining to shorten part cycle times

eco Tools has introduced the industry’s first product line specifically dedicated to knee implant machining. The new Jabro® medical range of solid-carbide cutting tools combines different machining strategies such as high-speed machining to shorten part cycle times when machining knee implants by as much as 50 percent. The tools’ continuous grades and optimized coatings result in exceptional part surfaces that reduce, and often eliminate, the need for polishing or fine finishing operations. These features also promote excellent process stability and long tool life. The Jabro medical range includes

MACHINE TOOLS WORLD MARCH 2018

9 advanced geometries and 39 tools, most of which are positioned in Jabro Tornado high-speed cutting family. Each geometry is designed for particular applications in the machining of tibial tray and femoral knee implant parts. And because the new dedicated tools excel in the machining of CoCr (Cobalt Chrome) and Ti6Al4V ISO-S12 parts (3D printed), they maximize machine performance for other medical components such as those for hip replacements and bone plates as well. Seco Tools is a leading manufacturer of high performance metal cutting tools. Seco’s product range includes

a complete programme of tools and inserts for turning, milling, drilling, reaming and boring as well as complementary tool holding systems. With more than 25,000 standard products, Seco is a complete solutions provider for the metal cutting industry and equips machine tools from the spindle down to the cutting edge. The company is headquartered in Fagersta, Sweden and represented in more than 45 countries worldwide with 40 subsidiaries, distributors and channel partners.

For more information, Website:www.secotools.com

INDIA’S LARGEST INTERNATIONAL DIEMOULD SHOW th

11 DIE & MOULD INDIA INTERNATIONAL EXHIBITION

11 - 12 - 13 - 14 APRIL 2018 Bombay Exhibition Centre, Goregaon, Mumbai, India Supported by:

Exhibit Range → Additive Manufacturing / 3D Printing → CAD / CAM system related to Dies & Moulds → Coating → Cutting Tools → CNC Milling / Machining Centre, EDM → Digitizing → Die/mould polishing/ Die Spotting machines → Dies & Moulds, Press Tools, Jigs, Fixture, Gauges → Heat Treatment → Hot Runner System → Injection Moulding Machine → Machine Tools & Accessories for Dies Moulds

→ Measuring Machines, Quality Assurance / Metrology → Mould base & standard parts of Dies & Moulds, Toolings → Moulding machines/ Die Casting machines, Sheet Metal Presses & ancillaries → Precision Machining / Aerospace → Surface Treatment → Rapid Prototyping & Tooling → Texturizing → Tool Steel → All ancillary materials, equipments, accessories , consumables, services & automation covering Die & Mould industry

Meet the Leaders of the World Tooling Industry See & Experience ‘LIVE DEMO’ to enhance Capability & Competitivity

To Visit Register Here

Pre-Register Online Book Appointment with exhibitor Supporting Partner Association

Supporting Media Partner

Organised by:

INDIA

A-33, NandJyot Indl.Estate, Safed Pool, A.K.Road, Mumbai- 72 Tel: +91-22-28526876/ 28508976 Fax: +91-22-28503273 Email: tagma.diemould@tagmaindia.org

www.diemouldindia.org

A GLOBAL DISPLAY OF IN

Organised by

Supported by

Awards by

Registered Office: 3rd Floor, Kailash-A, Sumangalam Society, Above HDFC Bank, Opp. Drive-In Cinema, Bodakdev, Ahmedabad-380054, Gujarat. M +91-98795 66567 admin@imtos.com +91-79-40048594, 40305602 www.kdclglobal.com

GUJARAT, LEADING THE FUTURE OF

IN INDIA

NSIC GROUND, AJI GIDC

28th November to 1st December, 2018 NSIC Ground, AJI GIDC, Opp. Gujarat Forging, Rajkot.

Indiaâ&#x20AC;&#x2122;s Premier Exhibition of Metal Cutting, Metal Forming, Automation, Forging & Foundry

Diamond Sponsor

Gold Sponsor

KMG BUSINESS TECHNOLOGY 207/208, Harmony Icon, Near Baghban Party Plot, Thaltej-Hebatpur Road, Thaltej, Ahmedabad - 380059, Gujarat, India. | Telephone: +91-79- 29297977, 40305602 Mobile: +91-98250 83530 | Email: info@kmgindia.com, kmg@kmgindia.com

MGM-Pubblicità(210x297)_Layout 1 08/04/13 10.33 Pagina 1

HIGH QUALITY FOR YOUR MACHINERY

MGM brake motor main features

VARVEL production lines

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

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

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

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

PRODUCTS SHOWCASE www.mtwmag.com

PRODUCT SHOWCASE Elesa+Ganter tubular handles: standard or customised solutions with an ergonomic and original design

For Product Enquiry Contact Elesa and Ganter India Pvt. Ltd. A-54, Sector - 83, Noida 201 305 (U.P.) INDIA Tel. +91 120 472 6666, Fax +91 120 472 6600 E-mail: info@elesaganter-india.com Website: www.elesa-ganter.in

Elesa+Ganter, makers of standard machine elements also offers a wide range of tubular handles that, by virtue of the wide variety of production materials, polymer, aluminium, steel or stainless steel, design and ergonomics makes it unique in size and able to meet the most varied market requirements. Some Elesa+Ganter tubular handles, which generally are widely used for manĹ&#x201C;uvering of large heavy doors in different industrial sectors, thanks to the possibility of modularity are also suitable to be used for the realisation of handrails. Elesa+Ganter, thanks to the know-how and the continuous R&D activities can also provide customised technical solutions to meet specific customer needs. For example, M.1043-HEI tubular handle, equipped with handle shanks in technopolymer and tube in glass-fibre reinforced polyester, it has been designed to provide a high electrical insulation. The different standard solutions available in the catalogue can also be supplied in different colours or personalised with wording or pad-printed or laser engraved logo. Elesa+Ganter tubular handles are available with technopolymer or metal shanks matched with tubes (diameter from 20 mm to 35 mm) in anodised aluminium, epoxy coating or stainless steel. Some executions have a special antirotation tube assembly system, studied to prevent rotation during manĹ&#x201C;uvering operations, ensuring a safe and comfortable grip. Versions without side supports are set up by bars or aluminium tubes according to the diameter (20 mm or 28 mm), and are also available in double curve. Completing the range, tubular handles with oval section, which thanks to the tube assembly to the side handle shanks by means of screws, offer a high stability during manoeuvring operations. Modern and ergonomic design without any protrusions or recesses for a firm and secure grip are the main features of Elesa+Ganter tubular handles.

MARCH 2018

MACHINE TOOLS WORLD

PRODUCTS SHOWCASE

The new Gast 86/87R Series of oil-less rocking piston compressors and vacuum pumps While other manufacturers have been busy selling rocking piston compressors that produce a lot of noise and less-than-ideal pressure, Gast has been quietly setting the new standard by re-engineering our oil-less rocking piston from the ground up. The result is a unit that delivers quieter performance, higher pressure, a longer life and greater application flexibility. The sleek, new 86/87R Series is not just another pretty product. It’s beauty runs deep as it performs in ways not yet seen in the industry. The patented crossover chamber design regulates and controls airflow to dampen sound and optimize performance, while delivering a wide range of pressure level options. Because the 86/87R Series can easily retrofit into an existing footprint, it’s also a smart, flexible solution for a wide range of markets and applications, viz. Environmental, General industrial, medical, printing & packaging, food and beverage, transportation, laboratory, and material handling.

Designed to performs

For Product Enquiry Contact Shavo Technologies Pvt. Ltd. Shavo House, S.No.21A/10B, Plot No,394 South Main Road, Hotel Cozy Inn Chowk Koregaon Park, Pune - 4112 001 Phoned: 020-2615 9641 Email: shavogroup@vsnl.com

“When we set out to re-engineer our rocking piston compressor, we aimed to do more than just increase pressure. We set out to dramatically reduce sound, enhance flow, create a standard footprint for easy retrofit anywhere in the world and improve the compressor’s aesthetics,” says Gast. The inherent design of rocking piston technology makes it the optimal choice for applications requiring high pressure or vacuum and air flow in a small package. The flexible cup is made with superior materials and mounted on top of the connecting rod, creating vacuum or pressure while maintaining a tight seal against the cylinder walls in a rocking motion. The forgiving design has fewer components, causes less friction and has a low exhaust temperature, for greater reliability and durability for the life of the product. Despite it’s small size, the versatility of 86/87R means this is the right product to deliver quality air solutions.

Welding Fume Extractor, King Extractor-II-MU 3 Welding Fume Extractor, King Extractor-II-MU 3 is a mobile mechanical high efficiency self-cleaning filter designed for workplaces. The filter cleans air from different kinds of dry dust, welding aerosols and other dry contaminants from most industrial processes. The filter cartridge is cleaned automatically without interrupting the filtration process. The cleaning extends the cartridge service periods and minimizes maintenance.

The Filter is designed for continuous indoor operation under the following climatic conditions:

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

MACHINE TOOLS WORLD MARCH 2018

• • • • •

Air temperature from +10 deg. C to +45 deg. C. Relative humidity : 80% at 25 deg. C The compact construction integrates the filter, extraction arm and fan The filter can be used at workplaces unreachable to other ventilating equipment, & The filter requires connection to a general compressed air supply.

The standard delivery set includes Built-in fan, Control console, Filtering cartridge of respective type, Spark arrester, Oil separator with reduction box for compressed air system, and Electrical grounded cable L= 5 m with plug.

PRODUCTS SHOWCASE www.mtwmag.com

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

Following are some of its unique features:

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

• • • • • • •

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

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

Comfortable Speed Monitoring

For Product Enquiry Contact DOLD Electric India Pvt Ltd (100% Subsidiary of E.DOLD & Sohne Kg - Germany)

B – 3 Vishranti Heritage, Gotri Road, Vadodara – 390 021 Call: +91 990 9001585 Website: www.dold.in

With the Safe Speed Monitor UH 6932 from the SAFEMASTER S-Series offers DOLD a comfortable solution for safety-focused speed monitoring, and how it comes into usage in wind turbines, centrifuges or in stage technology. The device excels itself particularly through simple operation and comfortable equipment. Standstill, high and low speed, are safely monitored in automatic operation as well as adjustment. The speed monitor finds use in machines and plants which can pose a threat to people whilst running through mobile machinery or movable parts. Therefore, through the safe monitoring of reduced operating speed during usage, for example, the safety of operating personnel will be increased. It also increases productivity, because unnecessary shut-down is prevented. The speed monitor is certified for use up to PL e/Cat. 4 or SIL 3. The device is additionally certified for safe use in the functional safety of electrical drive system (EN 61809-5-2) by TÜV. Furthermore, the UH 6932 has a comfortable LCD display and front side buttons, which enable simple operation and rapid configuration of the device without needing a PC. The monitoring function can be deactivated over a digital input or can be activated during operation, with up to four preconfigured speed modes with varying response thresholds. As well as safetyfocused contact paths, an analogue output for transfer of the current speed is also available to use.

MARCH 2018

MACHINE TOOLS WORLD

MACHINE TOOLS WORLD MARCH 2018

PRODUCT INDEX A

Plasma CNC Cutting Machines

AC I DC Geared Motor

Flex Clamps

Position Displays

AC Linear Servo Motor

Flexible Couplings

Power Conditioners

Actuator Line

Precision Air Moving Products

Air Compressors

Precision Ball Screws

Alloy Wheel Machining Solutions

Gas Flow Products

Pressure Control Solutions

Aluminium Profiles

Gas Management

Project Engineering Solutions

Angle Encoders

Gear Boxes

Automation Products

Gears, Racks & Pinions

R Real Time Power Factor System

Reamers

81 FALSE COVER

Ball Transfer Units

Harmonic Filters

Reffnlng Furnace

Brake Motors

High Pressure Filtration

Robot and Gantry Automation

Hydraulic Fixtures

Robotic Welding

Hydraulic Press

Rotary Encoders

Rotary Tables

C Cables

CAD CAM Software

Carbide Cutting Tools

Inserts

Centerless Grinders

Instrumentation Fittings & Valves

Centre Drills

FALSE COVER

Chamfers

FALSE COVER

I FRONT GATEFOLD 73

S Screwiacks

Sensor Systems

Slewing Ring

Clamp Meters

Laser Tool Pre-setting & Verification System

Spotting Drills

Clamps For Linear Guides

Laser-Line Scanner

Stabilizers

CNC Grinding Machines

Lathe Machines

Static Elimination Solutions

CNC Horizontal Boring Machine

Length Gauges

Stepper & BLDC Motor

CNC Lathe

Light Energy Management Systems

Surface Cleaning

CNC Lathes

Linear Actuators

BACK PAGE

Linear Encoders

CNC Machines

FALSE COVER

CNC Smart Mills

Linear Line

Taps

CNC Solutions

Linear Motion Guides

Telescopic Line

Test & Measurement Tools

Test Instruments

CNC Tool Grinding Machine

CNC Turning Center

CNC Vertical Machining Center

Machining Centers

Colling Towers

Mass Flow Controllers

Consumables

Contouring Controls Conventional Fixtures Conveyor & Assembly Solutions

FRONT GATEFOLD

Thermal Imaging Cameras

Thermal Spray Coatings

Metal Applications

Threading & Grooving Solutions

Metal Cutting Tools

Tool Holders

Metal Forming Machines

Tool Management Solutions

Metrology Solutions

Turning Machines

Curvic Coupling

Milling Solutions

IFC

Turning Solutions

IFC

Cycloidal Gear Boxes

Moisture Meters Motion Toolpaths

Multimeters

Deburring Applications

Dimensional Measurement Systems

Double Column Machining Centers

Drill Tap Center

Drilling Solutions

IFC

Drills

FRONT GATEFOLD, FALSE COVER

E End Mills End Mills Cutters

FRONT GATEFOLD

Twist Drills

IBC 67

N Non-Metal Cutting Applications

IFC

U Ultra Isolation Transformers

Universal Machining Centers

V O

Value-Selling Training Solutions

Oil/ Coolant Mist Cleaner

Vertical CNC Lathes

Optical Micrometers

Vertical Machining Centers

Oxy-Fuel CNC Cutting Machines

Voltage Detector

FRONT GATEFOLD FALSE COVER

Energy Absorption & Vibration Isolation Products Engraver Cutter

Parts for Die & Mould

Washing Machines

FALSE COVER

Planetary Gear Heads

Welding applications

MARCH 2018

MACHINE TOOLS WORLD

ADVERTISERS INDEX COMPANY NAME

PG. NO.

GEDEE WEILER PRIVATE LIMITED

ACE MICROMATIC GROUP

BACK PAGE

GEM EQUIPMENTS (P) LTD.

ACMEE - 2018

ADOR WELDING LIMITED

GLOBE-TECH ENGINEERING EXPO - 2018

AMTEX - 2018

GROB MACHINE TOOLS INDIA PVT. LTD.

ANCA MACHINE TOOLS PRIVATE LTD

HEIDENHAIN OPTICS & ELECTRONICS INDIA PRAIVATE LIMITED

HOSABETTU HEAVY MACHINERY LLP

HYUNDAI WIA INDIA PVT. LTD.

B BIRLA PRECISION TECHNOLOGIES LIMITED

C 41

CNC SOFTWARE, INC.

INSIDE BACK COVER

PARAGON MACHINERY CO. LTD.

QMET - 2018

QVI INDIA PVT. LTD.

R RAJKOT MACHINE TOOLS SHOW - 2018

RENISHAW METROLOGY SYSTEMS LTD

ROLLON INDIA PVT. LTD. - INDIA

INTERTOOL DELHI - 2018

JYOTI CNC AUTOMATION LTD.

SHAVO TECHNOLOGIES PVT. LTD.

SOLITAIRE MACHINE TOOLS LTD.

SPRAYMET SURFACE TECHNOLOGIES PVT. LTD.

L LEONI CABLE SOLUTIONS (INDIA) PRIVATE LIMITED

DMG MORI INDIA

PARADIGM TRAINERS PRIVATE LIMITED

INDO AFRICA B2B TRADE EXPO - 2018

ELECTROTHERM (INDIA) LTD.

ELGI EQUIPMENTS LTD.

MARPOSS INDIA PVT. LTD.

EPPINGER TOOLING ASIA PVT. LTD.

MGM-VARVEL POWER TRANSMISSION PVT LTD

MICRO-EPSILON INDIA PRIVATE LIMITED

MITSUBISHI ELECTRIC INDIA PVT. LTD.

YG-1 INDUSTRIES INDIA PVT. LTD.

MMC HARDMETAL INDIA PVT. LTD.

INSIDE FRONT COVER

F FACCIN S. P. A.

FATTY TUNA INDIA PVT. LTD.

FIBRO INDIA PRECISION PRODUCTS PVT. LTD.

FLIR SYSTEMS INDIA PVT. LTD.

MACHINE TOOLS WORLD

MARCH 2018

DOWEL ENGINEERING WORKS

OPEN MIND CADCAM TECHNOLOGIES INDIA PVT. LTD.

IMTOS - 2019

DIE & MOULD INDIA - 2018

PG. NO.

CNC INDIA TOOLS & SERVICES (P) LTD.

COMPANY NAME O

ACCUSHARP CUTTING TOOLS PVT. LTD.

APEX PRECISION MECHATRONIX PVT. LTD.

100

COMPANY NAME

TRUCUT PRECISION TOOLS PVT. LTD.

FALSE COVER

U UNITY CONTROLS PVT. LTD.

ZOLLER INDIA PVT. LTD.

FRONT GATEFOLD

DIFFICULT MATERIALS MADE EASY

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For more information, visit mastercam.com/dynamic

RNI No. MAHENG/2015/64267 Postal Reg. No. THC/173/2018-2020. 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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