Volume 05 No. 01 | June 2019 | ` 150
Pages 220 | RNI No. MAHENG/2015/64267
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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 6991 E: indiainfo@anca.com
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CEO CORNER
Publisher & Printer Shirish Dongre
CEO Shekhar D.
Editor Shilpa Dongre
Assistant Editor
Industry 4.0 : The future of machine tools industry
Shweta Nanda
Marketing Team Ladoji Pendurkar, Amol Powle, Bhavin Shah, Bharat Shah, Vinod Surve, Kamlesh Balkrishna, Kavita Chaudhari
Online Marketing Kailash P.
Print & Online Division Arun P. Shinde, Nandan S. Moghe, Ganesh B. Mahale, 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
As Industry 4.0 continues to take the whole manufacturing world by storm, machine tools are also becoming a part of the smart system. In India too, the concept, though in nascent stages, is slowly gaining steam, especially among large machine tool players who are innovating in this direction. Primarily, machine tools industry is looking at Industry 4.0 to meet increasing customer requirement for improved productivity, reduced cycle time and greater quality. Thus, adopting Industry 4.0 concept is at the crux of achieving the ambitious target of making India a global hub for manufacturing, design and innovation, and augmenting the share of manufacturing in the GDP from the current 17% to 25% by 2022. Industry 4.0 also has the ability to improve utilization of machine tools in manufacturing operations by cutting idle time. Industry research has indicated that machine tools are typically actively cutting metal as less than 40% of the time, which sometimes go to as low as 25% of the time.
(Chennai & Coimbatore) Y. V. Raghu : 09566141224 Bangalore E Vikram : +91 9591488434 Vaman : +91 9686721340 Hyderabad E Vikram : +91 9591488434
Clearly, given its advantages, the time is ripe for organizations to take the leap for Industry 4.0. That said, getting started with Industry 4.0 technologies can seem intimidating to many. The key for the success of Industry 4.0 lies in having a dedicated digital strategy.
EAST (Kolkata & Other regions) Kamlesh B. - 09819464242
WEST (Maharashtra & Gujarat) Pune Shilpa K. - 09833373371
As Machine Tools World magazine celebrates its fourth anniversary, we spoke to prominent players to know more about how the rising trend of Industry 4.0 is bringing a shift in the industry, how their products are in line with the trend and their vision for 2020.
Nashik Abhijit B. Joshi : 09890002333 Rajkot (Saurashtra) Swapnil Bhatia: 09227909005
Head Office : Divya Media Publications Pvt. Ltd., 3rd Floor, Harmony Tower, N.S. Road, Thane-400 602. Maharashtra Tel: +91 22-25380574/75, Telefax: +91-22-25418254 E-mail: shekhar@divyamediaonline.com Website: www.mtwmag.com
CEO
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
8
MACHINE TOOLS WORLD
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www.mtwmag.com
Contents
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COVER STORY
Driving the Future of Machine Tools Industry BUSINESS NEWS
48
IN FOCUS
22
EMO-2019 – Smart technologies driving tomorrow’s production
24
Schmersal launches new safety light grids with Bluetooth interface
67
68
72
78
82
91
26
Bettinelli’s High Precison Link Conveyors: A range in constant evolution
32
Walter: 100 years of innovation
36
Gifu’s Disc-Type Tool Magazine wins the National Invention and Creation Award
38
Oerlikon Balzers builds Competence Centre for sustainable metallisation of plastics
46
DEUBLIN SpindleShield™ Unions for CNC Machining Centers 10
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www.mtwmag.com
Contents
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COMPANY PROFILE
92
98
CASE STUDY
117
106
110
CASE STUDY
120
126
138
TECH TRENDS
164
172 Zero Lubrication, Low Noise: Speedy Rail by Rollon
176 200
182 12
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196 JUNE 2019
Complete analysis of heterogeneous data from TwinCAT controllers and third-party components www.mtwmag.com
| MW11-03E |
From compact to complex:
The scalable Beckhoff CNC. Servo drives
Industrial PC
I/O system
www.beckhoff.co.in/cnc PC-based controllers from Beckhoff cover the whole range of high-precision CNC applications, from compact to complex. Highly scalable: the TwinCAT software platform for engineering and runtime Highly scalable: the Industrial PC range with processors from Intel® Atom™ to many-core Highly scalable: the I/O system for all signals and fieldbus systems Highly scalable: the highly dynamic servo technology for all performance classes Highly scalable: the safety solution, from system-integrated I/Os to drives
Beckhoff Automation Pvt. Ltd. Pune – 411 001, India Phone: +91 (20) 6706 4800 info@beckhoff.co.in
Editorial Board
Mr. Arun Mahajan General Manager AMT- The Association For Manufacturing Technology
Mr. Arjun Prakash Managing Director
Mr. A.P. Jayanthram Ex-Managing Director, Heidenhain India
Mr. GK Pillai Managing Director & CEO
Ms.Samina Khalid Marketing Manager
Mr. Rupesh Paparaju Director,
Walchandnagar Industries Ltd
Effica Automation Ltd.
Renishaw Metrology Systems Ltd.
Bettinelli Automation Components Pvt. Ltd.
Mr. Dinesh Khambhayta President MTMA-RAJKOT
Manjit Singh Matharoo General Secretary
Mr. Suhas Belapurkar Director - Sales & Marketing ( Industrial Products)
Association of Ludhiana Machine Tool Industries
Sanjay Tools & Adhesives
Editorial Index A Ador Welding 160, 188 ANCA 204 Autodesk 44 B Beckhoff 138, 200 Bettinelli Automation Components 26, 106 Birla Precision Technologies 213 D Dahanuakar Machine Tools 91 DesignTech Systems 54 DMG MORI 32 Dold & Sรถhne KG 78, 214 E Elesa & Ganter 58, 92, 212 Elgi Equipments 22, 82 EMAG 206 Erwin Junker 49 ExxonMobil Lubricants 67 F Faccin 126 FARO 46 FIBRO India 110 FUCHS LUBRICANT 164 G Gala Precision 168 GEM Equipments 215 Gifu 36 H Hexagon 72 Hypertherm 44 I Imaginarium 53 ISCAR India 196
K Kennametal 24 KTR Couplings 120 KYOCERA SGS 155 L LANXESS 36 LMT Tools 56 M Maco Corporation 46 Marposs 180 Marvel Gloves 214 Master Fluid Solutions 117 Mastercam 52, 156 Maxon Motor 98 Micro-Epsilon 176 Millenia Technologies 124 MMC Hardmetal 68 O Oerlikon Balzers 38 R Renishaw 134, 186 Rocklinizer 159 ROLLON INDIA 172 S Schmersal 24 SCHUNK 216 Seco Tools 202 Shavo Technologies 102 SolBuggy Connect 182 STUDER 130 Superslides & Ballscrews 184 U UCAM 50 Unity Controls 215 W Walter 32 Y Yaskawa India 210
Contact : For editorial contribution E-mail: shweta@divyamediaonline.com For advertising material E-mail: advt@divyamediaonline.com
Mr. P.K. Balasubbramaniian President VBS Corporate Support
14
Mr. B.P. Poddar Vice President - Sales & Marketing FEMCO Fatty Tuna India Pvt. Ltd.
MACHINE TOOLS WORLD
JUNE 2019
Mr. Jayant Vaidyanathan VP - Sales & Application Tsugami Precision Engineering India Pvt. Ltd.
For accounts E-mail: accounts@divyamediaonline.com For online advertising E-mail: ganesh@divyamediaonline.com
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BUSINESS NEWS
EMO-2019 – Smart technologies driving tomorrow’s production EMO is the world’s No. 1 trade show for the metalworking industry, featuring 2,200 exhibitors from 44 countries and over 180,000 square meters (approx.1.94 million sq. ft.) of net display space. Industry professionals with decision-making authority and technical expertise – including CEOs, board members and subject specialists from all production backgrounds – attend the show to learn about all the latest innovations. The next edition of this premium event is scheduled from
16 – 21 September, 2019 at Hannover, Germany. EMO Hannover’s standing is such that the exhibiting technology providers align their innovation cycles with the show’s biennial schedule. Some 72 percent of the exhibitors at the last EMO Hannover had timed their new product launches to coincide with the show. The show also features a captivating supporting program that heightens its innovation focus. In 2019, visitors can look forward to the new IoT in Production display section,
which further underscores the show’s official motto, Smart technologies driving tomorrow’s production! The display section comprises a diverse offering, including the Industry 4.0 Special Show Area, the IoT Speakers’ Forum, and national pavilions showcasing initiatives from Spain, France, Japan, China and the USA. Display Categories: • Machine tools • Additive Manufacturing • Other machines • Precision tools
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ELGi announces results for FY 2018-19 Elgi Equipments Ltd., manufacturer of air compressors, recently announced the results for the financial year 2018-19 posting a PAT of Rs.103.06 Crores, compared to Rs. 95.30 Crores in 2017-18 on a consolidated basis. Consolidated sales for the group was Rs. 1,863 Crores compared to Rs. 1,622 Crores in the previous year. The standalone PAT for the financial year ended 31/03/2019 was Rs. 84.7 Crores as compared to Rs. 76.9 Crores during the corresponding year ended 31/03/2018. The Board of Directors in their meeting has recommended 22
MACHINE TOOLS WORLD
a dividend of 130% for the financial year 2018-19. The financial year 2018-19 witnessed healthy growth in diverse product segments and markets globally. The company grew 15% on a consolidated basis. The growth in automotive equipment business was modest, shadowing the growth trends of the auto industry. Outlook for 2019-20 “The company is ably positioned to realize opportunities in key markets. The realization would depend on the growth of key economies,”
JUNE 2019
said Dr. Jairam Varadaraj, Managing Director, ELGi. For the automotive equipment business, the company is exploring new avenues of growth through collaborations and technology transfers for select automotive products. About ELGi Elgi Equipments Limited is a global air compressor manufacturer with a broad line of innovative and technologically superior compressed air systems. ELGi has consistently worked towards ensuring that its customers achieve their productivity goals while keeping the cost
of ownership low. ELGi offers a complete range of compressed air solutions from oil-lubricated and oil-free rotary screw compressors, oil-lubricated and oil-free reciprocating compressors and centrifugal compressors, to dryers, filters and downstream accessories. The company’s portfolio of over 400 products has found wide application across industries.
For more information Web: www.elgi.com
www.mtwmag.com
BUSINESS NEWS
Schmersal launches new safety light grids with Bluetooth interface High range - global application - secure data transfer For the first time, the Schmersal Group is launching a safety light grid with a built-in Bluetooth interface. The SLC440/ COM with Bluetooth BLE is an active optoelectronic protective device that makes all status and diagnostic data on the operating status of the device available on smartphones or tablets via a Bluetooth interface on a real-time basis. The Bluetooth interface also supports easy start-up using a smartphone or tablet with the integrated setup aid. There is also the excellent option of saving the data, which can then be used, for example, to document a repeat test or for predictive maintenance purposes. The transmission of data to smartphones / tablets (Android, IOS) is facilitated by an app developed by Schmersal. BLE stands for Bluetooth Low Energy, a radio system for near-field data transmission with
secure transmission. Uniquely wide range This innovative technology for optoelectronic safety systems is unique with respect to the range over which the data can be communicated. Until now only diagnostic tools based on NFC technology have been available on the market. While NFC tools only offer a range of a few centimetres, the Bluetooth BLE interface can achieve a range of 100 times more at up to 5 metres. This means the BLE interface is perfect when the optoelectronic safety system is in a relatively inaccessible position. Bluetooth BLE also offers a greater range of applications because not all smartphones or tablets are equipped with NFC, but most have Bluetooth. As Bluetooth is an international industrial standard, the 440/COM range of light grids with Bluetooth BLE
interface can be used all over the world. Increased efficiency: Status data can be accessed in real-time “The SLC440/COM with Bluetooth BLE enable significantly improved efficiency in production processes. As the status data of the light grids can be accessed easily and in real-time, errors can be resolved more quickly to achieve increased machine availability,” explains Klaus Schuster, Managing Director of Safety Control GmbH, a centre of excellence for opto-electronics and part of the Schmersal Group. This status information and diagnostic data enables processes to be reactivated more quickly, particularly in the event of a system shutdown if a hazard is detected. It also represents a really
economical innovation as, compared to classic Bluetooth, BLE is characterised by considerably lower energy consumption and reduced costs at a similarly high communication range.
For more information, Web: www.schmersal.com
Kennametal introduces Mill 4-12KT Kennametal announced its new Mill 4-12KT, the next generation of tangential shoulder mills, producing high quality floor surface finishes for nearly all steel and cast iron applications. “The Mill 4-12KT 24
MACHINE TOOLS WORLD
uses15% lower cutting forces, an important consideration with today’s lighter duty, 40-taper machine tools,” said Tim Marshall, Senior Global Product Manager. “That allows customers to feed faster
JUNE 2019
without putting additional stress on the spindle. And in long overhang situations or where the part fixturing is less than optimal, lower forces equate to less chatter, reduced edge chipping, and smoother surface finishes.”
Mill 4-12KT has tangentially mounted inserts with four cutting edges per insert for reduced tooling costs. Seven corner radii from 0.016” (0.4 mm) to 0.122” (3.1 mm) are available, along with www.mtwmag.com
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BUSINESS NEWS coolant-through, medium and coarse pitch cutter bodies 2” (50mm) to 8” (200mm) in diameter. With an axial depth of cut range from 0.019” to 0.472” (0.5 to 12mm), Mill 4-12KT covers most shoulder milling applications. Multiple factors contribute to significant performance increases, even in aggressive cutting conditions: The tangential,
“on-edge” insert design also allows the insert to take advantage of the strength of the carbide thickness more
so than radially mounted inserts found on traditional milling cutters. A shallow pocket design, allows the
core size of the cutter body to be very robust. The axial and radial seating surface designs provide exceptional stability. The Mill 4-12KT is the perfect complement to Kennametal’s existing shoulder milling portfolio. This includes the Mill 4-11 and Mill 4-15, cutters known for their ability to generate shoulders with high quality wall surface finishes.
Bettinelli’s High Precison Link Conveyors: A range in constant evolution suitable solution. They are used on machines that require stability, precision, high speeds and low maintenance. They are different in terms of body width, allowing great flexibility and a more accurate choice during the designing phase.
Cam Driven Systems (CDS), a division of the Bettinelli S.p.A. group, has come up with the widest range of positioners, rotary tables and cam mechanisms for the automation processes. CDS Precision Link Conveyors TSL, TL and TXL provide the industry’s highest accuracy and repeatability for automated assembly and manufacturing machinery platforms combined with the highest dynamic performance available on the market. The precision link conveyor TL series has been designed to meet the requirements of high productivity and reliability of modern automation, combined with excellent precision and speed, with a high degree of versatility to offer customers the most 26
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The need of the market and customer orientation, added to the desire of CDS to expand & improve its product range has brought new innovations to the TL series: TSL 200 : In TL 200, the depth of the body has been reduced, with the same stroke, with a consequent reduction of the gearwheel diameter and a better ratio with the driver unit and a better positional accuracy. This makes the machine far more compact and it is a great advantage to the machine builder. Plastic Protections: In the TL range, the plastic protections have been studied to be applied on pallets in order to guarantee an anti-intrusion covering for the components being processed. These covers are printed in 3D.
Special Links Chain: Together with the plastic protections a new links chain has been developed. The latter is equipped with special seals to reduce the accumulation of powders or abrasive material during the process and increase the protection of leads and bushes. In a nutshell, following are the salient features of these conveyors: • Versatile and compact modularcomponent design • Precision machined cast iron chemical-nickel plated links • Precision chordal compensation cams • Cam Driven for fixed indexing motion or servo driven for flexible positioning The competitive price and fast lead time together with CDS quality and reliability make this series very attractive for the market, says Rupesh Paparaju, Director, Bettinelli Automation Components Pvt. Ltd., based in Pune. For more information, Website: www.bettinelli.in
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BUSINESS NEWS
Walter: 100 years of innovation Walter AG, a provider of specialized machining solutions based in Tübingen, Germany, is celebrating the centenary of its foundation today with some 150 guests from the worlds of business and politics. Guests include numerous international customers and partners, as well as Klaus Tappeser, Chief Commissioner of the district of Tübingen; Joachim Walter, District Chief Executive of Tübingen; and Boris Palmer, Lord Mayor of the city of Tübingen. Walter AG is particularly glad about welcoming Dr. Nicole HoffmeisterKraut, Baden-Württemberg’s State Minister for Economy, Labour and Housing. “For 100 years now, Walter AG has been a synonym
From left to right: Richard Harris, President Walter Franco Mambretti, Grandson of the company founder Boris Palmer, Lord Mayor of the city of Tübingen Klaus Tappeser, Chief Commissioner of the district of Tübingen Joachim Walter, District Chief Executive of Tübingen
for high-calibre engineering with a strong commitment to innovation. The company is an extraordinary exponent and shining example for manufacturing precision tools, where it holds a leading role in Germany.”, says Hoffmeister-Kraut on Walter. The celebrations will fo-
cus on the tremendous innovation, creativity and future potential of Walter. Prof Dr. Peter Post, Member of the German Council of Science and Humanities as well as Head of Applied Research at Festo AG, Germany, will speak about the meaning of digitalization and innovation for German industry.
This will be followed by the grand opening of the new company museum with Richard Harris, President Walter, and Franco Mambretti, grandson of the company’s founder, who himself led Walter for many years. Richard Harris says: “Walter employees have not only further developed the numerous inventions of company founder Richard Walter, but also created new tools, coatings and production methods. Our new company museum is a testimony to the Walter spirit of innovation, and it will be an inspiration to new generations of Walter engineers and technicians. Today, we celebrate their inventiveness and creativity.” www.history.walter
DMG MORI sells renewable energy to electricity producer STEAG Effective 1 July 2019, the Essen-based energy group STEAG will take over the significant business activities of GILDEMEISTER energy solutions from DMG MORI. Subject to the approval of the antitrust authorities, the group subsidiary STEAG Energy Services GmbH strengthens its position in the growth market of renewable energies. It was agreed to keep the purchase price confidential. All employees are taken over by STEAG. “GILDEMEISTER energy solutions are going into good hands. We are pleased to have found in STEAG a strategic investor with an excellent perspective for our employees,” says Dr. Maurice Eschweiler, Chief 32
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Representative of DMG MORI AKTIENGESELLSCHAFT. “Our focus is on our core competencies as sustainable and global innovator in the manufacturing industry.” DMG MORI entered the market for solar technology 2007. Now DMG MORI is focusing on its core business with machine tools and services as well as the development of the future fields of automation, digitization and ADDITIVE MANUFACTURING. “With the takeover of GILDEMEISTER energy solutions,
we have succeeded in strategically strengthening our service portfolio around the megatrend of photovoltaics. Thanks to the comprehensive knowhow and the international network of GILDEMEISTER energy solutions, we are making a big step forward in this growth market,” says Joachim Rumstadt, Chairman of the Managing Board of STEAG GmbH. GILDEMEISTER energy solutions perfectly complements the portfolio of STEAG Energy Services. Under the new leadership, the business field of renewable energies can be developed in a forward- looking manner and the growth course of recent years can be continued. www.mtwmag.com
BUSINESS NEWS
Gifu’s Disc-Type Tool Magazine wins the National Invention and Creation Award The disc type tool magazine from Gifu is awarded National Invention and Creation Award. The special design of structure for this awarded model is the key point why it is awarded by Taiwan IPO (Taiwan Intellectual Property Office). The magazine body itself is constructed by several brick modularized parts, which not only makes the assembling process easier and quicker but also reduces much machining costs on the components. The weight of the tool magazine is relatively lighter than the traditional design. This model was released in 2013 and it was marketed to several VMC
due to the simplified structure.
manufacturers worldwide. Besides, it was also awarded “Silver Award” of Taiwan Excellence Award. The easy structure, simplified assembling process and the eco-friendly materials allow to reduce much costs in terms of materials and time consuming. Moreover, the quality management & production progress can be effortlessly to be controlled
Company profile Gifu is established in 1979. We have the most professional research and development team with more than 35 experienced professionals. Aside from that, Gifu is the first professional tool changer manufacturer to earn the approval of Quality Assurance- BSI ISO 9001:2015 in Taiwan. Gifu not only offers modularized products but also customized products. Until now, Gifu has developed and produced over 400 models. Our products are sold to more than 300 well-known machine manufacturers in
more than 30 countries. We have the most efficient after-sale service locally in India; besides, our sales representatives always respond to the customers through the Internet at the shortest time to support the clients worldwide. Insisting on the operational principles of “honesty, stability and innovation”, we do the best to meet customers’ requirements & assist them in acquiring market opportunities. Meanwhile, to fulfill customers’ requirement of highend products, we began to produce milling heads since 2013. The milling heads are sold to Taiwan, China, India and Czech Republic.
LANXESS investing in application technology service Modern concrete formulations are based on the use of highly specialized additives. As a result, they exhibit considerably improved properties with regard to load-bearing capacity, workability, durability and design scope. The individual constituents in these ever more complex recipes must be highly compatible in order to meet the target performance requirements. These target requirements must also be kept in mind 36
MACHINE TOOLS WORLD
when selecting iron oxide pigments, whose properties make them the material of choice for coloring concrete
JUNE 2019
materials. Sound advice and application-specific support from an expert on pigments can be of great value
here. Specialty chemicals company LANXESS is known worldwide for its expertise in the field of concrete coloring. The company recently invested around EUR 1 million in the further modernization of its application technology laboratory for construction materials. With a production volume of approx. 375,000 metric tons per year and production facilities on five continents, LANXESS is a leading provider of www.mtwmag.com
Technopolymer transmission elements New range of racks and spur gears, pressure angle 20°
Spur gears, modules: 0.5, 1.0, 1.5, 2.0, 2.5, 3.0
Transmission elements in the most advanced engineering plastics: High resistance to torsion and tensile strength Corrosion and chemical agents resistance
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ELESA+GANTER is a worldwide sales joint-venture set-up to offer the widest product range of standard machine elements for the mechanical industry. Highly reliable products ensuring perfect functionality with a unique design represents the ELESA+GANTER distinctive quality code. elesa-ganter.com
Elesa and Ganter India Pvt. Ltd. : A-54, Sector-83, Noida-201305 | Ph: +91-120-4726666 | info@elesaganter-india.com www.elesa-ganter.in
BUSINESS NEWS synthetic iron oxide color pigments. The company, which offers comprehensive technical service along the entire process chain, has made targeted investments to significantly expand its global application technology offering. LANXESS has extensive expertise in the production and handling of pigments and their optimal use in concrete applications. In order to continue to provide
competent support for the future technological developments of its
customers, the company has expanded its application technology laboratory for
construction materials and the technical center for pigment applications at its production site in KrefeldUerdingen, Germany. With an area of roughly 1,000 square meters, the facility is equipped with state-of-the-art technology. This center of excellence offers extensive testing and analysis of the physical properties of the pigments as well as their effects in concrete.
Oerlikon Balzers builds Competence Centre for sustainable metallisation of plastics On 7 May Oerlikon Balzers, leading provider of advanced surface solutions, laid the foundation stone for its new Competence Centre in Bisingen, Germany. Once open by the end of the year, components made from plastic, primarily for the automotive sector, will be metallised with a chrome look using sustainable ePD technology on a site covering several thousand square metres. More than 100 new jobs will be created at the Bisingen Competence Centre, which will enable Oerlikon Balzers to meet the high demand and ever increasing requirements of its cus- tomers from the automotive sector. High-end components with high-gloss metallic or matt surfaces and a chrome look are being used more 38
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From left to right: Okan Akbas (Ronge Industriebau GmbH), Roman Waizenegger (Mayor of the Municipality of Bisingen), Christof Späth (Head of Business Unit ePD at Oerlikon Balzers), Torsten Martens (Property Team AG) and Stephen Kolling (Project Manager Competence Centre Bisingen at Oerlikon Balzers).
and more in interior and exterior vehicle design and in consumer electronics, not only because are they fashiona- ble, but also because they increase the performance and value of these products.The ePD technology from Oerlikon Balzers is an innovative coating method for high-
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end metallisation of plastic components. This technology complies with the REACH standard as it is a sustainable alternative to galvanic methods, which in- volve chromium (VI) and can be hazardous to health. The fully integrated and automated INUBIA I6 and
I15 production systems have been designed for large-scale manufacturing and produce metallised components without any harmful substances, and the new Competence Centre will meet all environmental production standards in their entirety. The site in Bisingen will be used for more than just metallising plastic components for customers; Oerlikon Balzers experts will also further develop the ePD process and be on hand to explain everything about the technology to interested businesses, including how ePD systems can be integrated into their production lines. The new Competence Centre will combine the ePD services previously offered at other sites, releasing capacity required for other technologies elsewhere. www.mtwmag.com
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BUSINESS NEWS
Automation enables us to do more, better, with less: Autodesk Autodesk, the global leader in 3D Design technology, for the fifth consecutive year, successfully organized the Moldflow Summit, 2019 at Conrad Hotel, Pune on 28th May. The event saw participation from around 350 professionals in the manufacturing, automotive, plastic engineering industry and marquee Autodesk customers like Tata Motors, Tata Technologies, Mahindra & Mahindra, Bajaj Auto, Whirlpool, LG, IFB, Schneider Electric, DuPont, Indo German Tool Room (IGTR) among others. The event showcased the success stories of some customers along with Moldflow in the 4th industrial revolution, its new features of and the related R&D.
In his keynote address, Mr. Mike Malkin Sr. Director, Global Sales - Autodesk Inc, discussed how automation will enable us to do more, do it better, and do it with less – less time, resource and negative impact on the world we live in. Autodesk, is already aligned with these new paradigms. And it is doing so by leveraging the power of Cloud and Digital, to enable better
Planning, improved Design and greater Productivity. He further spoke about Autodesk enabling the uptake of new-age concepts like Generative Design in Automotive and Manufacturing sector. A key highlight at the event this year was an interactive session on Generative Design in action, one of the latest innovations from Autodesk for Indian customers.
This session was presented by Mark Hennebicque, Simulation Business Line Manager, Autodesk Inc. Generative Design mimics nature’s approach to design, it lets users create highly optimized designs that meet predetermined goals and constraints. Machine-learning algorithms in computers detect patterns inherent in millions of 3D models and generate taxonomies/ thousands of design options, without intervention by humans. With the computer working in a lifelike manner to solve problems, designers can focus on the intention of their design—what they are trying to achieve—while the computer uses everything it knows to provide them with the best solution.
Hypertherm announces minor version release of nesting software Hypertherm, a U.S. based manufacturer of industrial cutting systemsand software announced a minor version update to ProNest® 2019, its advanced CAD/CAM nesting software for automated cutting. This new release contains targeted features and enhancements designed to make customers more efficient and profitable. “These feature additions incorporate feedback directly from our customer 44
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base, providing users with the specific tools they need to increase both productivity and profitability,” said Tom Stillwell, Marketing Project Manager for Hypertherm CAD/CAM software products. “At the same time, the software remains easy to use with a highly intuitive user interface that benefits both new and experienced users.” In addition, Hypertherm is announcing several major
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improvements to its ProNest LT software, designed for light industrial cutting. New features being added to ProNest LT include: • Cutting techniques used to specify how parts should be cut based on sections of a part’s geometry. For example, automatically adjusting cut speeds for corners, leads, and arcs. • Automatic height control can be automatically
disabled based on certain parameters such as interior profile size, crop cuts, skeleton cuts, or lead-outs. • PDF import will also be included at the LT level. www.mtwmag.com
BUSINESS NEWS
FARO® introduces CAM2 2019 Metrology Software FARO the world’s most trusted source for imaging for 3D measurement and imaging solutions for 3D manufacturing, announces the release of the FARO® CAM2 2019 metrology software platform. CAM2 2019 is specifically designed to enable users of FARO metrology hardware products to realize the highest level of measurement performance across the automotive, aerospace, machine tools, metal fabrication and a variety of manufacturing industries. This includes the recently introduced FARO Prizm™ Color Laser Line Probe and the 6Probe Laser Tracker product families. This release has evolved from extensive user feedback to the wellreceived CAM2 2018 introduced a year ago. CAM2 2019 sets a new standard for intelligent metrology via
improved ease of use, interactivity, flexibility and targeted, actionable intelligence. In addition to the tight integration with FARO metrology products that enables a seamless user experience, CAM2 2019 extends the narrative for high value interactivity and usability. For example, 6Probe users are now able to program button configurations and then interact with the software through the device in real time. Additionally, FARO Laser Line Probe users can benefit from immediate visual feedback of part quality via live deviation color scans. Finally, with Built-In Universal CAD Importer, all major CAD file formats can be directly imported into CAM2. This improves the workflow by eliminating the need for time consuming “double translations”.
CAM2 2019 features a standard set of software instructions, or routines, which automatically guide the user through specific operations, visually and audibly. This dramatically lowers the bar for the technical expertise required to use FARO 3D measurement solutions, shortens the workflow and allows users to direct their primary focus on the measurement results themselves. Additionally, presetScanning Profiles further streamline the end to end process by enabling users to select the appropriate scan setting for the specific part type with the click of a button.
DEUBLIN SpindleShield™ Unions for CNC Machining Centers DEUBLIN Company announces SpindleShield™ technology for use with the most sophisticated CNC machines. DEUBLIN coolant unions with SpindleShield™ employ a unique patent-pending electronic leak detection system that detects coolant problems and allows for rapid machine shutdown. Machining centers with through-coolant spindles require coolant unions to deliver coolant at high pressures through the cutting tool at the cutting surface. For dry running cycles or 46
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machining operations with multi-media such as air, MQL or coolant, DEUBLIN offers coolant unions with patented Pop-Off™ and patent-pending AutoSense™, a technology that separates the seals in the absence of coolant and allow indefinite dry run or multi-media capabilities. During each cycle from one mode to the other,
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a minute amount of coolant spills out, which must be collected and drained. Excessive leakage, if not detected, may leak past the spindle seals and eventually contaminate and damage the spindle bearings. DEUBLIN introduces SpindleShield™, an industry first and revolutionary new technology for
CNC machining centers. SpindleShield™ protects the spindle and prevents replacement of spindle bearings by allowing rapid, automatic shutdown of machines. The combination of remote diagnostics and a positive leak detection system virtually eliminate unnecessary preventative maintenance and costly spindle repair. This technology can be easily integrated into any standard system bus. For more information, Website: www.deublin.com
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COVER STORY
Driving the Future of Machine Tools Industry
T
oday, every discussion related to manufacturing advancement and revolution is centered around the concept of Industry 4.0, and rightly so. Based on the idea of new ways of human machine-interaction, advanced robotics, increased connectivity and huge sets of data, Industry 4.0 has the potential to fundamentally reconfigure the industry. In this new world of Industry 4.0, everything will connected to internet and cloud enabling the concept of smart factories. In these factories, all the component will function as a system rather than individual parts. As Industry 4.0 continues to take the whole manufacturing
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world by storm, machine tools are also becoming a part of the smart system. In India too, the concept, though in nascent stages, is slowly gaining steam, especially among large machine tool players who are innovating in this direction. Primarily, machine tools industry is looking at Industry 4.0 to meet increasing customer requirement for improved productivity, reduced cycle time and greater quality. Thus, adopting Industry 4.0 concept is at the crux of achieving the ambitious target of making India a global hub for manufacturing, design and innovation, and augmenting the share of manufacturing in the GDP from the current 17% to 25% by 2022.
Enabling better visibility and improved decision making One key advantage of Industry 4.0 is data collection. This data can offer actionable information to make better decisions about manufacturing processes, such as optimizing machine uptime, scheduling maintenance, etc. All of this put together results in improved productivity. Machine tools will have sensors that will enable collection of different kind of data, including how much the machine has operated, the condition of components, etc. This data also provides predictive capabilities about life of certain components, which in turn helps in running machines more
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COVER STORY efficiently and prevents downtime. For instance, the system would alert users to replace a component that has experienced a heavier load and more frequent use. One can exactly pinpoint finger on the faulty component and take corrective measures. Another big advantage is that the sensors embedded in machines can arm users with predictive capabilities about life of certain components and machine maintenance. This helps them in taking corrective steps in time. Further, Industry 4.0 can ensure that a particular machine is being used properly. For instance, a machine can be set to conditions (such as force or temperature), it can withstand. In case it detects conditions outside the defined limits, it could send out an alert. This can significantly bring down downtime caused by human errors. Industry 4.0 also has the ability to improve utilization of machine tools in manufacturing operations by cutting idle time. Industry research
has indicated that machine tools are typically actively cutting metal as less than 40% of the time, which sometimes go to as low as 25% of the time. Analyzing data related to tool changes, program stops, etc., helps organizations determine the cause of idle time and addressing it. This results in a more efficient use of machine tools. Embracing Industry 4.0 also helps organizations bring down energy consumption and even monitor CO2 emission level per part. Connected devices can collect data on electricity demand to increase production when the energy demand is low, resulting in low cost of energy. Smart connected devices also have the ability to shut down or reduce the power when not in use. Quality is another key area wherein Industry 4.0 can make a significant difference. Earlier, manufacturers typically used to come to know about the product quality only when the product was finished. This would mean complete rework in case there
was any fault in the finished product. Today, with the help of connected and smart systems, manufacturers have complete visibility into the entire manufacturing process right from the concept to finished stage. They can ensure quality at each and every step, with full visibility into the quality of finished product. This not only increases productivity but also helps manufacturers save time and resources. Clearly, given its advantages, the time is ripe for organizations to take the leap for Industry 4.0. That said, getting started with Industry 4.0 technologies can seem intimidating to many. The key for the success of Industry 4.0 lies in having a dedicated digital strategy. As Machine Tools World celebrates its fourth anniversary, we spoke to prominent players to know more about how the rising trend of Industry 4.0 is bringing a shift in the industry, how their products are in line with the trend and their vision for 2020. Excerpts follow:
Erwin Junker Maschinenfabrik: Helping Indian Companies on their Industry 4.0 Journey
Mr. Sunil Badave, Director Sales & Services, Erwin Junker Maschinenfabrik
Highlight the current landscape and growth prospects of machine tools industry in India. Indian Machine Tools Industry is in the midst of interesting times and is strengthening its position in the
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global market. Many tier-1 and tier-2 manufacturers are looking for better and sturdier/ reliable machines. Today, demand is high for proven equipment, which can produce quality parts rapidly. The long-standing notion of cost per piece calculation as the deciding factor for the cost of machine is fast disappearing. The manufacturers are realizing that up-time of machine, better tool cost, long lasting peripherals, tooling etc. with better man machine management are the key metrics that can help keep cost and quality under control and ensure better delivery schedule. Given the
focus on efficiency and quality, Indian component manufacturers are adopting better technologies, materials and machinery to improve the quality to international standards. This is proving an enormous opportunity to export the parts, which is giving further boost to the Indian industry. As the demand continues to grow, the country is slated to see advanced machine tool manufacturing. JUNKER has been implemented in India for the last 10 years and is pleased to contribute with its high precision grinding machines to the development of India.
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COVER STORY How are your products/services geared up to be in line with recent trends, such as Industry 4.0 and Smart Manufacturing? Industry 4.0 and smart manufacturing are fast gaining momentum world over. Indian industry is no exception to this global trend, which is poised to see faster acceptance in the coming years. There are plenty of Industry 4.0 use cases related to predictive maintenance, which is empowering manufacturing companies to prevent asset failure and increase operational efficiency. However, the entire process from raw material to finish product needs to be reliable to implement Industry 4.0 and realize its benefits. Systems and machines must be incorporated into a neverseen-before network of all company departments, with ultimate flexibility. The JUNKER Group has experience
in how to efficiently collect and analyze data so that it can be called up for many applications and various different systems: a huge challenge, which the traditional company has been tackling with success for many years now. JUNKER is committed to help Indian industry in its Industry 4.0 journey and our machines are already equipped with software in line with Industry 4.0. What is your vision for your company (in terms of new product launch, innovation/collaborations)? How do you see your brand growing by 2020? Headquartered in Black forest in Germany, Erwin JUNKER Maschinenfabrik GmbH is known for CBN High Speed Grinding machines. JUNKER has earned a
solid reputation in Indian market by offering Europeans standard products manufactured in Europe, without compromising quality and high technology. JUNKER is known for premium service in-line with international quality standards throughout the entire JUNKER Group. Our machines are flexible to accommodate new changes in the customer’s requirements, based on the market demands. Fast setup changeover is the key factor in JUNKER machines which helps cut down non-productive time. Recently Junker India branch office have celebrated its 10th year in business and to support growing Indian market, JUNKER India branch office recently moved to bigger location in Pune to induct additional workforce, which was inaugurated on 6th April 2019.
UCAM: Committed to Continuous Improvement and Innovation The Make in India Campaign has helped many small and mid-cap industries to grow. Many aerospace companies are planning for projects in India. This will definitely develop India’s aerospace and manufacturing capacity and it will also give opportunities for various manufacturing industries, since there will be a huge requirement for aerospace components.
Mr. Vijay Zaritaklikar, National Sales Manager, UCAM Pvt. Ltd.
Please tell us about current landscape and growth prospects of Machine Tools industry in India. Technology is getting advanced day by day. Getting equipped with modern advancements, machine tool manufacturers were able to improve their productivity, efficiency and quality of the components. The Indian Machine Tool industry has grown and is well positioned in the global market.
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How are your products/services geared up to be in line with recent trends, such as Industry 4.0 and Smart Manufacturing? Industry 4.0 and Smart Manufacturing has already created a buzz in the machine tool world and many of the manufacturing companies including us have started initiatives towards it. We have introduced various methods
and strategies in our manufacturing facility so as to manufacture rotary tables in a cost effective way and of higher quality. We developed Single Axis Controller that can be connected with wi-fi and our Noah Series Gear Hobbing Machine’s CNC Controller is also equipped with wi-fi making it more user friendly. We believe in “Continuous Improvement”. This has helped us give our customers quality products. It has also increased the efficiency and productivity. UCAM feels proud to announce the New Mint Series CNC Rotary Tables for the Machine tool manufacturers and VMC users. The new URXH and URX Series Rotary Tables from the portfolio of UCAM rotary table products enables users to give higher cutting forces onto the component, thus reducing the
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FACCIN GROUP
MORE PRODUCTIVE METAL FORMING WITH CNC AUTOMATION WIDE RANGE & TAILORED SOLUTIONS
Industry 4.0 Compliant
The Trusted Partner in Metal Forming Machines SWEDISH DESIGN, ITALIAN ENGINEERING
BIG-CAPACITY CNC-CONTROLLED ANGLE ROLLS | R SERIES
HIGH-PRODUCTION CNC-CONTROLLED PLATE ROLLS | 4HEL SERIES
HIGH-PRECISION CNC-CONTROLLED FLANGING MACHINES | RIBO SERIES
Faccin S.p.A. is a powerful group that combines a number of leading brands – Faccin, Boldrini and Roundo - in plate rolling, profile bending and dished-heads manufacturing, all united under one roof. Using the synergies provided by each brand, technically and commercially, Faccin is able to offer an even wider range of options and tailored solutions in the metal forming market.
COVER STORY cycle time and increasing productivity. These Rotary Tables are with very high clamping torque generated by the new technology brake discs which are specially processed to generate higher frictional torque. Also, the clamping area increased to generate higher clamping forces. The URXH Series compared to others, come with 3 times higher clamping torque (800 Nm @ 5 bar pneumatic pressure). Apart from the higher clamping torque, the URXH series is with a specially molded FRP motor guard which has helped in the reduction of overall weight of the Rotary Table by 6 percent. In URX 200 Rotary Table, the clamping torque is 400 Nm (@ 5 bar Pneumatic input pressure) and 900 Nm (@ 30 bar hydraulic pressure) against 250 Nm and 500 Nm respectively in URH series. Due to this, users can give higher cutting depths for their component. The users will be
benefited by faster indexing, reduction in costs and increased productivity. What is your vision for your company (in terms of new product launch, innovation/collaborations)? How do you see your brand growing by 2020? UCAM has also grown in every aspect and always keeps an objective to become the “Best Partner in Productivity” for our customer. Our Vision is to become one among the top 5 global players within the chosen domain. UCAM, pioneers in manufacturing of CNC Rotary Tables in India, and has established itself as a market leader in the field of precision CNC Rotary Indexing Tables. Our products are known for their quality, reliability and performance in challenging and high demanding applications in various industries such as Automobile, Aerospace,
Power Generation, Medical, Oil & Gas exploration, Pumps & Valves, General Engineering, etc. Over the years, we have diversified into new verticals under the brands Nimble Electric, Nimble Machines & UCAM Mechatronics. Use of stateof-the-art cutting edge technology, continuous product innovation through R&D and pro-active customer relation management has made UCAM a global brand. UCAM’s Research and Development center is recognized by Department of Scientific and Industrial Research (DSIR), Govt. of India. The stress on R&D and the passion to give the customers what they want has made us to come out with new innovative models and as a recognition we have won the FIE award 6 times. We are proud Indians and love to support and collaborate with Indian machine tool manufactures and VMC users to increase their productivity.
Mastercam: Powering Manufacturing with Innovative Technologies
Mr. Vineet Seth,, Managing Director – South Asia & Middle East, Mastercam APAC.
Highlight the current landscape and growth prospects of Machine Tools industry in India. The Indian Machine Tools Industry is estimated to have an annual turnover of a little over INR 7000 crores, according to IMTMA’s recent annual report, with a growth of around 26% over last year. These numbers are very encouraging and I’m positive that we
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are yet to go higher to hit the peak. Domestic consumption is at least twice as much, and we can gauge that imports account for at least 50% or more – considering that we also export machine tools from India. Government policies in the recent past look encouraging on the long term and are bound to increase manufacturing in the country. In line with ambitious initiatives such as Smart Cities, Make in India, Defence Privatisation, Aerospace and Automotive parks, amongst others, I wouldn’t be surprised if we see significant growth in machine tools manufacturing and consumption in the next decade or so. How are your products/services geared up to be in line with recent
trends, such as Industry 4.0 and Smart Manufacturing? We are working with leading Industry 4.0 initiatives to enable e-manufacturing solutions. For example, Searching for upto-date, accurate tooling data can be a tedious, time consuming task for CAM programmers. A myriad of websites, catalogs, and other sources are available for the task, but typically require manual entry methods that may result in data inaccuracies as the NC program takes shape. Every tooling manufacturer offers their own approach to making their product data available. It’s not only up to the user to find out if a tool is in stock, but equally important to ensure that its associated data files are comprehensive enough to get the job
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COVER STORY done right in the CAM system. The MachiningCloud application in Mastercam 2019 streamlines the entire experience, letting one quickly sift through its own cloudbased, digitized manufacturer catalogs with the latest inventory availability. Participating tooling manufacturers offer their product data through MachiningCloud, taking advantage of its dynamic search capabilities to narrow down tooling possibilities according to a product’s specifications. A growing list of manufacturers are already onboard. With MachiningCloud’s native, cloudbased CAD and 3D viewer capabilities, users can review 3D models, build digital tooling assemblies on-thefly, and package them into a single source, readable file format for use in Mastercam. Everything from the latest tool geometry to feeds & speeds data is ready for import and continuously
updated by MachiningCloud. MachiningCloud acts as an automated, intelligent advisor that compares manufacturer recommended product data to your machine’s specifications, alerting users to tool fitting and mounting, projection lengths, and more. Both MachiningCloud and Mastercam work together simultaneously, resulting in a new, transformative approach to handling tooling data. What is your vision for your company (in terms of new product launch, innovation/collaborations)? How do you see your brand growing by 2020? Mastercam as a brand has been celebrating its 35 anniversary. CIMData has ranked Mastercam #1 in Installed Seats Worldwide and “Most Widely used CAM Software” for 23 years in a row. We expect to keep the growth momentum high and ensure
that we retain our top position. We also would like to emphasize on our USPs of being a CAM centric company, offering the best possible solutions to our customers in the manufacturing domain. We also intend to focus on customer-friendly policies & the fact that we are a debt-free company. This will help us ensure both our customer’s and our progress. We will be focusing on the following in the next five years – • Listen to the customer voice • Embrace newer technology while maintaining quality and reliability • Provide solutions that will help customers win • Be ready for tomorrow’s possibilities, yet flexible for today’s needs • But most importantly, be there for the customer when they need us the most.
Imaginarium: Showcasing Value in Industry 4.0
Mr. Guruprasad Rao, Director & Mentor, Imaginarium India
Highlight the current landscape and growth prospects of the Machine Tools industry in India. Current Indian Machine Tool Industry is at cross roads. Machine tools had their share of computerization to become NC, CNC and Machining centers. Unlike Indian IT which grew into world’s mighty force, Machine tools somewhere lost the race initially
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to the innovative West and Japan. The economy was controlled by OEMs with their know-how monopoly. Making machine tool indigenously needed import of expensive hardware. This expensive development discouraged investments. After IP expiry, the scale up game was lost to the state sponsored china Industry. Thanks to subsequent economic reforms, today we have a decent growth in machine tool industry. Due to the efforts by government and Industry body, IMTMA, The Machine tool industry is poised to adopt Industry 4.0. We cannot miss the bus now! How are your products/services geared up to be in line with recent trends, such as Industry 4.0 and Smart Manufacturing? Imaginarium is into enterprise 3-D
printing and Rapid Manufacturing solutions. From a mere service bureau, we have transformed our business into a platform to make anything, anytime, any quantity. We are in the Digital Manufacturing space. 3-D printing is an important factor in Industry 4.0. They bring the physical side of Cyber Physical System, the other name for Industry 4.0. Being a process which depends on digital inputs, the process is controllable through a network of computer network and open up opportunities of new age such as cloud factory. Our digital platform are constantly improving to deliver reliable solutions across the globe. The computing power, stronger communications herald a super optimum agile fabrication of custom products. We also call it smart
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COVER STORY manufacturing. We are not only adopting to Industry 4.0 but also help industry to see the value they deliver. What is your vision for your company (in terms of new product launch, innovation/collaborations)? How do you see your brand growing by 2020? We are overwhelmed by the potential
and promise of Industry 4.0. We wish to enable every individual designers, scientists, startups, SME, OEMs to focus on design while we take care of how to make them. We do it by strategic capacity building through both organically and inorganically. We want to bring the best of technology to India and make it for the world. Imaginarium is standing
tall as a reliable and trusted brand. We see we need to constantly change to remain in this sweet position and for 2020 we are working on our new version, Imaginarium 4.0. We do it by embracing the latest technologies and skills. We will continue to focus on Lifestyle, Engineering, Medical solutions and aiding industries in adoption of new technologies.
DesignTech Systems: Helping in Harnessing the Power of IoT in Manufacturing already started to witness this growth momentum. The last fiscal quarter already saw industry in India touching a little over 8% productivity and growth rate. With all these sectors expected to experience tremendous boom, the tooling and mould and die industry will thrive on this growth opportunity. It’s their time to Shine.
Mr. Vikas Khanvelkar , Managing Director DesignTech Systems
Highlight the current landscape and growth prospects of Machine Tools industry in India. The Indian machine tool industry is growing at a steady pace and with the continuous support of the government aims to grow even further ahead. Government of India is putting dedicated efforts to expand Aerospace engineering, Manufacturing and ME&S market in India. To further this objective, they are establishing Aerospace dedicated SEZs and manufacturing parks in south India. Make-in-India initiative will further provide the thrust to overall engineering and manufacturing industry in India including Industrial Machinery and Consumer Goods. Manufacturing in India across all domains and industry sectors is thus expected to grow big, which will require equal support – quality and quantity wise from the Machine Tools and Die and Mould industry. We have
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How are your products/services geared up to be in line with recent trends, such as Industry 4.0 and Smart Manufacturing? At DesignTech, ever since our inception in 1998, we have been working closely with the Mechanical Engineering industry in India, helping them make a transition from traditional processes of yesterday to adopting the latest technologies to match the global standards of engineering excellence. We have some of the advanced CAE solutions, 3D Printing or Additive Manufacturing Technologies, latest CAD and PLM solutions from global leaders for the industries that would help companies attain their goals of product design and manufacturing excellence through efficient processes and systems that augment productivity, generate greater ROI and enable them achieve higher cost effectiveness. These technologies would help them remain competitive and relevant in the
fast changing market space. DesignTech Systems Ltd. has newly tied up with PTC as their Value Added Reseller to promote and sale their Industrial IoT (Internet of Things), Virtual Reality (VR) and Augmented Reality (AR) solutions, ThingWorx and Vuforia in India. These latest technologies would definitely help companies gear up for Industry 4.0. Digital Transformation with IoT is a must to compete in the world of Industry 4.0 Industry 4.0 is a revolutionary concept that will transform the way manufacturing has been carried out. IOT or the Internet of Things will be at the crux of it. Industry 4.0 basically is complete digitalization of processes, advanced automation and robotics, self-monitored and guided systems through Artificial intelligence that would manage the day-to-day working of the factories. This is predicted to be the next big Industrial revolution. The human interface would be minimum as regular processes would be largely governed, managed, and executed through Artificial intelligence. There will also be complete digital integration with suppliers and vendors. The entire communication, management and review of processes and data would be conducted and shared digitally. It will be an ‘All Connected’ Manufacturing platform.
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COVER STORY India already has earned a reputation for being an IT hub of the world, but Manufacturing is the next alternative that will bring more foreign companies to India. Our IT competency will certainly help us migrate to IoT backed Manufacturing approach. We can even contribute to providing Overseas Services and Consultancy for helping companies get their IT infrastructure in place for Smart Manufacturing. Technologies like 3D Printing, Digital Manufacturing and PLM are paving a slow and steady way into the manufacturing industry, but we need to expedite our process to migrate to new and improved way of conducting work. We are still far away from Industry 4.0. The products offered by DesignTech help companies in conceptualising and building Smart Factories. Smart factories essentially mean the factories which are automated and actually take decisions based on some predetermined events. This needs designing and using Smart Products. Such prod-
ucts are a combination of many technologies like Electrical, Mechatronics, Instrumentation (sensors) embedded systems and software. The range of 3D modelling and simulation solutions offered by us can help companies design and simulate such systems. What is your vision for your company (in terms of new product launch, innovation/collaborations)? How do you see your brand growing by 2020? We have tied up with hyperMILL CAM solutions from Open Mind Technologies, AG. hyperMILL is a state-of-theart CAM solution that offers 2.5D, 3D, 5-axis milling and turning, as well as machining operations such as highspeed cutting and high performance cutting. DesignTech has established a firm grounding in India. We now wish to step outside our comfort zone and attempt to establish a strong foothold in South Asian countries as well. With that objective in mind, at DesignTech
we have already expanded our presence in Singapore and Malaysia as a Value added Reseller of Stratasys 3D Printers and Altair Engineering for their CAE suite of Solutions. DesignTech is the authorised partner in Singapore and Malaysia for Rosetta Stone which is cloud-based Adaptive Blended Language Learning solutions. Besides that, DesignTech Engineering Services division has also started their operations and now has a physical presence in USA and Germany. Through our Services division we are working very closely with companies from India and overseas helping them attain their objective of product design and engineering excellence. DesignTech CAD Academy, an education and training division of DesignTech Systems, signed up with Dassault Systemes as their Authorized Training Partner for CATIA. Besides Dassault Systemes, DesignTech CAD Academy is also Authorized Training Partner of Altair Engineering for their CAE solutions in India.
LMT Tools: Leveraging Latest Technology to Spur Innovation in Metal Cutting
Mr. Ramakant Reddy, Managing Director LMT Tools India
Highlight the current landscape and growth prospects of Machine Tools industry in India. India stands 12th in production and 8th in consumption of machine tools in the world as per the survey. The India machine tool industry is
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projected to grow roughly by 6% annually through 2019. With presence of several small, medium and large industries, including international and regional players, the companies engaged in machine tools manufacture compete in product differentiation, service and pricing. Industry 4.0 is gaining its importance in India Machine Tool Industry, additive manufacturing, process automation are the core trends. How are your products/services geared up to be in line with recent trends, such as Industry 4.0 and Smart Manufacturing? Now everyone is talking about green
machining and Industry 4.0 and technology like IOT. We are working closely on Industry 4.0. Our recently introduced Tangential Evoline Thread Rolling System is manufactured using the 3D printing technology. The roller head hinges are produced using 3D printing methods to optimize the volume flow and distribute from the adjustable cooling and rinsing nozzles. The structures are also more precisely oriented to the force flow, which optimizes the break resistance of the tool. In addition, the rolling head is fitted with a sensor for force measurements, which continuously supplies data for more efficient tool use. Our Self-adjusted fine boring
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COVER STORY tools (Line Boring Bars) are digitally advanced. The line boring bar can be connected wirelessly to a measuring machine that measures all finished bores and uses the results to decide whether wear compensation is required at the cutting edges of the tool. These adjustment processes are fully automatic. They are driven by “actuators”, which are located at each individual cutting edge and which operate with micrometer precision. This is how we provide you with
highly efficient, self-adjusting fine boring tools: for consistently high component quality and minimized machine downtimes with an optimized cost per unit. Alternatively, the cutting edges can be readjusted by remote control or laptop. What is your vision for your company (in terms of new product launch, innovation/collaborations)? How do you see your brand growing by 2020? LMT Tools has been recognized as
Best Metal Cutting Brand 2018 by The Economic Times. We have been growing consistently year on year. We have the latest technology products in the market, this year we have introduced couple of our innovation at the IMTEX 2019 and some are in pipeline. We will continue our success journey, we plan to increase our manufacturing capacity at Chakan, Pune plant and by 2020 we will have more products to offer from our local plant.
Elesa and Ganter: Constantly Evolving to Cater to the Dynamics of Industrial World
Mr. Ram Grover, Managing Director, Elesa and Ganter India
Highlight the current landscape and growth prospects of Machine Tools industry in India. The Machine tool industry has evolved over the years and with the new impetus in government reforms, it is poised to grow further. One important factor which has provided substantial stimulus to the Machine Tool industry is the rapid growth of exports. With this the need for adopting better technologies, materials and machinery to deliver international quality has become very important for Indian businesses. As a result of this growing demand, the country is set to become a key player in terms of global machine tools industry and is likely to see substantial high-end machine tool manufacturing.
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How are your products/services geared up to be in line with recent trends, such as Industry 4.0 and Smart Manufacturing? Coming years will witness lot of changes with faster acceptance of Smart manufacturing into various industries. It actually does have solutions to a lot of problems faced by the industry and beyond, but faces its own unique challenges too. Manufacturers must change their processes and the way they work, at the same time they must welcome the technology that promises great efficiency and productivity. ELESA+GANTER® is into business of Standard Machine Elements and our manufacturing facilities in Italy and Germany are already equipped with fully automatic production units with the latest technologies. “With IIOT enabled machines, it has become more imperative that the machines are handled, operated and fueled with best of the standard parts and machine elements, this is where we come in and become part of the coherent mechanized ecosystem. Our Product & Design team are always evolving to cater to the dynamics of Industrial world.
Clearly, Smart Manufacturing is not a fad; it’s a trend that will completely revolutionize manufacturing. What is your vision for your company (in terms of new product launch, innovation/collaborations)? How do you see your brand growing by 2020? Across Industries and in the world of standard machine elements, Elesa+Ganter has carved a niche name for itself. We are currently investing into the Indian market by expanding team of Sales and service professionals in all the regions. Our Research & development departments are constantly working on new products and range extensions to always guarantee to customers a wide range of components capable of high performances. We invest in our people and every sales team member gets to visit & get trained at out Headquarters in Italy & Germany. Additionally, our well established Channel Partners Network across India ensures easy availability of our Products and on time deliveries. We are looking forward to our long bright future in India and very much confident to continue with the double digit growth Year on Year.
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IN FOCUS
Mobil edge for the machine tools industry Q. In terms of lubricant selection and usage, what are the specific challenges that a machine shops/ manufacturing sector face? For the manufacturing sector, a key operational challenge is to strike an optimum balance between throughput and maintenance. A direct fallout of this imbalance can be a breakdown of operations, which can severely derail deadlines and hamper production. Sometimes manufacturers are tempted to postpone or delay preventive maintenance or they replace original components with lower-quality items. This practice may create unsafe conditions in harsh manufacturing environments if these low quality components – including lubricants - can’t stand the up to operating conditions. Poor maintenance can also cause health and safety issues, as well as lead to unplanned or excessive downtime. Manufacturers need to perform preventive maintenance on recommended schedules to keep operating costs low and throughput high, while ensuring worker safety. Q. Incorrect lubricant usage often hampers productivity in a machine shop. How do ExxonMobil’s products and solutions address these challenges? Incorrect lubricant usage – even over usage of lubricants - can severely hamper productivity. For instance, disregarding the manufacturer’s recommendations for any piece of equipment or component could potentially lead to failure of the equipment or affect the machine’s
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Mr. Deepanker Banerjee, CEO, ExxonMobil Lubricants
warranty. With usage of lubricant closely linked to varying factors like environmental conditions, speed, load and temperature, getting the usage right is imperative for manufacturers. Using the appropriate grade and type of lubricant is essential for proper bearing performance. Failure to choose the right lubricant can lead to shortened bearing life. After many decades of serving the industry, we have the proven lubricants and expertise to help manufacturers at every stage of the manufacturing process. Our lubricants are designed to work together and minimize the impact of cross-contamination. For instance, our recent launch, the Mobil SHC™ Elite, is a breakthrough synthetic gear and bearing circulating oil that has been specifically engineered to deliver long-lasting protection for machines, delivering 12 times the oil life of mineral oils and double the oil life of regular synthetic oils, even in continuous high operating temperatures and under extreme operating conditions. In addition to our high performance lubricants and fluids, we provide a
range of technical services to help keep the machine running at peak efficiency while also extending machine and oil life, reducing downtime and lowering operating costs. Q. ExxonMobilTM is a lubrication expert. What are the Lubrication Solutions the company offers to a machine shop? The machine shop industry is core to the manufacturing sector. The Indian manufacturing sector is turning a curve - we are witnessing a focused and continuous effort on part of manufacturers to not just increase productivity and cut costs, but also adopt sustainable processes and technologies for a greener business. As newer technologies in the machine shops gain momentum, the lubricant industry is also gearing up to meet the need for customised specialty products. Industry leaders like ExxonMobilTM are powering this transformation, bringing technologically superior world-class lubricants developed through global expertise of decades that deliver significantly improved productivity and cost savings.
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MMC Hardmetal: The legacy of innovation and technological excellence
Mr. Prashant Sardeshmukh, Vice President & Director, MMC Hardmetal India Pvt Ltd.
Backed by the legacy of one of the most respected and trusted brands Mitsubishi, MMC Hardmetal has been on a steady growth trajectory. The company is at the forefront in driving innovation in cutting tool segment in order to stay ahead of evolving demands of end-users. In an interview, Prashant Sardeshmukh, Vice President & Director, MMC Hardmetal India Pvt Ltd., talks about advancements in metal cutting technology, the company’s core values and future vision and growth plans. Excerpts: Q. As a global leader in metal cutting, what are the latest trends that you are witnessing in the segment? Trends in manufacturing industry set up trends in development of metal working solutions. Changes in work-piece material, manufacturing process and even government regulations, parallel developments
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in metal cutting technology are observed. The manufacturers always try to apply new materials that are lighter and stronger, it necessitates cutting tool manufacturers to develop the tools that can machine new materials at the highest precision and optimum levels of productivity. These days high-technology areas like aerospace and high-end
automotive are making increasing use of variety of composite materials. These industries demand effective cutting tool materials that would withstand high abrasiveness of composite materials and provide superlative surface finish to avoid built-up edges in order to produce excellent finished parts and endure high cutting zone temperature.
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IN FOCUS High toughness and high hardness are the important attributes for an ideal cutting tool material for cutting composites. Since there are no materials that carry these two vital properties, many techniques are being applied to cutting tool materials and tool coatings in order to improve their performance. Q. What are end-users expecting from cutting tools today? How does MMC Hardmetal meet these evolving demands to ensure customer satisfaction? We are passing through the new industrial revolution and witnessing lot of advancements in metal cutting technology. These advancements are driven by smart manufacturing, robotics, embedded intelligence and Internet of Things (IoT) which lead to end-users legitimate expectations of high efficiency, cost benefits, environment protection, and human exertion to minimal levels. We always strive to take our technology beyond the established norms and practices of metal cutting normally observed on the shop floor. We are always perseverant about our core values, “For People, Society and the Earth”. That’s why whenever we develop any new technology our focus is to respect our core values. Naturally all our innovations and products come out with inherent qualities of precision, reliability, durability and versatility. This thought always inspires us to produce cutting edge technology to exceed the expectations of our endusers.
during the period 2017-23. India is steadily but confidently trying to capture the prominent position in the global market landscape. Current boom in the sectors like construction, infrastructure development and manufacturing has helped market players to do well in the Asia Pacific Region. With incumbent government voted to power again, initiatives like Make in India, and many other ambitious infrastructure projects will gain better moment. As a result, Indian manufacturing industry and overall market is expected to see significant upsurge in the coming years. Q. How are trends, such as automation, IoT, robotics transforming the metal cutting segment? These are increasingly becoming popular and reliable trends, I must say. And they will bring about revolutionary change in metal cutting segment. In the next couple of years IT & OT (Operational Technologies) converge will help to create smarter solutions with greater efficiency and transparency. Many global giants are stepping in the direction to evolve customized business model to move closer to the consumer in order to meet their requirements more effectively. Intelligent manufacturing involving Cloud
Computing, IoT and AI are set to dominate the industry in the years to come. Q. What is your vision and growth plans for MMC Hardmetal for 2020? We have set our footprints in Indian market for last 13 years and achieved encouraging growth right from the beginning. We have the legacy of one of the most respected and trusted brands ‘MITSUBISHI’. On the strength of our technological excellence, commitment and astute business planning we have been able to achieve exemplary growth over the years. We have accomplished commendable position and reputation in the manufacturing and automotive sectors. Our aim is to expand and establish our presence in all sectors especially the Aeronautical sector, oil & gas industry, pharma, medical and nonconventional energy etc. We started our sophisticated manufacturing plant at Aurangabad to manufacture special tools and initiated activities to launch our State-of-the-Art TechCentre at Pune. This centre will add to our technological muscle. With such activities under Make in India campaign, we are confident to scale new heights for “DIAEDGE” brand of Mitsubishi Materials in Indian market.
Q. How is India placed in the global cutting tools market? How is the future outlook and growth prospects? The global market for cutting tools is expected to achieve CAGR of 6.7%
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IN FOCUS
Amol Arun Mane, General Manager – Technical & Marketing (India & South East Asia)
Sandeep Srivastava, Director- India & South East Asia
Hexagon Production Software: Powering Manufacturing from Concept to Reality Last two years have been instrumental for Hexagon Production Software India. From bringing all brands in India under a single umbrella of Vero India to change of brand name from Vero Software to Hexagon Production Software, the company has been in midst of several interesting changes. Despite all these changes, one thing has remained constant—its relentless focus on meeting evolving customer expectations with a wide range of product offerings. The company today has earned the reputation of one the leading CAM centric – Manufacturing Software Solutions company. Its impressive client list and huge market share are a testimony to its growth. Shweta Nanda of Machine Tools World recently got an opportunity for an exclusive interview with Sandeep Srivastava, Director- India & South East Asia and Amol Arun Mane, General Manager – Technical & Marketing (India & South East Asia). In an extensive chat, they tell us about the company’s success mantra, how they ensure customer satisfaction across large and small organizations and the company’s future growth vision. Edited excerpts: 72
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Q. Tell us about Hexagon brand. How important is Hexagon Production Software division for the brand and how the company helps organizations attain their vision of smart manufacturing? Amol: Hexagon is a digital solutions company that is committed to shaping smart change within organizations. To get a clear perspective, let’s consider some facts. By 2054, the global population is expected to reach 9 billion, which essentially equals to a new city every 5 days. Also, middle class purchasing power is projected to triple. All these developments are spurring innovation and manufacturing demand. We, at Hexagon, are at the centre of powering this smart change. We strive to proactively and positively shape businesses and industry
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IN FOCUS landscapes in support of a sustainable future while helping organizations increase their bottom line, profitability and gain a competitive edge. When we talk about Hexagon Production Software, it is an integral part of Hexagon’s Manufacturing Intelligence division. We help customers embed quality throughout their production lifecycle. Earlier quality was assessed only of the finished product. For instance, take the example of car assembly line. If one comes to know of any defects/changes once the car has been fully assembled, then it requires complete rework from the manufacturer. This not only significantly affects the profit margins but also impacts the throughput. This is where Hexagon Production Software completely fits the bill with its motto of Quality drives productivity. We help manufacturers ensure quality right from the concept stage—they have full visibility into product outcome. This helps them effectively achieve the three-fold requirement of time, cost and quality. Q. Tell us about the scale and geographical presence of Hexagon Production Software. What is the company’s total market share? Sandeep: We have direct offices in the UK, Italy, France, Germany, Netherlands, USA, India, Spain, Japan, South Korea, China, Vietnam and Thailand. Also, we have development teams in the UK, USA, Italy, Netherlands, France, Germany, India and Russia. As per the findings of CIMdata 2017 Market Analysis Report, we are number one in industrial seats installed with 306,400 seats—more than double of the seats installed by number two ranked CAM supplier in the list. With market share of 22%, we are world’ no 1. CAM centric software company. Also, as we have acquired Spring Technologies, we have further solidified our market share.
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Q. Which industry segments do you cater to? Can you share an interesting case study? Amol: With our wide range of product portfolio, we cater to unique needs of major industry segments, including automotive, aerospace, die and mould, medical, electronics and machinery. Our global client list includes leading names, such as Volkswagen, GM, Hyundai, Ford, Siemens, Samsung, Schneider Electric, to name a few. One interesting case study that I can share with you is that of the automotive giant, Audi. The company has achieved significant benefits by using our product, WORKNC. Audi has been able to reduce processing times in various pre-finishing pressing tools by up to 30% while tool service life has tripled at the same time. The solution allows Audi to do programming for even highly complex parts in a quick and intuitive manner. Q. Hexagon Production Software has seen significant growth in India in the last two years. Please tell us about business strategy changes that have led to this growth and helped it acquire new customers. Sandeep: When we talk about India, till two and a half years back, all our products were available as a separate offerings through resellers. Customers identified our individual products but were unaware of the brand behind these products. Over the past two and a half years, we have made conscious efforts to consolidate all the fragmented products and bring them under the single umbrella of Vero India. With our acquisition by Hexagon and brand change to Hexagon Production Software (in January this year), we have further solidified our position as a complete solutions partner for customers. Backed by the experience & innovative solutions of our parent company, Hexagon, we are well-equipped to
We have a wide range of customers—right from big conglomerates to small manufacturing shops. We at Hexagon strive to meet the unique needs and requirements of all customer segments. Sandeep Srivastava help companies add value at each stage of their manufacturing process. We have also focused on expanding our geographic reach through our direct presence in Pune, Delhi, Mumbai, Chennai and Bangalore, as well as reseller network present across India. We have doubled our team strength. Essentially, capacity, coverage and competence have been our focus areas. Since bringing about these strategic changes, we have clocked a CAGR of 50% in India. We also conduct customer meet every month in major cities, which is attended by 60-100 customers. This is a novel initiative that helps us to not only make customers aware of our complete product line, but also gives us an opportunity to listen to our customers and understand their requirements. Q. Comment on how the demands of manufactures have evolved over time. How is Hexagon meeting these requirements/expectations to ensure customer satisfaction? Sandeep: India is a diverse country, we have a wide range of customers—
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FUCHS – HIGH PERFORMANCE METALWORKING FLUIDS In manufacturing today, the demands made on cutting fluids have increased enormously. As part of the Industry 4.0 concept, the entire added-value chain of people, machines, logistics and cutting fluids should be interlinked and optimized to achieve largely self-organizing production with the help of advanced IT and communications technologies. For this, cutting fluid measurement data must be accessible online, evaluated and corresponding adjustments made. For measured data to be accurately analyzed, high stability cutting fluids are essential.
IN FOCUS right from big conglomerates to small manufacturing shops. We at Hexagon strive to meet the unique needs and requirements of all customer segments. For instance, one key customer requirement is instant technical support. To meet this, we have a portal wherein customers can log their complaints and can get speedy resolution to any issue. However, at times we noticed that some customers from the MSME segment were facing issues in operating the portal or were not able to use it due to internet downtime. To aid such customers, we now additionally offer a toll free number which they can call and get immediate technical support. We listen to our customers and understand their pain areas. We then map this with our capabilities and in case there are any gaps, we acquire technologies to address these particular pain points. For instance, we realized that managing and using the right tool for the right job is a problem faced by many companies. To address this, we acquired a German technology called Fasys. The technology is currently quite popular in Germany, with several large companies using it to manage their tools. We plan to bring it to India too next year. Last year, we also acquired a French company Spring Technologies. The company’s NCSIMUL machine simulation and optimisation software helps manufacturers create ‘digital twin’ process models that gives them complete visibility into how manufacturing will happen before going to production. Today, multi-axis machines are very commonly used and the complexity has increased manifold, this technology gives a complete idea into how manufacturing will happen and how the end product will look like. Amol: Customers are constantly looking at ways to improve their productivity, reduce cycle time, and
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ensure product quality at optimum cost. We have technologies to optimize the complete manufacturing cycle to meet this customer requirement. Our products enable simulation on the screen that gives clients full visibility into if things are happing as planned. This helps them ensure they are manufacturing the right thing first time, every time. Q. What is your USP? How do you stand out from the competition? Amol: We, at Hexagon, are a customercentric company that believes in solution selling rather than product selling. We differ from our competitors as unlike them we not only sell software, but we bring in value throughout the manufacturing value chain. We provide total solution from concept to reality using different offerings from Hexagon portfolio. Over the course of years, Hexagon has acquired companies which are required in the Hexagon Digital
Customers are constantly looking at ways to improve their productivity, reduce cycle time, and ensure product quality at optimum cost. We have technologies to optimize the complete manufacturing cycle and help customers on their journey to smart manufacturing Amol Arun Mane
Thread concept connecting the Digital & Physical Worlds so we have the capabilities to help customers on their journey to smart manufacturing. Q. Please tell us about challenges in India and how Hexagon addresses these challenges? Sandeep: Capabilities to serve the unique requirements of both small and large companies is typical to India. We, at Hexagon are committed to serving both these segments with our customized product offerings and initiatives like customer portal and toll-free number. Skills gap is also a major challenge in India as universities are still following the old curriculum and have not updated their courses as per market requirements. We, at Hexagon, are doing our bit to bridge the gap. We have training centers in Pune and Kolhapur and collaborate with universities to provide required training that make students industry-ready and increase their chances of employment. Also, we had organized skill development workshops in Maharashtra and had trained 300 + faculty members from various universities in Maharashtra. Q. What are your future business growth plans for your region – India & South East Asia? Sandeep: We have aggressive growth plans for the region and in the next three years we plan to double our capacity by adding more people and resellers in our network. If we look at India, it is a booming economy and we see immense opportunities here. Although, we have strong presence in the western region of the country, certain parts of North India and South India are still untapped for us. We also plan to launch several new products and technologies in the country. In terms of industry, apart from automotive & aerospace, we are also focusing extensively on the wood industry segment.
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Circuit Identifiers Clamp Meters
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Just like the human body, electrical equipment require a complete examination to identify any glitches. Whether the process is of installation, maintenance or repair, Extech’s testers and meters are always up for the task. To ensure smooth operation of your electrical equipment, Extech offers a wide range of test instruments that help you identify a problem before it occurs. For more details call us on: +91-11-4560 3555 or write to us at flirindia@flir.com.hk FLIR Systems India Pvt. Ltd. 1111, D Mall, Netaji Subhash Place, Pitampura, New Delhi – 110034 Fax: +91-11-4721 2006 | Webiste: www.extech.com
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Problems like unplanned shutdown, overheating of electrical appliances and connections, insulation problems and harmful gas leakages can lead to a major issues and bring an entire production to a standstill. To tackle these problems and to resolve them on time, FLIR brings a wide range of preventive maintenance solutions which help you identify problems before they arise or start to worsen. Include FLIR's state-of-the-art gadgets in your regular preventive maintenance check-up and make your business operations hassle-free.
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IN FOCUS
DOLD: Extending Horizon with technology expertise DOLD products are successfully utilized whenever people, machines or equipment must be protected from damage and whenever productivity requires enhancement. A high inhouse production depth guarantees highest quality and flexibility.
Andreas Gebert, Sales Director, Dold & Sรถhne KG
Q. What characterises Dold as a competent partner for the Indian market? Dold & Sรถhne KG is an internationally operating mediumsized family enterprise based in Germany. It develops, manufactures and sells high-quality components along with complete solutions in the area of safe automation and electrical safety for facility and machine building worldwide. It is important and of essential importance to us that our globally active customers have a local contact person. Therefore, we are represented in India with our own branch office in order to ideally serve our customers there. DOLD has successfully managed to undergo continuous development: from paving the way as a pioneer in relay technology to being the leading industry representative for functional safety, electrical safety and drive technology in Europe.
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Q. Which industries does Dold focus on in India? Our main industries for the Indian market are the railway technology, the medical technology, renewable energy, energy distribution, ships and ports and machine building. Besides standard solutions, we are always the right partner for you when it comes to individual and customized industry solutions with a certain extra. Due to our high flexibility and deep branch expertise, we are prepared to react quickly and effectively to economic changes. As a competent partner in
functional safety, electrical safety and drive technology, we offer you solutions in your industry as well. Further industries we cover: Machinery and plant, power generation/distribution, oil and gas industry, automation, transport and material handling systems, aviation/marine industry, paper and printing industry, food industry, rubber/plastics industry, heating and refrigeration, automotive, mining/metal working, chemical/ pharmaceutical applications, water/ wastewater treatment and wherever safety has high priority. We can cover your industrial applications as well! Q. Wich Products are manufactured by Dold and are particularly suitable for the Indian Market? DOLD offers solutions for automation in the field of safety switching
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IN FOCUS devices for the safe shutdown of machines and systems as well as safety switches, guard locking and key transfer for the reliable protection of safety guards. As a specialist and manufacturer of pcb relays with forcibly guided contacts and miniature relays, DOLD offers the right electromechanical relay for a wide range of applications in the field of functional safety. We also offer a wide range of electronic enclosures for switch cabinets, distribution panels and building installation enclosures as well as a DIN rail bus system.
Q. How would Dold like to position itself on the Indian market in the future? The DOLD philosophy “Our experience. Your safety� is the program: As a solution provider with over 90 years of experience and more than 400 employees, we develop and produce leading products and solutions for a wide range of target industries at our headquarter in Germany. Right now, we are expanding our market activities in India and establishing a service and support office to provide perfect support to Indian customers.
Thread Milling Cutters The thread milling cutter GSF with its optimised cutting geometry enables a universal use in different materials. Its geometry with countersinking step results in highest efficiency by machining the chamfer and the thread in one working process.
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THE WORLD’S #1 CAM SOFTWARE COMPANY World leaders in CAD CAM software with a proven track record of reliable product delivery, Hexagon Manufactuing Intelligecne provide solutions for the tooling, production engineering, and sheet metal industries with unparalleled ease of use and sophisticated toolpath generation.
HexagonMI.com
CONTACT INFORMATION
Hexagon Manufacturing Intelligence c/o Vero India Software Pvt Ltd 201, Second Floor, “RED” Building, Near Yes Bank, Plot No.2 Galaxy Society, Boat Club Road Pune -411 001 Maharashtra India
CIN - U72200PN2003PTC018378 Tel. +91-8793093946 Web. www.HexagonMI.com
EDGECAM
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VISI
EDGECAM is a market leading production CAM solution, combining the power of sophisticated toolpath generation with seamless CAD integration.
WORKNC is the leading high-end CAM software solution for complex models in the mould, die and tooling industries for 2 to 5-axis CNC programming.
VISI is a CAD/CAM solution for the mould & die industries offering 3D tool design, plastic flow analysis, sheet metal stamping and comprehensive multi-axis milling strategies.
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WORKPLAN
WORKXPLORE
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WORKPLAN is a fully-scalable family of manufacturing software solutions, from project management to ERP, which enables companies to automate and manage their business processes.
WORKXPLORE is a high-speed CAD file viewer and analyser, providing a powerful combination of feature rich capabilities, import functionality, and incredible speed.
RADAN is the world’s leading CAD/CAM solution for the Sheet Metal cutting industry, providing applications for Punching, Profiling, Bending, Design and Production Management.
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ALPHACAM is the CAM software of choice for the woodworking and stone cutting industries. The software portfolio provides customers with proven technology to increase productivity.
A complete engineering solution for the casegood industry. From entry level cutlist packages to fully integrated solutions, CABINET VISION can truly grow with your business.
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TECHNICAL SUPPORT HELPLINE NUMBER 1800 - 233 - 8881
IN FOCUS
Our focus is on providing the customer with the lowest life cycle cost: Dr. Jairam Varadaraj In our estimate, the global oil-free market is between $ 3-4 Billion. We expect it to grow well considering the health of the food and pharma verticals which are large consumers of oil-free compressors. We have disrupted the traditional norm that oil-free compressors are less efficient and more expensive to buy and maintain. Our AB (Always Better) Series of oil free compressors are significantly more efficient than conventional oil free compressors and substantially more attractive financially to buy and maintain, says Dr. Jairam Varadaraj, Managing Director, ELGi Equipments Ltd. in an interview with P.K. Balasubbramaniian. Excerpts:
Dr. Jairam Varadaraj, Managing Director, ELGi Equipments Limited
Q. What’s ELGi’s standing in compressed air technology today? Any technology has two dimensions – know-how and know-why. Know-how is the ability to put together a product based on a set of drawings without understanding why they are so. Know-why is the deep understanding of the science behind the engineering. Very few companies possess knowwhy in the compressor business and ELGi is one of them. Q. How significant was your participation in Hannover Messe, held recently? And what are the technological innovations you could showcase there? Oil free compressors are used in specialized applications and traditionally these compressors have been significantly less efficient than oil lubricated compressors and substantially more expensive to buy and maintain than oil lubricated compressors. What we have
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launched – Oil Free. Disrupted – is exactly this. We have disrupted the traditional norm that oil free compressors are less efficient and more expensive to buy and maintain. Our AB (Always Better) Series of oil free compressors are significantly more efficient than conventional oil free compressors (almost close to oil lubricated compressors) and substantially more attractive financially to buy and maintain. We will continue to push the envelope on the AB Series so that we eventually merge the current distinction between oil lubricated and oil free compressors. Even as we do this, we continue to expand the boundaries of efficiencies across all of our compressors and we expect to be the best in class in energy efficiency very soon. Q. How do you help the customer optimize the life cycle cost of his compressor? Besides innovating new products that are superior in energy efficiency, we engage with customers through structured air audit programs that enable us to study the customer’s application pattern and recommend solutions that can significantly save energy. Q. How big is the global oil-free market and how do you expect it to grow? In our estimate, the global oil-free market is between $ 3-4 Billion. We expect it to grow well considering the health of the food and pharma
verticals which are large consumers of oil-free compressors. Q. What are your strategies to enhance your market share globally? Within Europe, we have identified sub-regions that we want to focus on. This is again using the principle of being focused in our approach. Till date in Europe, the focus has been primarily Italy and to a lesser extent France. We are now expanding this focus. Q. What are the investments you envisage to increase your footprints in Europe and elsewhere so as to achieve your global aspirations? Our major investment, if any, would be in the form of acquisition of distributors in Europe. This is not something we control fully as it takes two organizations to agree to come together. Besides this, our focus would be building the talent required to execute our strategy. Q. Your oil-free compressors are said to be a hit in the European market. What’s the differentiated offer you could make to meet the specific needs of the market? The focus is on providing the customer with the lowest life cycle cost. And towards this, it is about energy efficiency and lower cost of owning and maintaining the compressors. Q. Which are the industry verticals you target in Europe? No specific industry verticals.
www.mtwmag.com
WHAT DO YOU NEED TO MEASURE?
WHAT DO YOU NEED TO MEASURE? Delivering world-class test & measurement tools with the accuracy, reliability, and versatility you need to tackle your most challenging jobs FLIR C2 and FLIR C3 Full-Featured, Pocket-Sized Thermal Cameras
FLIR TG167 Spot Thermal Camera
The FLIR C2 and C3 is full-featured, pocket-sized thermal camera designed for electrical/building industry experts and contractors. Keep it on you so you’re ready anytime to find hidden heat patterns that signal energy waste, structural defects, plumbing and overheating issues and more.
The FLIR TG167 Spot Thermal Cameras bridge the gap between single spot infrared thermometers and FLIR’s legendary thermal cameras. Equipped with FLIR’s exclusive Lepton® micro thermal sensor, these cameras let you see the heat so you know exactly where to target the measurement spot. Easily find unseen hot and cold spots for instant troubleshooting, and store images and data to show customers and include in reports.
Key Features: • Thermal Measurements from -10°C to 150°C • Bright 3” touch screen • Fully Radiometric - save thermal image JPEGs instantly • MSX® real time image enhancement • Wi-Fi (C3 only) • Picture-in-Picture (C3 only) • Area measurement box indicates hottest or coldest (max./min.) spot (C3 only) • 2-10 year warranty after product registration
Key Features: • Rugged & reliable – withstands a 2-meter drop • Dual laser pointers to frame area of interest • Object Temp Range -25°C to 380°C • IR resolution upto 60x80 pixels • Distance-to-spot ratio 24:1 • Fits every budget • 2-10 year warranty after product registration
FLIR Ex-Series Infrared Cameras with MSX®
FLIR Exx-Series Advanced Thermal Imaging Cameras
FLIR E4, E5-XT, E6-XT, and E8-XT are powerful, cost-effective, easyto-use troubleshooting tools for building, electrical, and mechanical applications. With four resolution options—up to 320 × 240 infrared pixels—and the ability to accurately measure temperatures from -20°C to 550°C/-4°F to 1022°F (E6-XT and E8-XT), the Ex-Series has models to fit your target size, working distance, visual detail needs, and budget.
FLIR designed the Exx-Series to offer the best performance, resolution, and sensitivity of any pistol-grip handheld thermal camera. The E75, E85, E95, and now the new E53 thermal imaging cameras are packed with the features you need to find hot spots, detect the early signs of building deficiencies, troubleshoot electrical and mechanical systems, and prevent problems before they cause serious damage.
Key Features: • IR resolution upto 320x240 pixels • Object Temp Range -20°C to 550°C • Display: 3” color LCD • Easy-to-use, weighs only 0.575kg • ±2% Accuracy • Fully automatic and focus-free • Simultaneous storage of IR/Visual/MSX images • Withstands a 2-meter drop test & IP54 Enclosure provides a high level of protection against dust and water • 2-10 year warranty after product registration
Key Features: • IR resolution upto 464x348 pixels • ±2% Accuracy • Object Temp Range -20°C to1500°C • Produce brilliant imagery at 4x the thermal pixel resolution with UltraMax® processing • Multiple measurements • MeterLink®, MSX® • Save time and money with interchangeable, autocalibrating lenses you can share between cameras • 2-10 year warranty after product registration
www.flir.in Equipment described herein may require US Government authorization for export purposes. Diversion contrary to US law is prohibited. Imagery used for illustration purposes only. Specifications are subject to change without notice.
WHAT DO YOU NEED TO MEASURE?
FLIR TG54/TG56 Spot IR Thermometers Easily take measurements in hard-to-reach spots from farther away
FLIR CM82/CM83/CM85 Industrial True RMS Power Clamps FLIR offers an excellent choice of industrial-grade Power Clamp Meters engineered with advanced power analysis and variable frequency drive filtering functions required by electrical troubleshooters.
The TG54 and TG56 Spot IR (Infrared) Thermometers provide a distanceto-spot ratio of up to 30:1, the TG54 and TG56 can measure smaller targets from a safer distance. The TG54 and TG56 are your go-to, pocket-sized devices for efficient temperature measurement.
Key Features: • VFD Mode • Harmonics mode • Inrush current • Phase Rotation • True RMS DMM functionality • METERLiNK Compatibility • Powerful LED lamps • Power factor and active power
Key Features: • Non-contact surface temperature measurements • Laser pointer to identify hot or cold • Easy emissivity selection with predetermined levels • Stunning visual high and low alarms • Rugged, industrial design that can withstand a 3m drop • Bright LED worklight • Tool-less battery compartment
• Rugged and shock-resistant Model CM82 • 600 A True RMS AC/DC Current Measurement Model CM83 and CM85 • True RMS AC/DC Current Measurement (CM83: 600 A) (CM85: 1000 A) • Bluetooth connection to FLIR Tools® Mobile for remote viewing and sharing
FLIR CM275 IGM™ Clamp Meter With Datalogging
FLIR CM72/CM74 Commercial Clamp Meters
The FLIR CM275 clamp meter combines thermal imaging with electrical measurement into powerful inspection, troubleshooting, and diagnostic tools. Through Infrared Guided Measurement (IGM), the CM275 provides a reliable way to identify hot spots and overloaded circuits from a safe distance. Confirm your findings with the clamp meter’s wide range of functions plus temperature readings.
The FLIR CM72 600A AC Clamp Meter and the CM74 600A AC/DC Clamp Meter give you better access to wiring in hard-to-reach places, and provide all the measurement capabilities you need for advanced troubleshooting. Advanced electrical features include Autoranging, True RMS Voltage and Current, LoZ, Inrush (CM74 only), VFD Mode (CM74 only).
Key Features: • Safely check for live connections using non-contact temperature measurement • Use advanced electrical features including Variable Frequency Drive (VFD) mode, True RMS, and Low Impedance (LoZ) mode • Pinpoint exact hot spot locations with laser or crosshairs • Store electrical measurements and thermal images internally, for later review • Rely on the protection of CAT IV-600V, CAT III-1000V safety ratings
Key Features: • Portable and slim, with a narrow jaw for easy access to crowded panels • High-powered LED worklights guide you to your target in low light • Advanced measurement features including True RMS, LoZ, smart diode with Disable, and MIN/MAX/HOLD • Rubberized, double-molded hand grips and bright, backlit LCD display • Premium gold-tipped silicone test lead included • Expandable to 3000 A AC with TA72 and TA74 Flex Clamp accessories (sold separately)
www.flir.in Equipment described herein may require US Government authorization for export purposes. Diversion contrary to US law is prohibited. Imagery used for illustration purposes only. Specifications are subject to change without notice.
WHAT DO YOU NEED TO MEASURE? FLIR TA72/TA74 Flexible Clamp Adaptors
FLIR CM55/CM57 Flexible Clamp Meters
Designed to add capabilities and simplify challenges, the FLIR TA72 and TA74 Universal Flex Current Probes let you easily take measurements in tight or awkward spots — a difficult task with a traditional hard jaw clamp meter. The connection is a standard banana plug and the output is a voltage signal, so it’s compatible with most DMMs and clamp meters, regardless of brand.
FLIR CM55 and CM57 flexible clamp meters are ergonomic tools designed to simplify your workday. The narrow, flexible coil clamp allows you to measure currents in tight or awkward spots. The clamps are Bluetooth-enabled for direct connection with the FLIR Tools® app on iOS and Android devices, so you can transfer data, then analyze and share it — right from the job-site.
Key Features: • Adds 3000A AC current measurements to existing meters • Convenient 10” or 18” flexible clamp with locking mechanism • AC voltage probe output for universal compatibility • Banana plug connections fit most meters • Switchable AC current range: 30A, 300A, 3000A • Bright LED work lights for easy inspection • Limited lifetime warranty with registration
Key Features: • 3000A AC True RMS current measurements • Convenient 10” or 18” flexible clamp with locking mechanism • Inrush current for equipment start up spikes • Bluetooth to mobile devices for remote viewing • Data recording for trend analysis transferable via Bluetooth® • Bright LED work lights for easy inspection and navigation • Limited Lifetime Warranty with Registration
FLIR VP52 Non-Contact Voltage (NCV) Detector + Flashlight
FLIR DM285 Industrial Thermal Imaging Multimeter with Datalogging and IGM™
The FLIR VP52 is a tough, CAT IV-rated Non-Contact Voltage Detector featuring a combination of alerts - tactile vibration and red LED alarms, a powerful LED flashlight, and versatile voltage sensitivities. We engineered the FLIR VP52 to reliably detect voltages on the latest tamperproof outlets and electrical systems installed using modern construction methods. Key Features: • Enhanced Detection • Powerful Worklights • Tactile Alarms • High/Low Sensitivity • Intelligent Design • Rugged & Durable
Dual Voltage Range
The FLIR DM285 is an industrial, True RMS digital multimeter with Infrared Guided Measurement (IGM) to guide you directly to hot spots and temperature anomalies. The built-in 160 × 120 thermal imager will help you pinpoint issues faster, so you can get to repairs safely and efficiently. The DM285 features on-board data storage and Bluetooth® connection to the FLIR Tools® Mobile app, for data sharing and reporting. Key Features: • 19,200 pixel thermal camera visually guides you to an electrical problem • Includes high-quality test probes and a Type-K thermocouple • Performs 18 measurement functions including LoZ and non-contact voltage (NCV) detection • Saves electrical parameter data and thermal images with onboard data storage • Drop-tested and IP rated for greater durability • Fast and easy battery swaps with the ‘no tool’ battery compartment
www.flir.in Equipment described herein may require US Government authorization for export purposes. Diversion contrary to US law is prohibited. Imagery used for illustration purposes only. Specifications are subject to change without notice.
WHAT DO YOU NEED TO MEASURE? FLIR DM93/DM92 True RMS Industrial Multimeters
FLIR IM75 Insulation & DMM Combo with METERLiNK
The FLIR DM92 and DM93 digital multimeters offer variable frequency drive filtering to help you accurately analyze non-traditional sine waves and noisy signals. The DM93 also offers Bluetooth connectivity, so you can upload and share data through the FLIR Tools mobile app. No matter the electrical challenge, the DM92/DM93 have the features and flexibility to make the job simple.
The FLIR IM75 is an all-in-one multi-function digital multimeter and insulation tester for installation, troubleshooting, and maintenance professionals. It features a handheld insulation tester and multiple resistance ranges for insulation test levels, as well as METERLiNK compatibility and Bluetooth
Key Features: • VFD Mode • LoZ Mode • Bright Dual-LED Worklights • Rugged, Shock-Resistant • No need to select AC or DC Mode for quick tests • Backlight features user-configurable timeout • Large, sharp display is easy to see • Tool-less battery changing • Built-in tilt stand
Key Features: • Advanced Insulation Modes • Multiple resistance insulation test level ranges • LED indicator with Compare Mode • Remote viewing of real time readings on Android™ and iOSTM smartphones and tablets with METERLiNK connectivity and free FLIR Tools Mobile app • Transmit readings to METERLiNK™enabled FLIR thermal imaging cameras to document and analyze thermal changes during insulation measurements • Extremely bright LED worklights in a flood pattern to illuminate test areas and targets • Durable double-molded construction (IP54, 2m Drop Test)
DM93 Additional Features: • Bluetooth Connectivity • METERLiNK® Compatibility • Continuous Data Recording • Data Record captures electrical measurements and provides wireless data transfer
FLIR MR176 Imaging Moisture Meters with IGM™
FLIR MR59 Ball Probe Moisture Meter with Bluetooth®
MR176 visually guides you to the precise spot that moisture may be hiding for further testing and investigation. Use the integrated laser and crosshair to help pinpoint the surface location of the issue found with IGM.
The FLIR MR59 is a pinless meter with wireless connectivity, which offers the convenience to view live readings from a mobile device via the FLIR Tools® Mobile app. Thanks to the ball-shaped sensor, users can cover a large area in a short time without making a mark; measure into corners and around baseboards easily; and detect problems below the surface.
Key Features: • IGM powered by a 80X60 pixels Lepton thermal imager • Customizable thermal images: (moisture, temperature, relative humidity, dew point, vapor pressure, mixing ratio) • Choose from one of four color palettes (Iron, Rainbow, Ice, Greyscale). • A lock-image setting prevents extreme hot and cold temperatures from interfering with images while scanning for issues • Field-replaceable temperature/relative humidity sensor • Integrated pinless moisture measurements for fast detection • Rugged, portable design with intuitive menu system • Document readings and images to share via USB cable
Key Features: • Run the meter over and around objects on the measuring surface with the ball-probe sensor • Identify potential moisture problems up to 100 mm (4 in) below the surface • Wirelessly connect the meter to FLIR Tools Mobile to view readings on a mobile device • Detect moisture in a wide range of common building materials • Receive stable, repeatable readings • Clear, easy-to-read display • Work in dim conditions with the backlit display and bright worklight • Use with the MR04 extension pole to reduce the need for a ladder, or to optimize ergonomics for ‘high’ and ‘low’ measuring targets (accessory not included) www.flir.in
FLIR Systems India Pvt Ltd. 1111, D-Mall, Netaji Subhash Place, Pitampura, New Delhi – 110034 | Tel: +91-11-45603555 | Fax: +91-11-47212006 | E-mail: flirindia@flir.com.hk
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Manufacturing Issues Electrical Distribution
Problems • Electrical surges from utility/supplier • Panel board fires • Skyrocketing electrical costs Solutions • Identify specific power quality problems • Monitor electrical loads and temperature • Benchmark energy usage trends Extech Problem-Solvers • Power quality analyzers • Electrical testers, meters and kits • Infrared thermometers
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Extech Tools Get the Job Done Extech meters and testers help you ensure uptime, maximize productivity and verify compliance. Whether used as a component of an effective predictive maintenance program or as a key tool for a rapid response repair team, Extech Instruments are the meters of choice for manufacturing facilities crews who need to solve problems and reduce costs.
Clamp Meters
Digital MultiMeters
Thermometers
Power Analyzers
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• Circuit loads up to 3,000 A • Voltage, resistance, capacitance, contact and non-contact temperature measurements
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• Maintaining motor controls • Electrical panel lacindiagnostics ahceM & RCAVH • Troubleshooting pumps, drives
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Tachometers
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Applications in Manufacturing
Used for
Used for
• Contact or non-contact temperature measurements • Differential temperature calculations • Monitoring moving components
• Diagnosing power quality issues • Monitoring electrical demand trends • Identifying equipment inefficiency
Applications in Manufacturing
• HVAC sub-cooling, superheat • Overheating detection
Applications in Manufacturing
Electrical Testers
Inspection Tools
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Environmental Meters
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Used for
Used for
Used for
Used for
• Measuring motor conveyor and belt speed • Reducing premature wear
• Monitoring humidity, temperature, and airflow • Measuring light, noise levels • Monitoring CO and CO2 levels
• Tracing outlets to breakers • Testing continuity in circuits • Identifying rotary field indication
• Electrical equipment diagnostics • HVAC diagnostics • Building envelope inefficiency
Applications in Manufacturing
• Check 3-phase sequence and motor rotation • Wiring installation and troubleshooting • Insulation resistance testing
Applications in Manufacturing
• Motor conveyor and belt speeds • Pump efficiency
• Identifying mold and static • Troubleshooting HVAC IAQ • Optimizing light/sound in work areas
Applications in Manufacturing
Applications in Manufacturing
• Electrical panels and motors Steam traps/valves • Overheating equipment • Hard-to-reach visual inspections
INDIA FLIR Systems India Pvt Ltd. 1111, D-Mall, Netaji Subhash Place, Pitampura, New Delhi – 110034 Tel: +91-11-45603555 | Fax: +91-11-47212006 | E-mail: flirindia@flir.com.hk Copyright© 2010 Extech Instruments Corporation. All rights reserved including the right of reproduction in whole or in part in any form. Specifications are subject to change without notice. For the most up-to-date specs, visit our website www.extech.com . All other brand and product names are trademarks of FLIR Systems, Incorporated. Images used for illustration purposes only. (Listed APAC – IND 04/19)
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IN FOCUS
Indian companies must adopt to process automation, additive manufacturing, Industry 4.0 Q. Highlight the current landscape and growth prospects of machine tools industry in India The machine tool industry is set to grow to more than 120 billion dollars by 2020 and with the elections behind us, and the same government coming to power, there would be no major disruptions in the policies, which would further boost confidence in the machine tools market. Machine tools being the back bone of any manufacturing activity and with high growth projection for near future there is an immense opportunity for development of the same. Indian companies must adopt to process automation, additive manufacturing, Industry 4.0 and other emerging techniques to hop on to this growth bandwagon. This emerging technology would be necessary to cater to huge demand that is going to come from auto components manufacturing, electronics engineering goods, dies and moulds in both domestic as well as international markets. Companies failing to adopt to the same are at risk of being left out. With the world perspective, India has the right mix of everything needed with huge pool of man force, skilled engineers available at a very reasonable cost and companies willing to adopt new techniques of manufacturing etc and with added advantage of huge domestic demand, it’s poised to take a big chunk of the manufacturing market across globe. That said, there are also challenges faced by the industries too, huge capital investment are needed for upgrading of technology, for training of man force , retraining of the man force, improving productivity and changing the mind-set of the work force to work
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like Industry 4.0. Although implementation of such things not only requires to change our mind-set, but also puts a pressure on all the resources of the company in the short term. But with committed management, Dahanukar Machine Tools Team is positive to emerge as a recognised player in its field of operation.
Santosh Dahanukar, CEO Dahanuakar Machine Tools
with new emerging concepts. Even there is reluctance on the part of the financial institution for lending to the machine tools industry is hurting the growth. Q. How are your products/services geared up to be in line with recent trends, such as Industry 4.0 and Smart Manufacturing? The current manufacturing is going through a tremendous change, with focus now being to produce accurate components, very fast, with higher repeatability, increasing productivity and keeping a bird’s eye view for safety for workers, operators, customers and all concerned. That’s industry 4.0. At Dahanukar Machine Tools, we are working on two verticals. Firstly we are adopting smart manufacturing technologies to streamline our manufacturing process to global bench marks and at the same time making a safe environment for our work force and secondly we are making our products compatible to global safety standards for our customers. With right blend of IOT and smart manufacturing our products are getting ready to be compatible with emerging technique
Q. What is your vision for your company (in terms of new product launch, innovation/collaborations)? How do you see your brand growing by 2020? We are currently looking at our entire product portfolio and analysing the same with regards to the demand in the market. Many products that have lost the relevance in the market would be discontinued, but at the same time many new products would be launched keeping pace with the requirement in the market. Being surface grinding machine manufactures we are developing many new machines with different concepts which are not available in the market. This would not only create NICHE for us but also would make us ready to secure our customer base and improve the same. We are also actively looking for collaborating with foreign counterparts for manufacturing, reselling such grinders in India in which we are not present. By 2020 we want to increase the quality of our product portfolio with right blend of niche products, automation and collaboration in the space of surface grinders.
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PORTFOLIO
ELESA+GANTER®: Two companies one world of standard parts
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LESA (Italy) + GANTER (Germany) is a worldwide sales joint-venture set-up to offer the widest product range of standard machine elements. 60,000 product codes distributed in more than 70 industrialized countries with local presence and the highest technical consultancy. Our extensive product range proofs the typical cultural background of both the mother companies: high material quality combined with the best original design and accuracy in production. The strong customer orientation of the parent companies led to the foundation of its subsidiaries in many countries including India.
Mr. Ram Grover, Managing Director, Elesa and Ganter India
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Elesa+Ganter India: Established in 2010, Our India Headquarters
JUNE 2019
USP: Optimized and widest range of standard machine elements with fastest delivery times.
at Noida (U.P.) is powered with a dedicated team of qualified sales engineers and technical managers along with our pan India network of authorized channel partners. With maximum stock availability and faster delivery times alongside a robust team of technical engineers have ensured customer satisfaction par with the best in industry. Product Range Elesa+Ganter offers wide range of Operating elements, Machine elements, Indexing Elements • Clamping knobs, Clamping Levers, levelling elements, Joints, Hinges • U-handles, Fixed, revolving, fold-
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An ISO 9001:2015
Visit us at :
14th to 17th June 2019 Pragati Maidan, New Delhi, India
Hall: 12A, Stall No.: 1
An ISO 9001:2015
PORTFOLIO
away handles • Control elements, Rotary controls, Latches, Hook, toggle and power clamps • Accessories for hydraulic systems, • Tube clamp connectors, Castors and Wheels, Retaining magnets etc. Manufacturing Facilities With automatic production units in (Monza) Italy and (Furtwangen) Germany, Elesa+Ganter extensive product range of standard parts and machine elements is a testimony of European manufacturing prowess. High performing items Our high performing items are marked with their own icons, allowing standard parts to be selected specifically in terms of certain requirements: AE-V0 range, ATEX range, Clean Range, Ergostyle Range, INOX range, ESD Line, SAN Line, Soft line, Profile Compatible items.
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the development of new and innovative solutions. Our Research and development departments are constantly working on new products and range extensions to always guarantee to customers a wide range of components capable of high performances. Application based Customized Solutions
New products
Elesa+Ganter has a solution for virtually every application. In the unlikely case that you can’t find what you need in our extensive range of products, we can also offer you a customised, made-to-measure solution with Special shapes, colours, surface treatments, product branding etc.
We are constantly engaged in
DESIGN AWARDS Elesa+Ganter range products contribute to improve the quality of the machines and equipment they are destined for. Constant research on ergonomics, production materials, functionality results and a unique design as proven by 52 industrial design awards by the most prestigious international juries.
MACHINE TOOLS WORLD
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Product Applications Our products are widely used in all the industrial sectors like Catering & food Industry Machines, Printing & Packaging Machines, Construction & Material Handling Equipment, Medical, Chemical and pharmaceutical industries, Textile Machinery etc. and many more. Every product of ours is like a living testimony to our tag line “Designed for Engineering”.
For more information, Website : www.elesa-ganter.in
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PORTFOLIO
maxon motor: High-Precision Micro Drives Powering Innovation From earth’s core to outer space to medical, maxon motors drive systems are the product of choice to move anything that has to be rotated with high precision and reliability. Established in 1961 in Switzerland, the group has come a long way and today has production sites in 8 countries and a distributor network across 40 countries. Over the years, the group has established itself as prominent solution provider, with the capability to serve unique needs of various customers. Currently, the group is expanding its network and is focusing extensively on tapping India market through its subsidiary, maxon motor India Pvt. Ltd. Shweta Nanda of Machine Tools World takes a look at the group’s journey, interesting applications of its drive systems and the future growth vision
Atul Bhardwaj, Director, maxon motor India Pvt. Ltd.
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ith more than 50 years of experience to its credit, maxon motor is a known and reliable provider of drive technology throughout the world. A family owned company, which started operations in 1961 in Switzerland, maxon motor today has increased its manufacturing footprint outside Switzerland in Germany, Hungary, France, US & Korea. When we look closer to home, the company’s products have been present in India for around two decades through distributors. In 2010, its Indian subsidiary was established to better understand customer expectations and provide the required technology. “Indian subsidiary operation was started keeping in view of our esteemed customers so that we
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understand their needs and support them in execution. Our customers have helped us grow year by year, which has enabled us to support them better,” says Atul Bhardwaj, Director, maxon motor India Pvt. Ltd. The company’s journey in India has been interesting, with lot of learnings and takeaway considering Indian environment matching with maxon Swiss technology. “There were some initial challenges when we were setting up our operation and team. We had to set up maxon Indian operations going through the Indian bureaucracy. As we grew, the digitalization of various tax authorities has helped us to be lean and at the same time effective. Another key challenge was to maintain consistent growth as project orders create spikes,” shares Bhardwaj. Over the years, maxon motor has acquired companies like Zub, Parvalux, mdp & Kwapil which complements maxon offerings to adopt a solution-centric approach. “Today, we not only provide products, subsystem but also system solution. We now have Parvalux as maxon company, which offers economy of scales along with maxon Korea to suit Indian customers who always look value for money. On the other hand, demanding requirements need maxon coreless motors and drive solutions. Going forward, we see they complement each other and
offer ample opportunities for maxon to grow in India. From highly demanding aerospace industry to industrial automation, you will find maxon in all the industrial sectors to augment growth,” elaborates Bhardwaj. Focus on R&D One thing that has been at the core of maxon’s success is the company’s firm focus on R&D. maxon has R&D departments both at the headquarters in Sachseln (Switzerland) and at the subsidiary in Sexau (Germany). In addition to continuous product development, these departments are responsible for ongoing improvement of manufacturing processes, production and testing systems. “At maxon, R&D is the basis for future viability. We have been investing in R&D around 8-10% annually on almost consistent basis where more than 200 employees work. We come up with new products and features on a consistent basis and all this is possible because of R&D,” asserts Bhardwaj. Today, the company’s product offerings include DC motors (cored & coreless), AC motors, planetary, helical & worm gearboxes, drives, sensors & customized system solutions. The R&D activities of maxon are directed toward the requirements of the market and the customers. When the combination of standard products
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INFO: VDW – Generalkommissariat EMO Hannover 2019 Verein Deutscher Werkzeugmaschinenfabriken e.V. Corneliusstraße 4 · 60325 Frankfurt am Main · GERMANY Tel.: +49 69 756081-0 · Fax: +49 69 756081-74 emo@vdw.de · www.emo-hannover.de 19038_MTW_India_190x120_in.indd 1
Information, Tickets, Invitation letter & Travel Packages: Hannover Milano Fairs India Pvt. Ltd. 16th Floor, Maker Tower E Cuffe Parade Mumbai 400005 Tel.: +91 22 6267 2119, +91 22 6267 2132 Fax: +91 22 6267 2121 E-Mail: info@hmf-india.com
14.03.19 15:57
PORTFOLIO do not suffice, the company focuses on developing custom designs, which can either be product modifications or new developments. “We also collaborate with higher educational institutes and universities around the world to ensure that our drive systems meet the demands of new technology,” shares Bhardwaj. Driving Innovation across Industries Given the sophisticated and advanced technology, the company’s drive systems are used in several industries across manifold applications, including medical, aerospace, industrial automation and instrumentation. “Our micromotors move anything that has to be rotated with high precision and reliability from the earth’s core to outer space. Under, on, and above ground,” asserts Bhardwaj. One of the interesting case studies is maxon drives being used to drive several Mars rovers. The DC motors withstand the harsh conditions—they resist brutal temperature changes, dust, dirt, and storms. “This is achieved with state-of-theart technology, uncounted lab tests, and specific modifications. maxon engineers transfer their knowledge from
custom projects to other aerospace projects such as actuators in passenger planes or stabilizers in unmanned aircraft,” states Bhardwaj. Apart from space, maxon drive systems are also being used in medical technology. Applications in medical technology place high demands on drive components and maxon drive systems are customized for each application from inside the body or in the operating room to improve patient’s quality of life. “maxon medical finds a matching drive and controller for each application, or will work with customers to develop a tailored solution. Applications include insulin pumps, surgical robots, precision hand-held tools, prostheses, and many others,” informs Bhardwaj. The company’s drives are also used in meteorological instruments and climate control devices, precision scales, and laser measurement devices. Some applications go kilometers underground. In deep drilling, the company’s robust drives are in high demand. They work reliably even while exposed to strong vibration at temperatures up to 200 °C. Further, maxon has also emerged as the partner of choice when it comes
A world of drive technology – Powerful DC brushed and brushless motors, gearheads, control electronics and much more.
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to drives for Exoskeleton, humanoid robots, hand-held tools, multi-axis robot controllers, packaging machines or welding systems. “Robots are driving the world, and we are driving the robots. Complex mechatronic systems work only if every single component is very high quality,” avers Bhardwaj. In India, the company has been involved in automation for high-end medical applications, aerospace, industrial automation, instrumentation, etc. Some of its key customers include prominent organizations and companies, such as ISRO, DRDO, L&T, Tata, Bosch, Phillips, GE, to name a few . The Road Ahead While maxon in the past has been playing in niche areas, in recent years it has started focusing more on Asian markets. The company is eyeing huge opportunities in China, India, Taiwan, Korea and other Asian countries for incremental growth. Specifically in India, maxon group is investing & will continue to invest to expand operations. “Asia will witness highest growth in the world in next decade. With the stable government, India expects GDP to grow by around 8%+, with the thrust in manufacturing. We are in India at the right time to leverage Swiss technology and ecosystem to have synergy for growth. We want maxon to be the preferred choice of customers in India when they look for DC/AC motors, drives and system solutions. maxon is synonyms for quality, reliability technology and good after-sales support and in future we are looking at further strengthening the situation,” asserts Bhardwaj. Given maxon’s extensive experience, huge product portfolio and growth plans for India, the company’s outlook looks extremely positive and maxon is all set to scale greater heights in the country.
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PORTFOLIO
Shavo’s tailor-made technology solutions
Mr. Rushil Shah, Managing Director, Shavo Technologies Pvt. Ltd.
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rom static elimination solutions to precision air moving products to instrumentation fittings and high purity gas delivery systems, Shavo is dealing in a wide spectrum of products and technologies. “Our endeavour has always been to work in niche high technology areas across industries where we can offer significant value for a variety of problems. Our products and their applications find solutions in a diverse range of industries such as Semiconductor, Aerospace and Defense, Converting, Automotive, Chemical and many more,” says Rushil Shah, Managing Director. The company’s core selling concept is its deep application knowledge and command over the technologies it sells.
Applied gas delivery systems
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Shavo Technologies Pvt. Ltd., a part of the Shavo Group with a standing and reputation spanning over five decades, is in the frontiers of niche high technologies cutting across diverse disciplines. The company 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 product portfolio, the company serves over a thousand customers from diverse key sectors including semiconductor, aerospace, defence, chemical, oil & gas, automobile and so on. The company has gone from selling component to systems and solutions and turnkey capability in an effort to keep offering better value by leveraging the technologies it provides. Cutting edge technologies All Shavo’s Principals have specific technologies that would be classified ‘cutting edge’ considering that almost all its principals are world leaders in their fields. For Static Elimination, it has integrated power supply ionising bars with full feedback control for Gas Delivery. Shavo has some of the most sophisticated fully automated systems capable of dealing with the most dangerous gases. It offers from HORIBA a multi gas, multi range Mass Flow controller - a first in the industry.
Static measurement for effective static neutralization
The company’s journey of working with High Technology Industries has started with Gast which today remains one of the world leaders in Air Motors and Fractional horsepower. Over the years, it has released many new pumps that have extended typical service life to new frontiers especially with the new rocking piston technology pioneered by Gast. Its latest 87 R series offers industry leading pressure performance at lowest noise levels. Corrosive gases are used in a wide range of industries from Chemical, Tooling and the new areas of Nanotechnology, Photovoltaics, etc. Handling corrosive gases requires deep application knowledge, understanding of the materials to be used especially soft goods. Many corrosive gases are
High quality instrumentation valves
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PORTFOLIO
Rocking piston compressor
also liquefied which need special considerations, from heating to weight measurement, etc. The awareness on the causes and cures for static electricity are low in industry but steadily growing. A lot of problems of contamination, material misbehavior, etc., are often attributed to other causes when they really are static related issues. Shavo continues to publish articles and bring awareness to the industry by working with a number of industrial associations. The valves and regulators it supplies to the Chemical Industry in general have a wide range of certifications. For valves, it has course type approvals from various third parties like Llyod’s, TUV, DNV, etc. and the products meet all industrial standards wherever required such as ASTM F-1387, for Oil &Gas , ECR 110 for Automotive NACE, for Sour Service and many more. Tescom vaporizing regulators, in addition to having ATEX Approval, is the first such unit to have PESO / CCOE Approval from Nagpur. Generally of course ‘Energy Absorption’ has applications wherever we need to decelerate motion, in the Industrial space. Factory Automation especially with Pneumatics is the key application, but Shavo also finds safety applications such as end stops for large cranes like those found in steel and ports as an important area. Lately the company’s focus has been vibration isolation with special attention to strategic electronics in the
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Shock absorption products
Defense Sector which has some of the most stringent requirements for G force transmissibility. The company’s Fluid Control products once again find applications in a very diverse range of industries, but the main end-users are Oil & Gas, Chemical, Analytical and general manufacturing. The growth areas in the Fluid Control Industry lie in Semiconductor manufacturing and Photovoltaics which demand ultra high purity gas delivery systems. Equipment to service these industries is typically made to the exacting specifications of the SEMI code which controls all processes from raw material to manufacturing, testing and even packaging. The surface finish and cleanliness requirements for these industries are extremely demanding often requiring products to be assembled in Class 100 environments. The company’s supplies to the Automotive Industry almost cover the entire range of its product lines e.g. all engine testing for the new EURO IV and Euro VI norms use Shavo’s Tescom Central Gas Supply Systems for calibration of gases. It supplies Gast Air Motors almost extensively to all automotive paint kitchens. You will also find Enidine shock absorbers at the end of travel on many assembly lines. The Meech Jet Stream Ionizing Systems, on the other hand, clean & neutralize car bodies and plastic parts prior to painting. Other Fluid Control
High pressure regulators
products find extensive applications in the CNG space and the automotive testing area such as car air bag testing for instance. Shavo is currently working with some of India’s Top Companies such as Reliance, Tata’s, Biocon, GE, Department of Space, Ministry of Defense and many more. The company has over 1000 live accounts as of today. Eminent service set-up Shavo’s service set-up / service team has been growing from strength to strength. It has full service capability at the Pune office and is in the process of building a world class center in its Bangalore Factory. “Our service support is a key pillar of the value we provide,” underlines Mr. Shah. When asked about addition of new agency lines, Mr. Shah says: “We have generally been extremely selective and have refrained from having a long line card, preferring a deeper involvement with our current partners to fully exploit their potential, but we have recently signed with Horiba to introduce flow control solutions and we would probably close with 2 more agencies in the Fluid Control area over the course of the next year.”
- P.K. Balasubbramaniian
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PORTFOLIO
The Bettinelli
advantage Over the years, Bettinelli Group and CDS Indexers have become synonymous with high quality automation products and technologies.
Rupesh Paparaju, Director, Bettinelli Automation Components, India
B
ettinelli S.p.A, established in 1953, specializes in the development and manufacturing of precision motion control components and systems. In 1996 a separate division named CDS Cam Driven Systems was created for engineering solutions in automation and motion technology. CDS produces the widest range of mechanical Cam Driven Units, commonly known as rotary / indexing tables for precision motion control applications, requiring rotary or linear transfer, positioning and handling. The products range includes, cam indexing and servodriven tables, ring positioning drives, intermittent and oscillating drives with parallel or right angle configuration, rotary & linear part handlers, precision link transfer systems, and epicycloidal servo reducers.
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Wide ranging products The broad product spectrum covers IP parallel shaft indexers, IT roller dial indexing tables, TR roller dial indexing tables, HP roller dial indexing tables, IG/IGA roller gear
indexer, TL precision link conveyors, MHP/LHP part handlers, FT-HT open center ring tables and packages of rotary indexing tables. Bettinelli has a wide range of standard products. These are delivered in 3 weeks.
Rotary Indexing Tables, TR Series
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PORTFOLIO
Parallel Shaft Indexer
When it comes to customized products, these are designed, manufactured and shipped in 6-8 weeks. The manufacturing takes place centrally in Italy. The regimen starts with design & engineering, CNC induction hardening, CNC milling, grinding, quality check and then assembly, painting and shipment. In order to ensure quality, all components are machined internally, including the cam hardening by a proprietary CNC controlled induction hardening equipment. For better finish, the products are also subjected to chemical nickel plating, blasting and painting. The manufacturing process is constantly controlled to conform to international standards. The company’s quality systems are ISO9001-2008 certified. Strategic advantages Over the years, Bettinelli Group and CDS Indexers have become synonymous with high quality automation products and technologies. “Our design and manufacturing systems have furnished competitive and strategic advantages to numerous industries
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in pharmaceutical, automobile, manufacturing, packaging and a plethora of other sectors. And for automation functions, our solutions are invariably preferred by companies,” says Rupesh Paparaju, Director, Bettinelli Automation Components, India. The Indian subsidiary, headquartered in Pune, serves its customers in India by providing installation, commissioning, and after-sales support. It also offers technical consultation. In the pharmaceutical industry cam driven systems are used in filling, blister pack, tablet making and packaging machines. In automobile industry, they are used in pallet transfer tables, assembly machines, painting applications and test rigs, just to mention a few. In machining industry, they are used with advantage in deburring, lapping and pressing machines and in transfer lines. In SPM & robotics, they find applications in transfer lines, station loading, sequential operations and so on. Inwelding, these indexers are inevitable in positioners, synchronous welding, robotic welding and component transfer. Packaging too is a major
application area. Cam systems are used in box filling machines, wrapping machines, cartoning and capping machines. Indexers are also used in casting, printing and cosmetics industries. Closer to the customer The Indian arm of Bettinelli, based in Pune, Bettinelli Automation Components Pvt. Ltd., is highly customer-centric. “Our presence in India means quite something in fostering a symbiotic relationship with our customers. It helps us to match our world-class products with our eminent customer support,” underlines Paparaju, Director, who has built up a team to improve Bettinelli’s response time. “CDS are high-tech products which lend themselves to enhance the operational efficiency and productivity at the customer’s end. We stay close to the customer to understand his needs and offer customized solutions within the shortest possible time to ensure peak uptime of his equipment and operations”, he adds.
- P.K. Balasubbramaniian
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DELHI
MACHINE TOOL EXPO
2019
TM
08 - 11 August 2019
India Exposition Mart Limited Greater Noida
Biggest show in the region to connect with best manufacturing industries Delivered by the organiser of SPECIAL PAVILIONS
AM
www.mtx.co.in
PORTFOLIO
FIBRO : German Precision Crafted in India
Mr. Vivek Nanivadekar Executive Director, FIBRO India Precision Products Pvt Ltd
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Q. What are the milestones your company has achieved till date ? FIBRO India is a 100% subsidiary of FIBRO GmbH and was established in 2008 and started manufacturing in a small way in rented place. But within couple of years it became difficult to meet the market demand from that small rented place. As such FIBRO India bought the plot of 4000 sq. m. in MIDC Phase II, Chakan and started the construction in 2011. Finally, FIBRO India shifted to its own plant in March 2013 and in 2017 we started the construction of our 2nd plant adjacent to the existing one. We started manufacturing guide pillars for domestic as well as export market. But then as market expectations increased, we kept on adding new products every year in our manufacturing range.
Subsequently in 2015 our Rotary Table division in Germany also decided to join FIBRO India to manufacture the Rotary Tables of ‘FIBROTOR’ series for automation industry. Our new plant is now ready for production. We have successfully commenced the assembly of FIBROTOR Rotary Table in 2018. The journey in Indian market so far has been quite interesting with ups & downs but every team member enjoyed it. We have been growing at an average CAGR 30%. Our strategy has been ‘working closely with the customer to understand the problems/difficulties and offer them the right solutions. Based on the market feedback we keep on adding new products every year. We are positively responding to the government initiative of ‘Make in India’.
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23 - 28 January 2020, Bangalore, India
PORTFOLIO Q. What product technology you represent? FIBRO has two distinct operationsStandard parts also known as Die components, and Rotary Tables. FIBRO GmbH has been closely working with Mercedes Benz, AUDI, Volkswagen etc for pressed components. In India, we are manufacturing fast moving standard parts like oil less guide elements, spring plungers, cam slide units etc. catering to domestic as well as
international markets. We have been adding new products and their variants every year catering to the Global market requirements. Also, FIBRO are the pioneers in the Rotary Table. There are basically two types of applications for Rotary Tables one in the Automation and second in the Metal cutting, for which FIBRO has the largest range in both segments Rotomotion and Rotocutting respectively.
Q. What is the future of your products in India? As per the TAGMA survey report the Tooling industry is expected to grow at CAGR 11% in next three years. Besides, India is considered
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as developing economy. Due to initiatives taken by the government like ‘start up India’ ‘Make in India’ it has opened the doors in IT as well as manufacturing sector. I firmly believe India can become Global manufacturing hub sooner than later. As a result of above initiative, the Sheet metal forming industry is also on the rise in India and thus the Tooling industry. Secondly there is tremendous pressure on lead time as well as on the cost at every stage of new product development. This will drive the local manufacturing of tooling with reduced lead time and cost competitive. The use of cost competitive quality standard parts will help the Tool makers to deliver the results. That is where FIBRO India has a role to play. At FIBRO India we are manufacturing standard parts and keeping the stock of fast-moving items to support the local Tooling industry to reduce their lead time. Similarly, there is the substantial growth anticipated in automation sector. Therefore, it was decided to manufacture the Rotary/ Indexing tables in India to cater to this sector. FIBRO India will be making these tables for the world market soon. We are “Expanding our Horizons” to meet the market demand. Q. What is your vision for forthcoming years ? To put it in simple words ‘Working closely with the customers, understanding their problems/ difficulties/challenges, FIBRO India will provide precision technical solutions thru. Standard parts and Rotary Tables to the toolmakers, Automation and general manufacturing industry by adapting innovative, cost competitive manufacturing methods.
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Synthetics
TRIM® Product
TRIM® C270
Semisynthetics
TRIM® SC310 TRIM® SC410
Emulsions
Microemulsions
TRIM® MicroSol® 455
Product Description
Synthetic coolant concentrate operates at very high fluid pressures and volumes with little or no foam. Very stable formula, exceedingly long operational life with consistent performance. Nonchlorinated.
Highly versatile for machining/grinding a very wide range of materials. Chlorine-free, semisynthetic coolant using vegetable-derived and ester lubricants. Very clean running in moderate-duty machining and grinding of both ferrous and nonferrous materials, including "gray iron" castings. Low-foam semisynthetic, microemulsion for high-volume cast iron, ferrous, and some aluminum and nonferrous metalworking. Prevents leaching of elemental iron. Eliminates clinkering and oxidation of ferrous micro fines.
TRIM® MicroSol® 585XT
Extended-life, high-lubricity, microemulsion coolant delivers excellent cooling and mechanical lubricity. Well suited for machining and grinding titanium and aluminum alloys, gray iron, and mixed metal situations.
TRIM® MicroSol® 590XT
Specifically designed for aerospace; protects sensitive alloys from surface stains and corrosion. Maximum lubricity. Unsurpassed sump life and foam control. No boron or DCHA, nonchlorinated, needs no tankside additives.
TRIM® MicroSol® 690XT
Ultimate lubricity. Robust stability package for long life. Exceptional foam control. Excellent environmental and regulatory profile. Boron free and nonchlorinated. Multi-metal compatible.
TRIM® E709
High-quality, universal soluble oil requires minimal maintenance in the most demanding fluid management systems. For tough machining and grinding jobs and high-quality, consistent parts manufacturing.
TRIM® E950
Extremely high-performance but clean running emulsion product for the toughest applications. Very low foam even in soft water. Fully approved by Rolls-Royce.
Let us create a detailed, facts-based, customized analysis to prove just how much we can save your operation in time, material, and cost, while improving quality, with the premium coolant just right for your production.
For prices or additional information, contact your Master Fluid Solutions Representative.
www.masterfluidsolutions.com ©2017-2019 Master Fluid Solutions. TRIM® and MicroSol® are registered trademarks of Master Chemical Corporation d/b/a Master Fluid Solutions.
TECHNO FOCUS
Master Fluid Solutions® committed to provide the most advanced metalworking fluid solutions to the globe, announces their new precision machining center Master Fluid Solutions continues its investment in innovation and future development with the creation of their new Precision Machining Center. The center will quicken and significantly improve their product development process as well as enhance their unique customer training methods.
M
aster Fluid Solutions continues its commitment to its customers across the globe with the announcement of its new Precision Machining Center. Known worldwide for its TRIM®, long-lasting, premiumperformance, and aerospace-approved metalworking fluids, Master Fluids Solutions continues to invest in the development of state-of-the-art cutting and grinding fluids to surpass their worldwide customers’ ever-increasing needs for more efficient metalworking fluids that deliver exactly what is needed directly to the point of cut. Mr. Michael A. McHenry, President and Chief Executive Officer for Master Fluid Solutions commented, “In all aspects, we aim to serve our global customers to the highest level of excellence. This investment is one key element of our goal of speeding up and expanding our innovation and future development processes. We are committed to bringing the best and most productive metalworking fluids
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to all of our unique customers’ hightech and demanding applications.” “Master Fluid Solutions is a very data-driven company,” remarked Dr. Steven M. Florio, Chief Technology Officer for Master Fluid Solutions. “In the course of new product development, we rely on a variety of validated functional tests to drive our product development efforts. Among these tests is a statistically-validated, on-machine method, utilized to evaluate lubricity, which is one of the key performance metrics for any metalworking fluid. Having the ability to control all interactive functional parameters, such as substrate, tooling, machine settings, and of course, the metalworking fluid, allows for an improved ability to optimize performance.” Master Fluid Solutions’ newly crafted Precision Machining Center includes an advanced, vertical Makino PS105 CNC equipped with throughspindle cooling, high-pressure capability, and 30-tool capacity. The
Precision Machining Center also includes many high-tech measuring tools to quickly and efficiently help Master Fluid Solutions collect large amounts of data to guide the product development process. Dr. Florio continued, “additionally, we know that we can utilize our CNC to develop data that is more relevant to the customer, in their language, utilizing their key metrics. Tool life, surface finish, and optimization of machine parameters will be fully developed for all new-to-market products. Key, inmachine performance characteristics such as foam, rust prevention, and metalworking fluid stability will be vetted as part of our development processes. The ability to establish functionality, to troubleshoot, and to conduct in-machine product evaluations for our customers is also a critical key advantage.” Mr. John O. Treese, Director of Global Training for Master Fluid Solutions excitedly explained,
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TECHNO FOCUS
Master Fluid Solutions continues its investment in innovation and future development with the creation of their new Precision Machining Center
“we are really looking forward to utilizing the new Precision Machining Center in our employees’, distributors’, partners’, and customers’ training programs. The new center gives us many new opportunities to help our customers to further understand the role of the cutting fluids in their challenging manufacturing operations. That understanding can lead them to greatly improved process efficiencies that save time, reduce waste, and increase their profitability.”
Mr. Michael A. McHenry, President and Chief Executive Officer, Master Fluid Solutions
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About Master Fluid Solutions Master Fluid Solutions®, working closely with the worldwide metalworking community, develops and markets a full line of environmentally sound, extremely durable and stable cutting and grinding fluids, straight oils, parts cleaners, and rust preventives under the TRIM® and Master STAGES™ brands. Master Fluid Solutions’ XYBEX® fluid management systems lower their customers’ total cost of operations. Master Fluid Solutions is committed to the safety
Dr. Steven M. Florio, Chief Technology Officer, Master Fluid Solutions
of the people who use their products, the protection of the planet, and the overall impact on their customers’ profitability. Master Fluid Solutions is proud to have received a Toledo’s “Top Work Places” award from 2014 through 2019.
For more information, www.masterfluidsolutions.com.
Mr. John O. Treese, Director of Global Training, Master Fluid Solutions
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TECHNO FOCUS
“If you want to set things in motion: KTR”
Mr. Shivashankar Pikale, Managing Director KTR Couplings India Pvt. Ltd.
K
TR Couplings (I) Pvt. Ltd., which is a 100% subsidiary of KTR Systems GmbH, Germany, a well-known name worldwide for Couplings & Power Transmission Products. KTR established in 1959, with headquarters in Rheine, Germany has subsidiaries in over 23 countries & 7 manufacturing plants – in Germany, USA, Poland, Brazil, China, India & Taiwan. KTR India, established in 1998, having manufacturing plant at BHOSARI, PUNE with full-fledged manufacturing set-up, is catering to coupling needs of every industrial sector. We manufacture variety of couplings and transmission products for all types of conceivable drive applications. Apart from couplings, we also supply Hydraulic Components, Clampex, Universal Joints, Torque Limiters and Torque Measuring Equipment, Hydraulic & Electro-mechanical Break Systems, Oil/air/ water cooling systems. “Accuracy Meets Speed: Rotex GS, Toolflex, Radex NC & Countex Couplings” Automation Technology has to meet with contradictory demands: Speed and Accuracy, Flexibility and Reliability, highest efficiency combined with highest profitability. It is good to see that KTR Couplings are as multipurpose as their applications.
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For feed drives in machine tools, gantry robots or other handling units driven by servo motors, accurate positioning with at the same time full dynamics is important. The selection of coupling has a decisive influence on behavior of overall system. KTR offer you four different types of backlashfree couplings: Jaw Coupling (Rotex GS), Servo Lamina Coupling (Radex NC), Metal bellow-type coupling (Toolflex) and Special coupling for shaft encoders (Countex). Positional Technology ROTEX GS: The back lash free flexible jaw coupling ROTEX GS has proven it’s worth in positioning technology and on main spindle drives. In spite of it’s feature of damping vibrations it is sufficiently torsionally stiff so that even with highly dynamic servo drives accuracy does not suffer. This is why it is said to be the standard solution for ball screws with inclines S < 40. Clamping Ring Hubs are suable for circumferential speeds up to 50 m/s. Rotex GS P was developed by KTR in cooperation with VDMA (Association of German Manufacturers of Machines and Plants) to be used on stub spindles of multiple spindle heads. Integrated clamping system of back lash free, highly precise shaft coupling is made of 100% steel. With circumference speed of 75 m/s and higher, it is ideally suited for applications on HSC main spindle drives. ROTEX GS P is manufactured to DIN 69002. TOOLFLEX: The backlash-free metal bellows-type coupling TOOLFLEX with a non-positive connection of bellow and a hub and a frictionally engaged clamping hub is suitable for temperatures
up to 280°C. For higher inclines S ≥ 40 TOOLFLEX coupling is recommended. TOOLFLEX remains fatigue endurable in high temperature up to 200°C. It’s main application ranges are both positioning drives e.g. ball spindles with high incline and indexing tables or planetary and work gears with small gear ratios. RADEX NC: RADEX NC is developed for Servo Technology. Stainless Steel Laminas make it torsionally stiff and at the same time flexible. Aluminum hubs ensure a low mass moment of inertia even with double cardanic design. RADEX NC can be used in high temperatures up to 200°C and under aggressive ambient conditions. A typical application of RADEX NC is backlash free worm gear pairs with low transmissions ( for i < 8). Clamping Hubs are frictionally engaged and are thus backlash free even in a reversing drive. COUNTEX: COUNTEX is a three part, back lash free and torsionally stiff coupling mainly used in measuring and control technology. It’s axial plug-in ability combined with geometry of hubs results in a coupling system with a specifically easy assembly, offering options of mounting fitting with processing. Material of spacer is resistant to high temperatures ensuring continuous properties of coupling system temperatures up to 160°C. The measuring and control technology demands for a high torsion spring stiffness in order to realize reproducible positioning. The double –cardanic principle of COUNTEX reduces the restoring forces.
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TECHNO FOCUS
Forecast Highlights for 2017 - 2026 on Global Automotive Lubricant Market
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ffectiveness of lubricants remains closely associated with the performance of automobiles. High-performance automotive lubricants ensure that the vehicle works on optimized fuel consumption, reduced carbon emission, and increased torque. In the past, elevating the performance of automotive lubricants has led manufacturers towards adopting additives in the production procedures. In the years ahead, automotive lubricant manufacturing will witness emergence of new products made of advanced polymers and performance additives. Changing designs of combustion engines and automobile components will play a key role in transforming the quality and advantages of automotive lubricants. Moreover, OEMs will be partnering with automotive lubricant manufacturers to develop new engines and sub-components for meeting the driving needs of future generations. According to a recent study published, the global automotive lubricants market is anticipated to expand at a CAGR of 5.3% in terms of volume during the forecast period, 2017-2026. By the end of 2026, an estimated US$ 113,944 Mn worth of automotive lubricants are pegged to be sold in the global market. The report observes that fluctuating prices of base oils and additives, coupled with increasing customization of automotive parts, will limit the adoption of automotive lubricants to a considerable extent. However, steady sales growth of conventional fuel cars will continue to facilitate a firm consumer base for automotive lubricants through 2026. 4 Insights on How Global Automotive Lubricants Market Will Evolve by 2026 • Gear oil segment in the in the
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lubricants type category is forecasted to exhibit a robust CAGR during the period of assessment and is estimated to reach a value of nearly US$ 22,400 Mn by the end of 2026. The gear oil segment was expected to account for nearly one-fifth of the revenue share of the lubricants type category by the end of the year 2017. • Semi-synthetic oil segment in the base oil type category is forecasted to exhibit a CAGR of 6.1% during the period of assessment and is likely to reach a valuation of nearly US$ 57,800 Mn by 2026 end. The semi-synthetic oil segment was expected to account for nearly half of the revenue share of the base oil type category by 2017 end and is expected to gain market share during the forecast period. • The LCV segment in the vehicle type category was forecasted to exhibit a moderate CAGR during the period of assessment and is expected to reach a valuation of nearly US$ 23,525 Mn by the end of 2026. The LCV segment was estimated to account for more than one-fifth of the revenue share of the vehicle type
category by 2017 end. • The United States automotive lubricant market is likely to reach a value of nearly US$ 21,000 Mn and exhibit a robust CAGR during the period of assessment from 2017 till 2026. The report has also profiled leading manufacturers of automotive lubricants, which include, Chevron, Valvoline Inc., Fuchs Group, Buhmwoo Chemical Ind. Co., Ltd., Total S.A., Nippon Oil, Royal Dutch Shell plc, British Petroleum, Quaker Chemical Corporation, AMSOIL INC. and Exxon Mobil. These companies will be responsible for almost entire automotive lubricants produced in the world through 2026. Environmental law compliance will continue to remain a challenge for automotive lubricant manufacturers. In the foreseeable future, several market players are likely to explore their capabilities in producing biolubricants for automotive applications. These insights are based on a report on Automotive Lubricant Market by Fact.MR
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TECHNO FOCUS
Increase your tool life upto 300%
DF - Series
T
he quality of cutting tools can be improved considerably by finishing in DF and SF machines from OTEC, Germany. Defined edge rounding dramatically increases the life of cutting tools, as a rule by a factor of three. The OTEC process not only rounds the edges but also smoothâ&#x20AC;&#x2122;s the surfaces. Also the Drag Finishing & Stream Finishing process significantly reduces chipping and improves chip flow. The friction acting after PVD and DLC coated tools can be reduced dramatically by removal of droplet after a short finishing process in DF & SF which thereby significantly reduces wear of coating from tools. With forming tools, Ra values of up to 0.02 Âľm can be achieved and the percentage of contact surface
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greatly increased. Special polishing processes largely prevent corrosion at the tool holder, so that no further anti-corrosion treatment is needed for several months. Deburring between the thread profile and the cutting edges with defined rounding of the cutting tools can be extend tool life and improved adhesion of the subsequent coatings. In Stream finishing machines with Pulsfinish process taps can be deburred and rounded reliably, quickly and economically. Surfaces Before & After Edge Honing Processing in a drag finishing or stream finishing machine reduces the risk of chipping. Precision rounding of the cutting edges and polishing the chip flutes increases tool life and improves cutting performance.
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SF - Series
Polishing greatly improves the appearance of tools. It also largely prevents corrosion. Cutting tools are often coated with a carbide material in order to reduce wear. As a result, droplets can form on the surface of the tool. The drag finishing
process selectively removes these droplets. Lubricant can be retained in the tiny holes and depressions left behind. This gives an improved film of lubricant on the surface of the tool, resulting in much less friction and reducing wear dramatically.
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CASE STUDY
Faccin delivers special plate rolls for wind tower door frames Eng. Andrea Comparin – Technical Sales Manager – Faccin S.p.A.
W
ind towers is certainly an important business sector for Faccin which consistently delivers heavyduty automated rolling lines that help increase the manufacturers’ productivity. However, in the fabrication of wind mills, the towers are not the only component that require the bending of heavy-duty steel plates. In fact, wind towers door frames are also an essential component used in every wind mill that entail experience in plate bending and special technical solutions for its fabrication. Wind towers door frames are oval rings made for reinforcing the entry
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hole necessary for an operator or technician to access the towers. The door frames are generally made of steel plates 400-500mm wide with thicknesses that range from 50mm up to even 100mm thick to comply with the design norms. Being oval shaped with rather small radii, they require for their fabrication, a machine capable of bending these thicknesses down to radii of around 250-400mm. Faced with this challenge, several customers asked the company
to design a special 4 rolls linear machine, half meter long, with extra bending force and torque in order to increase automation and precision for this kind of dedicated production. In order to satisfy the customers’ needs, Faccin engineers have designed the 4HEL/DF, a special 4 rolls linear model for door frames that can roll these complex shapes with minimum cycle time and the shortest pre-bending possible. The 4HEL/DF is equipped with the latest generation of CNC, the PGSUltra, that thanks to its automatic calculation of the bending cycle and the perfect interpolation axis, can help the customers outstrip the
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MACHINE PROTECTION
MARPOSS offers intelligent module-based systems for Machine Protection - GEMCMS02. It can easily integrated into machine tools, equipments or robots. An improved way to protect and safeguard your machine tools and minimize the risk of downtimes. Detailed event records. Date, time and other signals are recorded and can be used for further evaluation and analysis offline. The system can runs permanently also in background and can easily integrated into GENIOR MODULAR Tool and Process Monitoring.
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MARPOSS INDIA Pvt. Ltd. - 147, Sector 7, IMT Manesar 122 050 - Tel. +91 124 4735700 | sales@in.marposs.com
CASE STUDY competition in the business of wind towers door frames. “Faccin is glad to announce that is currently producing yet another 4HEL/DF that will be available for demonstration at the Faccin facilities for one month before the delivery to another important customer.” Customized cost-effective solutions Reliability, speed and accuracy must go hand to hand with costs reduction, and the job should be accomplished by a single operator through the use of a user-friendly CNC capable of controlling automatically not only the machine but also the handling system. Maximizing profits Our highly technological machines are designed to maximize the productivity, thus the profitability
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of the wind tower manufacturer. All this is achieved by a precise and fast rolling machine, which helps reduce time in the following steps of the wind tower assembly and welding, an oversized reliable structure. The high level of supply availability and the lowest possible processing time is our priority. Installation and training are always provided in order to develop our customers skills. It allows them to operate confidently and independently in their day-to-day business. The Company More than 200 years combined experience, forming today’s future. Faccin S.p.A. is a very powerful group which combines the best brands – Faccin, Boldrini and Roundo – in plate rolling, profile
bending and dished-heads manufacturing, all united under one roof and offering the widest range of high-quality options available in the metal forming market. Should you be interested in this technology, do not hesitate to contact us and book a demonstration.
Scan and see the machine in action supplied to our good customer Madesta.
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CASE STUDY
STUDER - Your 360-degree solution for internal cylindrical grinding It was 1933 when the first internal cylindrical grinding machine, Type 01, left the premises of Fritz Studer AG. 85 years later STUDER offers what is probably the world’s largest portfolio in internal cylindrical grinding, with a range of 12 machines.
K
ptec Components GmbH from Schorndorf (Germany) is a component manufacturer for the machine tool industry. The focus is on spindles, rotors, spindle housings, draw rods and flange parts. The core competence is grinding. “Achieving micrometer precision in series is the great challenge in grind-ing”, states Walter Wiedenhöfer, Managing Director of Kptec Components. In the manufacture of spindle components, coaxialities of one micrometer are state-of-the-art. It is often necessary to grind an H6 fit into bores up to 400 mm deep for the clamping mechanisms of the interface. In addition, the machine must produce as economically as possible. In other words: You should only pick up the component once and then produce it completely, if possible. But a good machine must also be flexi-ble and capable of performing unusual operations, such as relief grinding of a spindle, for instance. A machine that fulfils such requirements is the S151 universal internal cylindrical grinding machine. When fully equipped, it has three internal and one external grinding spindle, as well as a measuring probe. Kptec was convinced by it. Today, Wiedenhöfer comments: “This machine is the best we have in the company – it was absolutely the right decision to buy a STUDER machine. The universal machines STUDER has the right machine for every requirement in internal cylindri-
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Probably the world’s largest portfolio in internal cylindrical grinding.
cal grinding. In the universal range these are the S121, S131, S141 and the S151. The affordable universal S121 is the ideal ma-chine for internal, surface and external grinding of chuck components. The S131, S141 and S151 form a series for every conceivable application in internal cylindrical grinding. They are used wherever the highest precision and efficiency are required – for example, for flange parts, spindle shafts, spindle housings, rotor shafts, bushes and much more. The maximum workpiece weight is 250 kg, and the maximum length is 1300 mm. For production The S110 is a very flexible and compact internal cylindrical grinding machine, ideal for chuck applica-
tions for individual components through to small batch production. Thanks to its small footprint it can fit in any workshop. The S122 is specialized for small bores and has a swing diameter of 220 mm. It offers cutting-edge technology for machining small to medium-sized workpieces in small to large-scale production. Both types have up to three grinding spindles in a parallel arrangement, which ena-ble external and internal grinding in a single clamping. “Price, quality, technical requirements – these were our selection criteria for a new machine. The biggest advantage is the high production capacity”, Miroslav Martinek, Production Manager at Sellier&Bellot, explains his decision to invest in an S110.
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CASE STUDY Three sizes for radii The S121, S131 and S141 are the experts for high-precision internal cylindrical grinding of radii, spheres, balls, cones and diameters. The maximum swing diameter is 400 mm and the maximum workpiece weight is 100 kg. The main fields of application are in the manufacture of die plates from carbide and ceramic and the production of hydraulic components such as axial pump pistons, guide plates and housings from hardened steel, cast iron and copper. The application range also includes workpieces made of industrial ceramic, sapphire and carbide for the manufacture of human implants. The automatic B-axis with direct drive allows grinding with interpolation for high-precision machining of radii. The radius grinding machines are supported by the StuderSIM software. AKS Hartmetalltech-nik GmbH in SchwäbischGmünd has an S131 – with radius grinding option. “The sophisticated CNC technology, the ability to execute several work steps in a single clamping whilst achieving absolute precision. These criteria convinced us. Set-up times, maintenance costs and failure times can now be calculated. We also benefit from the fast response times of STUDER Customer Care”, explains Pro-duction Manager Edgar Feifel. Solid construction The internal cylindrical grinding machines are based on the Granitan® machine bed with its excellent damping behavior and StuderGuide® guideway system. This system’s big advantage in comparison with hydrostatic guides is the damping component in the direction of movement. The dressing pro-cess can be flexibly and optimally adapted
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There is hardly a workpiece that cannot be machined with the STUDER internal cylindrical grinding machines. The Swiss grinding machine manufacturer offers the right machine for all conceivable ap-plications. The excellent ergonomics of the machines ensures comfort for the operator and also en-hances the machine value. to the workpiece, tool and materialspecific characteristics - according to the customer’s requirements. A further STUDER speciality is the grinding wheel refer-ence points (T-numbers). These enable programming with normal dimensions, which considerably facilitates the development of grinding programs. The workhead can be moved in a longitudinal direc-tion on the swiveling B-axis, has a high roundness accuracy and is low-maintenance. The airlift simpli-fies adjustment when setting up or resetting the workhead. Sophisticated sensor technology monitors the process during grinding and dressing and offers sim-ple registration of grinding wheel and workpiece. The air-gap elimination serves for reducing the cycle time. The modular spindle concept enables optimal adaptation to the grinding task. The direct drive in the grinding spindle turret offers minimal positioning ranges on the radius and universal grinding ma-chines (except S110/S122). On the S122 the highprecision machining of minimal diameters can also be done efficiently, thanks to the proven arbor deflection compensation. Different loading systems are available for automation. Thanks to their modular design, these can be
precisely adapted to the machine application and machining processes. Appropriate peripheral devic-es guarantee seamless integration into the respective production process. Anyone can be a grinding expert It is no longer necessary to be a grinding expert to operate the machine. You only need to know what the workpiece is made of and what the surface quality of the workpiece must be at the end of the process. StuderTechnology suggests the optimal grinding parameters and generates the program. StuderWIN offers the possibility of fully integrating the in-process gauging and sensor technology for process monitoring, including contact detection and automatic balancing systems in the operator interface. This enables standardized programming of the different systems. StuderWIN is supple-mented by the StuderPictogramming grinding software. The operator strings the individual grinding cycles together – the control unit generates the ISO code. The machine’s functionality is enhanced by the software option for thread and form grinding. The StuderSIM software has been specially devel-oped for the internal grinding of radii. The operating system enables programming of all basic cycles for grinding, dressing and processsupporting measurement. This type of programming guarantees high flexibility together with maximum user-friendliness. After programming, the process can be simu-lated and optimized. This ensures reliability, as well as guaranteeing short programming times and increased cost effectiveness. For more information, Website: www.studer.com
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CASE STUDY
Making time for Holthinrichs watches
Michiel Holthinrichs, the founder of Holthinrichs Watches, is working with a Renishaw Additive Manufacturing Solutions Centre to build up his knowledge about the potential of metal additive manufacturing (AM) & to speed up the overall manufacturing process for his high-end, limited-edition watches.
H
olthinrichs Watches was founded by Michiel Holthinrichs in 2013. Whilst studying for a Masters in Architecture at Delft University of Technology, he began to collect and repair vintage watches. Architecture had taught him the importance of detail and ornamental features, which are ubiquitous in art deco, and he recognised these elements in watch design.Michiel viewed the elegant time pieces as miniature, precise constructions and this inspired him to transfer his artistic and engineering skill into creating his own watch design. His first design ‘Ornament 1’ combines traditional watchmaking elements, including a Swiss movement with manual winding and a design inspired by classic watches of the 1950s, with the new technology of metal 3D printing, which was used to produce
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the case, crown and buckle. Michiel produced his first design iterations traditionally with pencil sketches, developing them into handdrawn technical drawings and taking into consideration that the parts would be produced using CNC machinery, or on a manual lathe. However, he did not have the machinery or skills to produce them himself, so he needed to find a manufacturing partner. This proved to be more difficult than anticipated because the Netherlands does not have an established watchmaking industry. Michiel had read reports in the media about 3D printing and discovered that Renishaw manufactures metal AM systems. He contacted Philippe ReindersFolmer, General Manager of Renishaw Benelux, who suggested Michiel begin his journey into AM with a reputable
3D printing bureau in Belgium that had recently installed a Renishaw AM250 system. Michiel worked with the bureau to 3D print prototypes and the first ‘Ornament 1’ watch on its Renishaw AM250. The case, crown and buckle of the ‘Ornament 1’ were metal 3D printed in stainless steel 316L. The watch case has a diameter of 38 mm and is only 10 mm thick; it has a raised inscription of the Holthinrichs brand on its edge with the words ‘stainless steel’, ‘3D printed case’ and ‘Swiss movement’, in capitals on its reverse. These details were achievable only by using metal AM. The batch of watches took approximately thirty hours to print on the Renishaw AM250 system. Postprocessing, including machining of the parts, was out-sourced and they were returned to Michiel, who finished them with hand filing and polishing.
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CASE STUDY The post-processing, assembly and adjustment by hand took a further thirty hours per watch. Challenge When ‘Ornament 1’ was formally launched, it attracted publicity due to the novel use of 3D printing technology. The elegant 1950s art deco design and beautiful presentation combined with a limited-edition run justified its added value price of over €3,000. Michiel noted, however, that customers seemed to be less concerned by the method of manufacture, but rather more by the details in the design which are not offered by other watches. The Holthinrich’s signature which appears as raised fine script on the edge of the case could not be achieved by traditional manufacturing and highlights the capability of Renishaw’s high-performance AM systems to produce highly precise and fine detail features. Now that Michiel has proved ‘Ornament 1’ can be produced, he wants to investigate how reproducible it is and to streamline the labour-intensive finishing process. In addition, his manufacturing costs were relatively high because the metal 3D printing, machining and other automated postprocessing all had to be outsourced. He did not have the necessary skills to take these processes in-house, nor was he at a stage where he felt he could make an informed decision about new investments. Michiel can see the potential for increasing his range, noting “The whole watch industry is changing; there used to be big companies which run on tradition [...] but I think people overall – not just in the watch market – but across a broader scale of products, are moving towards a more personal, more authentic product”. His plan is to develop a core range of classic style watches that are high-end and have a strong element
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Ornament 1’ watch case printed in titanium on a Renishaw AM 400 system.
of personality, but which could be completely customised like bespoke jewellery. Solution After an evaluation by Renishaw it was concluded that a Renishaw Additive Manufacturing Solutions Centre (AMSC) would be the best way to take Michiel forward on his journey in metal AM production. Located globally, Renishaw Additive Manufacturing Solutions Centres are places where customers can rent time with Renishaw AM technology, supported by Renishaw engineers. Services at an AMSC can cover the full production process from design for AM through to finishing and inspection. Customers have access to technologies complementary to AM, including machining and metrology. The aim is to allow customers to build up their knowledge in less than six months so they may make a fully informed decision about the potential of the technology and process for their business, before they take metal additive manufacturing in-house. “We make the machines and we use them. With that experience we can help companies progress further with advanced manufacturing systems”, explained Philippe. Based on the success of the ‘Ornament 1’ in stainless steel, Michiel wished to offer the watch design in an alternative material. Renishaw recommended titanium because it is possible to achieve a highly polished finish and
it is suitable for investigating chemical post processing which could help reduce finishing time. Also, titanium is lighter than stainless steel and this would provide Michiel with an additional point of differentiation in his ‘Ornament 1’ design range. One of the key benefits of metal 3D printing is that no tooling is required and the design is drawn up in 3D CAD (computeraided design) software. “If Michiel wants to tweak a design, or change an engraving or a signature he can do that on his computer and there’s no knock-on effects further down the process line”, explained Charlie Birkett, a Renishaw AM Applications Engineer who supports customers in the UK AMSC. Renishaw exported Michiel’s new design into its QuantAM build preparation software. QuantAM was developed specifically for use with Renishaw metal AM systems. Using this software, the Renishaw team could show Michiel how to check and configure the parts on the build plate and apply the necessary supports. The team’s know-how ensures that the minimum number of supports are applied to avoid waste and save time. Once the build was prepared in QuantAM, the file was sent to a Renishaw AM 400 metal AM system. This system was chosen due to its flexibility in terms of material changeover and ability to reproduce sharp corners and the fine detail in the design. Results Michiel described the titanium watch parts as “very aesthetic – a rough industrial aesthetic” and in anticipation of a solution to speed up postprocessing he stated, “We are just at the beginning, so I am very curious as to where it goes.” For more information, Website: www.renishaw.com
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CASE STUDY
PC-based control becomes the standard for sheet extrusion applications
Picture credits/Copyright: Graham Engineering, USA
Increased functionality & cost benefits all along the line The plastics industry is one of the fastest growing industries in the USA. Many of the plastic products that we use every day start as huge sheets of plastic, manufactured from plastic pellets by sheet extrusion machines. American company Graham Engineering Corporation, based in York, Pennsylvania, manufactures, among other solutions, sheet extrusion machines under the Welex® brand name. These machines rely on Beckhoff controls to optimize their operation and processes.
I
n the Welex® Evolution® series, Graham Engineering Corporation has created a machine portfolio that provides robust, customizable sheet extrusion for winding, sheeting and in-line thermoforming systems. The state-of-the-art systems operate with a co-extrusion process, where up to nine extruders can be included in the system, for example to manufacture multi-layer products. The applicationspecific machine configurations from Graham Engineering Corporation feature, among other things, high-performance screen changers, melt pumps, mixers and co-extrusion feed blocks. The XSL Navigator® machine control platform, which was developed by
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Graham Engineering Corporation, provides efficient operation of the Welex sheet extrusion machines. The basis of this control platform is a Beckhoff Industrial PC with TwinCAT automation software. Graham Engineering Corporation optimizes extrusion process The raw material for the extrusion process is a plastic granulate, which is often mixed with recycled material. This granulate mixture is conveyed into an extruder. The rotating extruder screw, housed in a heated metal barrel, mixes and melts the filled material while conveying the material forward. The molten plastic is pressed through
a metal screen to filter out any particulates before it enters the melt pump. The screen is continually changed and cleaned in an auxiliary unit. The resulting homogeneous plastic melt is fed to a pump in order to generate an adequate plastic melt pressure. “The melt pump provides a reliable, continuous material flow through the slot die, which can be adjusted to provide the desired material thickness,” explains Justin Kilgore, Vice President of Engineering at Graham Engineering Corporation. The material then flows onto polishing rolls. These rolls counter-rotate, pulling the material through and feeding it down through the rest of the line to be delivered either to a winder or directly into a thermoformer, where it is given its final shape. Graham Engineering Corporation standardized on PC-based control from Beckhoff for its blow-molding
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Behind Harmony Arcade, Pimpalghar, Bhiwandi - Kalyan Road, Taluka Bhiwandi, District Thane - 421311, Maharashtra India. Mobile: +91 9167620639 / 643 / 648 / 231 | www.precihole.com | Email: sales@precihole.com
CASE STUDY machines 10 years ago. The company has now chosen to integrate the Beckhoff platform into its new control system, the XSL Navigator®. This powerful, feature-rich control system has been adapted for use in sheet extrusion lines. “The flexibility and scalability of the PC-based solution are the two biggest reasons why we chose to standardize on this platform,” says Justin Kilgore. “The open control architecture makes it fast and easy to integrate with any downstream equipment we choose.” Universally PC-based: from PLC to motion control to safety solutions The control platform of the Welex sheet extrusion lines is based on a C6640-0040 Industrial PC with an Intel® Core® i3, dual-core processor running Windows 7. Justin Kilgore explains: “The C6640 has been our workhorse for many years and is used on a number of our systems. It provides ample processing power for anything we’ve thrown at it, and has proven to be a reliable control platform.” Digital EtherCAT I/O terminals, thermocouple inputs and analog inputs for pressure measurement, all from Beckhoff, provide high-speed communication across the machine and with all field devices, including those for safety.
“Standard on the sheet extrusion machines are EL-series TwinSAFE I/O terminals, networked via Functional Safety over EtherCAT (FSoE) to implement numerous safety functions in the system,” as Kilgore explains: “We use RFID-enabled switches for safety doors, as well as numerous emergency stops. Some applications also integrate a light curtain into the control system via TwinSAFE. With this integrated solution, we can dispense with standalone safety controllers. The built-in diagnostic functionality in EtherCAT helps us precisely pinpoint any errors and push notifications to operators, increasing machine value.” Customized Control Panel forms robust machine front end The XSL Navigator® control system integrates a customized Beckhoff CP3921 multi-touch Control Panel with 21.5” screen, providing superior access to machine data via the HMI software. “The Beckhoff control panels provide a modern and elegant look that enhances the appearance of our machines. In addition, integrating the push button extension and an RFID reader into the panel adds a high level of security, functionality and a uniqueness that sets our solutions apart in the industry,” notes the engineering expert.
Openness of TwinCAT permits integration of customer expertise The machine control is based on TwinCAT PLC software and Graham Engineering Corporation takes full advantage of the numerous programming tools offered by TwinCAT. Justin Kilgore explains: “Overall, the TwinCAT development environment gives us the flexibility to program all necessary process functions, regardless of the machine type or application we’re working on. We were also able to develop our own software libraries, including everything from PID temperature control to function blocks for integrated winder control. The ability to create a library of function blocks that we can then reuse across all of our extrusion lines is another way Beckhoff helps us maximize the value of our intellectual property (IP).” Cost savings all along the line “In terms of hardware costs, we’ve achieved cost savings of approximately 15 percent by switching to PC-based control, mainly due to the reduced wiring and installation labor cost,” Justin Kilgore explains. “When we discussed the introduction of TwinSAFE, we quickly identified potential savings: routine queries are eliminated and the search for error sources can be minimized.” XSL Navigator is now the standard controls system for Graham Engineering Corporation’s Welex sheet lines. The demand for plastic products will not slow in the foreseeable future, and Graham Engineering Corporation has the tools and expertise to continue innovating for the market via best-inclass solutions engineered to meet this demand. For more information,
A customized 21.5” CP3921-1009 multi-touch Control Panel serves as the front end of the Welex® sheet extrusion line. Picture credits/Copyright: Graham Engineering, USA
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Website: www.beckhoff.co.in/C6640 www.grahamengineering.com Email: info@beckhoff.co.in
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AMT SECTION
TECH TRENDS
AMT SECTION LEARN MORE ABOUT AMT’S CHENNAI TECHNOLOGY CENTRE AMT’s Chennai Tech Centre (CTC) is located in the MEPZ duty free zone just 7 km from the Chennai airport. It encompasses an area of 1,500 sq.m., including a 650 sq.m. technology demonstration area. Operational since May 2011, CTC has successfully served as a bridge between the Indian manufacturing sector and American advanced manufacturing technology. To learn more, please contact or visit CTC: AMT - Chennai Technology & Service Centre A 44 - Phase 1, MEPZ, SEZ Unit Tambaran, NH 45, Chennai - 600 045 Tamilnadu, India Phone: (+91) 44-22622690-92 Fax: (+91) 44-22622693 Arun Mahajan General Manager AMahajan@amtonline.org Cell Phone: (+91) 9790887032
WWW.AMTINDIA.ORG
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AMT SECTION Cut through challenges. 4TEX® & NOVITECH™
4-sided indexable inserts reduce your cost per hole
Enlarged twisted coolant hole design allows for superior chip evacuation
Holder rigidity is designed to improve hole size and straightness
Absorber mass Damper module with viscoelastic bearing
Chips Formed in Stainless Steel Application The surface quality tells it all.
Competitor
M
Precision boring head with standard steel extension
4TEX®
Precision boring head with Wohlhaupter® NOVITECH™ intermediate module
BORING
REAMING
BURNISHING
THREADING
DRILLING
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SPECIALS
Email: info.in@wohlhaupter.com | Phone: +91 11 41827044 Holemaking Solutions for Today’s Manufacturing JUNE 2019
www.wohlhaupterindia.in
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AMT SECTION
TECH TRENDS
KSPT : The technology competence through innovation
K
YOCERA SGS Precision Tools (KSPT) is focused on providing innovative and specialized tooling solutions. Through testing and development, the KSPT team focuses on the latest technical competence and machining techniques to bring a continuous stream of new products and advancements to market. Our engineering team is committed to continuous improvement and optimizing machining parameters. KSPT has a dedicated technical team with a heightened aptitude for materials, applications and customer centered solutions within the highperformance machining industry. We test materials, tools, applications and coatings and engineer designs for improvements and operational advancements. The portfolio of KSPT products and services offer an unparalleled track record in performance, cost savings, quality and VALUE AT THE SPINDLE®. Certain stainless steels like 440C can be challenging to work with due to the varying carbon content. This can make the material gummy and difficult to create a proper chip. The use of the proper tool becomes so crucial that you may need a modified version of an existing tool to get the job done. KSPT engineers, Using the latest in engineering design and grinding capabilities, Series 33 High Performance End Mills are ideal for aggressive ramping, pocketing, and slotting in difficult to machine materials such as Stainless Steel, Titanium, and Inconel. Designed for applications challenged by heavy chip evacuation, this 3-Flute design offers increased chip clearance and a reduction in harmonics. The proprietary 3-Flute design allows for
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more controlled chip formation and efficient chip evacuation. Specially engineered stepped core design provides stability for aggressive ramping and rigidity when flutes are completely engaged. Open design at the axial end accommodates material flow and load reduction during operations. Variable geometry design provides superior chatter and vibration suppression during aggressive milling. Available with KSPT Patented Jet Stream Technology for precise coolant placement. Exclusively coated with Ti-NAMITE-A, which helps to prevent edge build-up while ensuring superior wear and enhanced tool life. Series 33 is exclusively available with the abrasive resistant AlTiN hard coating, Ti-NAMITE-A. With excellent thermal and chemical resistance, TiNAMITE-A allows for dry cutting and improved performance of carbide. The coating has a high hardness ensuring the ultimate protection against abrasive wear and erosion. Ideal for cast iron, high temperature alloys, titanium, steels, and stainless-steel applications. A KSPT sales engineer, with use of the series 33 high performance end mill was able to turn one customer’s problem into an opportunity for dramatic improvement. Working with
the end user to understand their needs, KSPT approached the application with a 1” Series 33 End Mill, allowing for increased tool life and greater feed rates to improve cycle times. The results were astonishing. The changes made to the application combined with high-performance geometry of the KSPT Series 33 End Mill resulted in an annual gain of 104.25 production hours. In addition to meeting the goal for improved cycle times, tool life was increased from 20 to 240 parts per tool. This reduced the tooling cost per part by 91%, allowing the end user to achieve a total annual cost savings of $263,100!
For more information, KYOCERA SGS Precision Tools Tel: (800) 447-4017 Email: webmaster@kyocera-sgstool.com Website: www.kyocera-sgstool.com
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TECH TRENDS
IMTMA Technology Centre Launched Mastercam Certified Training Programme for Practicing Engineers and CNC/CAM Programmers
I
ndian Machine Tools Manufacturers Association (IMTMA) Technology centre, Bangalore, in association with Mastercam India, has launched the Mastercam Certified Training Programme for Practicing Engineers and CNC/CAM Programmers. This initiative, a first of its kind, integrates content from Mastercam University™ and the knowledge of experienced trainers to deliver a CAM training package suitable for young engineers and seasoned CAM programmers. After successful completion of the programme, candidates will be awarded a joint certification from IMTMA and Mastercam, for global recognition. This programme encompasses many concepts of CNC programming, G-codes, M-codes, cutting tools and machining parameters; how to set work and tool offset on CNC VMC; concept of CRC using G41 and G42 programming and simulation; cycles used for programming and operation; hands-on operation on CNC vertical machining centre; measurement and dimension control using wear offset; hands-on exercises for programming and operation; geometry creation in Mastercam; importing and programming 3D models; selection and modification of geometry; machining components with different strategies like face milling, contour milling, pocket milling, drilling, etc.; selection of tools and parameters into the CAM system; toolpath creation and simulation; and post processing and generating NC codes. Speaking on the occasion, M. Krishnamoorthy (Sr. Director, IMTMA) said: “The IMTMA Technology Centre is well known for providing quality training towards skill devel-
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opment that assists manufacturing growth in the country. In line with this thought, we have conducted several thousand days’ worth of training during April 2018 – March 2019. 3344 industry professionals / students participated and benefitted through the 202 training programmes & courses delivered by IMTMA, pan-India. CAM is a very important component within advanced manufacturing, and we’re happy that companies like Mastercam are providing knowledge base to help aspiring CAM programmers and manufacturing managers excel in their fields.” Vineet Seth (Managing Director – Mastercam India & South Asia) shared: “We’re excited about the new training programme launched by IMTMA. Mastercam is the world’s most widely used CAM software, as validated by CIMdata and it’s a very popular CAM system amongst CNC programmers – worldwide. Joint certification by IMTMA and Mastercam will help candidates receive industry accreditation and thereby increase their chances
of gainful employment when applying for a Mastercam programming position. We are fortifying the programme by keeping the IMTMA trainers up-to-date with the latest in our software and interactions with our CAM experts who have extensive knowledge of CNC programming and advanced manufacturing techniques.” David Moskey (Territory Manager – India and South Asia, Mastercam USA) adds: “I’m amazed by the great work that the IMTMA is doing in the Indian sub-continent, especially in the areas of Skill Development and Career enhancement of Manufacturing professionals. This is very unique to what I have seen in most parts of the world where we do business, and it’s very encouraging to be a part of the journey for a new growth story in the region. We look forward to taking this programme to greater heights.” For more information: Mastercam Website: www.mastercam.com.
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SPECIFICATIONS:
Metric
English
Tons Capacity . . . . . . . . . . . . Adjust . Stroke Length . . . . . Speed Range (SPM) . . . . . . . Slide Adjustment . . . . . . . . . Quick Lift . . . . . . . . . . . . . . . Passline Height . . . . . . . . . . Area of Slide, R-L x F-B . . . . Area of Bed, R-L x F-B . . . . . Opening in Bed R-L x F-B . .
630kN . . . . . . . . . . 71 25-75mm . . . . . . . 0 .98-2 .95” 275-500 . . . . . . . . . 275-500 75mm . . . . . . . . . . 2 .95” 25-100mm . . . . . . 0 .98-3 .96” 100mm . . . . . . . . . 3 .94” 1000 x 630mm . . . 39 .4 x 24 .8” 1000 x 630mm . . . 39 .4 x 24 .8” 876 x 229mm . . . . 34 .5 x 9”
STANDARD FEATURES: • Vamco High Speed Quantum Feed • Minster Production Management Control • Hydraulic Shutheight Adjustment Lockup • Quick Lift Slide • One-Piece High Tensile Cast Iron Frame • Low Bed Deflection • Die Lubricant Troughs • Counterweights on Crankshaft • Combination Hydraulic Clutch and Brake
Vamco High Speed Quantum 14 Servo Feed Max. Material Width ................... 14” Max. Material Thickness ............... 0.188” Color flat panel display; GOS software; upgraded in 2013 to shoe box style computer
• Air Operated Flywheel Brake • Pressurized Monitored Lubrication • High Accuracy Piston Slide Guiding System • Large Hydrostatic Piston Drive • Special Gerb Spring Mounts • Die Safety Block Receptacle • Eddy Current Main Drive Motor • Four-Channel Load Monitor • 16-Point Die Protection
For information Contact: Avijit Dutt Avijit.Dutt@Minster.com +91 9845034656
AMT SECTION
TECH TRENDS
Electronic carbide metal impregnator applies a hard & wear resistant surface The portable rocklinizer allows wear prevention and maintenance to be easily performed in your plant.
S
oldering of the aluminum, magnesium or zinc casting material to the die surface is also a cause for rejection of many castings. Treatment with carbide prior to a production run has eliminated soldering at gates,vents, parting lines, and the die cavity where molten metal has a tendency to solder to the cavity. Less Lubrication is needed resulting in a much better finish on the die casting. These are some of the successful uses of the Rocklinizer (Carbide Metal Impregnator) especially in the die casting industry. There are hundreds of die casters throughout the world who regularly use the Rocklinizer equipment for both preventive and regular die maintenance. Your company can enjoy the cost savings generated from using this equipment. Improving wear and thermal fatigue of die casting dies The patented ROCKLINIZER process has been successfully used for many years to improve die casting technology, especially for aluminum, magnesium and zinc. The ROCKLINIZING technique protects wear areas of dies with tungsten carbide / titanium carbide electrode material. The ROCKLINIZER electronically applies wear resistant electrode materials by spark deposition process. Material is impregnated both underneath and on top of the workpiece surface metals, tools and dies. Tungsten
Minor cracks in the die can be Rocklinized as long as they havenâ&#x20AC;&#x2122;t gotten too wide.
Carbide electrode is applied to prolong useful life and reduce wear. Solid carbide tooling is given a sealant coating with the titanium carbide electrode. The â&#x20AC;&#x153;Rockhardâ&#x20AC;? or build-up electrode is used to restore undersized dimensions, and for maintenance. Deposit capabilities range from (.0025 mm) to approximately (0.178 mm) in a single application controllable within (.0025 mm) by machine dial setting. Specific advantageous applications for die casting include: Heat check (thermal fatigue which results from the stresses created by alternative heating and cooling of the die surface during the casting process) Rocklinizing reduces the tendency for heat checking to occur on a new die by treating all dies with tungsten carbide / titanium carbide on a preventive maintenance basis. Also, dies can have extended overall life as well as longer runs without maintenance if Rocklinizing is applied before heat checking exceeds the limit of acceptable quality standards.
Galling and Seizing of Cores - The thermal expansion of aluminum, magnesium and zinc die cast metals is much greater than that of the steel core. The metal shrinks onto the cores, thus resulting in extreme pressure at the core section. When applying Rocklinizing to the cores, it will appear that the core is too rough for releasing the casting. However, this roughness is so shallow that the core actually makes the casting smoother as the aluminum, magnesium or zinc will not adhere to the core as it does to a core that has been stoned to a high polish. The cores with the carbided surface make the lubricant or die releasing agent adhere better to the steel thereby providing a nice finish on the cast parts. Fits on Slides - Carbide has been successfully applied to rework areas of fits on slides and has reduced galling. Ejector Pin Flash can be eliminated if the die is in fair condition before treatment. National Distributors
Sanjay Tools & Adhesives X20, MIDC Ambad, Nashik 422010 Suhas Belapurkar Mobile : +91 9892516810 Email: sbelapurkar@sanjaytoolsnsk.com
Runners, Overflows, and Vents - The vents on a die stay much cleaner when they have received a carbide coating.
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Mr. Mandar Gokarn Mobile: +91 9822028518 Email: mandar@sanjaytoolsnsk.com
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INDUSTRY SPEAK
INDUSTRY 4.0 ARE WE READY?
Mr. Satish Bhat, Managing Director, Ador Welding Ltd.
In India, the adoption of Industry 4.0 is still at a nascent stage. High investment outlay will have to be planned in order to implement it as Industry 4.0 requires the utilization of a wide set of technological platforms, says Satish Bhat. Q. Whatâ&#x20AC;&#x2122;s the level of automation at your end? Ador Welding has automated several of its manufacturing processes; our clean room with a fully automated assembly line for the assembly of inverter welding equipment; the only such clean room in the country, fully automated ready dry mix flux units that dispense through a fully
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automated setup very accurately the exact quantities of minerals and alloys of varying densities giving our products unmatched quality; automated spool dispensers, conveyor lines for subassemblies, automated wet drawing lines, QR codes for equipment as we move towards industry 4.O implementation, Automated edge
winding equipment; Multipoint auto greasing arrangement interlinked through PLCs and many more projects have been implemented at our plants and many more are in progress. Q. Are we ready for Industry 4.0? Intelligised welding; Weld 4.0 is a part of the latest industrial revolution
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INDUSTRY SPEAK
industry 4.0. Interconnectivity among welding power sources, software, and manufacturing decision makers makes this possible. This involves intelligent power sources, robots, specially configured data collection and storage systems and a weld monitoring software that can feed the information to various platforms either on a smartphone or on a flat screen tv in the engineering office. The software used will have to be flexible to be able to sync with the equipment in the process flow and provide a complete flow of the entire welding process. In Asia, India is way behind its developed counterparts such as South Korea, Japan and Singapore and even behind China in terms of Industrial Automation. In terms of installed robot capacity in Indian factories, for every 10,000 factory workers, there are only 3 installed robots. The Automobile Industry where the number of installed robots is 58 for every 10,000 workers, is nearly 19 times more than the national average of just three. Though the government has been pushing for more indigenous production, the biggest problem in India is its lack of a skilled workforce. The number of trained people that can understand the sophistication of seamless integration, which collects / analysis data, right from the shop floor to the enterprise level, using it to improve manufacturing in real time, is far too low as compared to its developing and developed counterparts. Promotion of local production and start-ups would help bring about a meaningful change. Govt of India’s “Make in India” initiative will encourage Indian
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manufacturers to look at technology enhancements and evolve rapidly to meet the ever-changing requirements of the market Q. What will be its impact on the manufacturing sector? And benefits? Manufacturing has emerged as one of the high growth sectors in India. Attracted by India’s market of more than a billion consumers and increasing purchasing power, global giants have either set up or are in the process of setting up manufacturing plants. In India, the adoption of Industry 4.0 is still at a nascent stage. High investment outlay will have to be planned in order to implement it as Industry 4.0 requires the utilization of a wide set of technological platforms. It also has to address the need of appropriate infrastructure and education to handle such technologies. Penetration of Industry 4.0 will vary as per sector needs. Seamless end-to-end communications ensuring greater flexibility will aid Industries with large product portfolio’s such as the automotive industry, while industries which demand high quality such as pharmaceuticals will benefit from the churned data, enabling improvements that reduce error rates. While capital-intensive sectors such as Automotive are already gaining from adoption, other industries, in order to actively shape the transformation and reduce the total cost of ownership, have developed optimal solutions through forming common platforms and alliances with many different partners. As the industry uses smart materials by 2020 there will be
significant opportunities to program and control subsequent welding operations. This new technology will be exploited by product designers, manufacturers and welders to improve the entire manufacturing cycle. The virtual factory is a term that will be heard frequently over the next 20 years as computer modelling and simulation tools become common place in welding operations. Welding will move from being an ’art’ to a manufacturing science with the help of computers. Q. What are the challenges in the implementation of Industry 4.0? In India, various industries are still in the dilemma of identifying the right technology that can best address their needs. While high cost of digital technology is a major concern, what exactly do they hope to transform is still an uncharted territory. Lack of infrastructure, both physical and digital, have further dampened the scenario. The lack of knowledge with new age technologies such as IoT, data analysis, etc, both at the plant and leadership level have further added to the crunch currently being faced. Significant contributions will be a key factor in up-skilling the workforce capable of handling digitalisation creating a more adaptable, responsive and unified environment empowered in making more informed decisions.
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Complete Lubricant Solutions for all your Machining Processes
F
UCHS LUBRICANTS (INDIA) PVT. LTD. is a wholly owned subsidiary of FUCHS PETROLUB SE, Germany, the world’s largest independent lubricants manufacturer. Founded in 1931 by RUDOLF FUCHS, the group is manufacturing a comprehensive range of lubricants and derived specialties for a wide range of applications. Great emphasis is placed on research and development in the FUCHS group. The company currently has more than 600 ongoing research and development projects that aim to evaluate the potential of new technologies such as nanotechnologies or minimum quantity lubrication. These projects are supported by around 400 engineers and scientists at 25 laboratory locations throughout the world. FUCHS engages in applicationoriented development directly at and in cooperation with the customer with the aim of adapting lubricants optimally to the process and machinerelated requirements. FUCHS lubricants stand for performance and sustainability, for safety and reliability, for efficiency and cost savings. They represent a promise – Technology that pays back! In manufacturing today, the demands made on cutting fluids have increased enormously. As part of the Industry 4.0 concept, the entire addedvalue chain of people, machines, logistics and cutting fluids should be interlinked and optimized to achieve largely self-organizing production with the help of advanced IT and communications technologies. For this, cutting fluid measurement data must be accessible online, evaluated
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FUCHS cutting fluids are suitable for latest machine tools because they are: • Free of nitrosamine-forming secondary amines • Free of hard complexing agents • No Corrosion to Machine Internal parts • Skin compatible • Compatible with Paint, Seals and Elastomers • Single Product for Multiple Metals and alloys • Non -Foaming behaviour till 80 Bar coolant pressure • REACH compliant and corresponding adjustments made. For measured data to be accurately analysed, high stability cutting fluids are essential. FUCHS products work closely with world’s leading Machine Tool manufacturers. FUCHS is the specialist for metalworking operations. FUCHS metalworking fluids, water-miscible and neat cutting fluids are safe and reliable and fulfil all legislative requirements so that their use can be judged to be almost risk-free. The sustainability of our ECOCOOL, ECOCUT, RENOFORM, ANTICORIT products were factored into their formulations. FUCHS cutting fluids thus offer long service life. FUCHS offers full range of products for nearly all Metal Cutting, Grinding, Forming, Stamping, Thread Rolling, Broaching, Hobbing, Cleaning, Corrosion protection solution. These products are inter-operation process compatible hence it offers reduction in cost per component. FUCHS offers full ownership by offering CPM (Chemical Process Management) to production units.
Our experienced engineers are well trained and experts in providing competent, on-site advice on product selection and the best service with the aim of reducing process times and complexity and optimizing tool life and process efficiency. The interaction between manufacturers, users, developers and researchers generates successful synergies and new product and process innovations which drive the development of advanced lubricants. FUCHS has a perfect cutting fluid for every machining operation operation in the metalworking industry. Just contact us, we will be glad to be of assistance.
For more information, TEAM FUCHS INDIA Phone: +91 22 6625 5900 Email: marketing@fuchsindia.com
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TECH TRENDS
The Process of Phosphating Some FAQs by Gala Precision Technical Team Q. What Is the phosphating Process? Phosphating is the process of converting a steel surface to iron phosphate. This is mostly used as a pretreatment method in conjunction with another method of corrosion protection. A layer of phosphate coating typically includes iron, zinc or manganese crystals. Phosphating is a chemical process for treating the surface of steel, where barely soluble metalphosphate layers are formed on the base material. The layers created are porous, absorbent and suitable as a conversion layer for subsequent powder coating without further treatment. Q. Why is phosphating done? The process of Phosphate coating is employed for the purpose of pretreatment prior to coating or painting, increasing corrosion protection and improving friction properties of sliding components. Metal coating offers both zinc
Galaâ&#x20AC;&#x2122;s Phosphating Plant
phosphate and manganese phosphate coating. Manganese phosphate coating is applied when wear resistance and anti-galling properties are required. Manganese phosphate also possesses the ability to retain oil, which further improves anti-friction properties and imparts corrosion resistance to the coated parts. Zinc and manganese coatings are used to help break in components subject to wear and help prevent galling. Most phosphate coatings serve as a surface preparation for further coating and/or painting, a function it performs effectively with excellent adhesion and electric isolation. Q. Why is phosphating done before powder coating? The process of phosphating aluminum and steel parts is typically
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listed as a conversion coating because the process involves metal removal as part of the reaction. However, it is not like anodizing or black oxide in that the phosphate coating is actually a precipitation reaction. Q. How many types of phosphating are there? 3 Types of Phosphating. Phosphating is a conversion coating applied to Steel and Iron components. In its basic form, the process involves immersing a component in a dilute solution, which converts the surface of the metal into a layer of microscopic Phosphate Crystals. Q. How does phosphate prevent corrosion? Corrosion resistance and resistance to detergents are also higher when compared to Zinc Phosphate.
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More Precision Precise laser scanners for profile & gap measurement scanCONTROL Compact design with integral controller For high speed, high precision measurements Comprehensive software included Easy set up using predefined measurement programs Choice of interfaces for direct connection to PLC Blue laser scanner for red-hot glowing and organic objects
+91 20 2674 1009 | info@micro-epsilon.in | www.micro-epsilon.in
TECH TRENDS
Appearance is gray. Manganese Phosphate: Used primarily on friction and bearing surfaces to prevent metal-to-metal contact and reduce wear. This coating is also used as a base for dry film lubricants. The following is a typical phosphating procedure: Cleaning the surface, Rinsing, Surface activation, Phosphating, Rinsing, Neutralizing rinse (optional), and Drying. Q. What are the main applications of phosphating? The main applications of phosphating are: • Corrosion protection in conjunction with organic coatings, such as paints and polymer films • Facilitation of cold-forming processes, such as wire drawing and tube drawing, or deep drawing • Corrosion protection in conjunction with oils and waxes • Corrosion protection with no subsequent treatment • Improving anti-friction properties, such as break-in, wear resistance, anti-galling and coefficient of friction • Providing strong adhesion bonding for subsequent painting or other organic coating Q. What are the highlights and salient features of Gala’s Phosphating Plants? The phosphating process comprises
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alkaline degreasing, water rinsing, activation, manganese phosphate application, water rinsing again, protective oiling and then drying in that sequence. Gala’s multi-stage phosphating plants are compatible for use with all modern phosphate formulations with multiple process stages to include degreasing / phosphating and multiple rinse cycles. Ideal for batch processing, these units are operatorfriendly with easy-to-use control systems to set independent fluid tank temperatures and cycle times. The component basket is rolled from the wash machine on to an external fixed or mobile platform for easy loading and unloading of the components. Corrosion resistant electric immersion heaters and stainless steel wash pump are fitted as standard accessories. Sturdy construction with thick thermal insulation, heavy duty stainless steel component basket, component holding jigs, fully independent fluid tanks, low fluid level protection, integral fluid filtration network,
electric heating, load / unload station, auto fresh water refill in rinse tanks and digital display fluid temperature control are some of the prominent features of this totally PLC controlled system. Gala also offers the following optional extras with the system: Hot wash, rinse, air knife & dry cycles to suit the application; Disc type oil skimmer; Fine inline fluid particle filtration; Oil / water separator units; Effluent transfer pump; Steam extraction fan & condenser units; Auto dosing units and DI water plant. Gala Precision Engineering is a leader in disc springs, assemblies and surface engineering solutions in India. The company designs and manufactures integrated systems for mass finishing, washing & cleaning for a wide range of applications in automotive, defense and general engineering segments.
For more information, Website: www.galagroup.com
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The success story continues! 2nd generation of small controllers PNOZmulti.
1:0 to you because our safe small controllers support all communication systems installed worldwide. 2:0 to you because you rely on the global safety standard for all machine types and automation environments, which is cost effective and sustainable. 3:0 to you because ready-made software blocks and universal diagnostics reduce your commissioning and operating costs. 4:0 to you with the safe, complete solution comprising sensor technology, drive technology, operating and monitoring. Small controllers PNOZmulti: many functions â&#x20AC;&#x201C; one solution!
For further information on small controllers PNOZmulti: www.pilz.com/pnozmulti, webcode: web150500
& Co. 73760 Ostfildern +910711 3409-0 info@pilz.com Pilz GmbH India Pvt. LtdKG Pune 411042Â (0) 20 49221100 info@pilz.inwww.pilz.com www.pilz.in
TECH TRENDS
Zero Lubrication, Low Noise: Speedy Rail by Rollon
Rollonâ&#x20AC;&#x2122;s linear rails with plastic compound coated rollers can work for over 80 thousand km with practically no maintenance. This drastically reduces machine down time, provides a crucial advantage for improving productivity in automated processes, and makes our clients more competitive.
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0,000 Km without planned maintenance. This is the main strong point of the selfsupporting Speedy Rail product by Rollon, which is specialized in linear motion solutions. Integrated into the companyâ&#x20AC;&#x2122;s range after the acquisition of TMT, Speedy Rail is an important tool for optimizing productivity in automation processes, reducing operating costs and eliminating machine down time intervals due to re-lubrication operations. This is an important advantage for efficiently fulfilling the needs of our clients with regard to automated applications in the automotive, packaging, and
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medical machines sectors, as well as different processing operations for materials such as metal sheet, ceramics, marble, glass, wood and metals. Which technical features make this type of performance possible? Letâ&#x20AC;&#x2122;s find out. A low noise producing system that requires zero lubrication Speedy Rails are structural selfaligning structural rails made of hard, deep anodized extruded aluminum and steel bearings coated with plastic. This material, combined with the lifetime lubrication of
rollers with high performance grease, renders maintenance on the rails and rollers almost unnecessary. In fact, they can work up to 80,000 km without requiring any maintenance operations. Even in the dirtiest environments, Speedy Rail guarantees excellent results: the special plastic compound used to make the rollers allows them to work without protection even if in environments with welding spatter and abrasive dust, such as workshops where ceramics and tempered glass are produced. Rails designed to work without lubrication offer many benefits in addition to saving
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Linear solutions global provider.
Linear Line
Actuator Line
Telescopic Line
Actuator System Line
ROLLON India Pvt. Ltd. - INDIA 1st ďŹ&#x201A;oor Regus Gem Business Centre 26/1 Hosur road, Bommanahalli Bangalore 560068, INDIA www.rollonindia.in - info@rollonindia.in
Rollon is a global provider of linear motion solutions for several industrial sectors, such as: industrial machines, railway, automation, packaging and logistics, aerospace.
TECH TRENDS money and increasing productivity, which, nevertheless, are certainly very important. Dispersion of oil and grease into the work environment becomes a thing of the past, along with noise. Thanks to the plastic coated rollers and the rail structure, Speedy Rail guarantees very silent operation, in compliance with increasingly strict laws and standards that classify noise as a significant risk in the production environment. Quick assembly and self-alignment... Resistance and reliability go hand in hand with speed and easy assembly: this single product is made up of self-aligning rails with a structure and sliding system that requires only a few support points instead of finished metalwork structures. Moreover, simple joining kits are all that is necessary to ensure that the rails can withstand an unlimited stroke (these self-centering mechanisms have plates and dovetail joints). For parallel rails, the Speedy Rail rollers and supports are able to compensate for parallelism errors of up to 8 mm. This high flexibility means that installation time is reduced to a minimum, regardless of the production sector, and this advantage
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saves a considerable amount of money. …without giving up high performance Speedy Rail guarantees high performance, with speeds up to 15 m/s and accelerations up to 10 m/ s2. The product also offers a great load capacity, higher than 3,000 kg for gantry configurations with 4 sliders and 8 rollers. They can be used as linear rails or actuators, and can be operated with a belt or rack and pinion drive. They are available with V type and cylindrical rollers, in five different sizes: 60, 90, 120, 180 and 250mm. In addition to individual components – rails, rollers and supports – with which clients can build their own systems, a wide range of linear models is available with belt or rack and pinion drives. If necessary, these systems can be customized. The Rollon technical office is happy to help clients during each phase, from defining their system layout to start up, and offers technical assistance for the entire product life cycle.
in Italy and offices in Germany, France, the United States, China, India, and Japan. It produces linear and telescopic rails and actuators for many sectors, such as railway, aeronautical, logistics, packaging, machine tools, and medical. Numerous end markets and a vast clientèle are Rollon’s strong points. The company is known for high quality standards in its products, pre-sales support and product customization. All these characteristics have made it a leader outside of Italy as well, where 85% of production is sold. Thanks to the its growth strategy in recent years, the Italian company has positioned itself as a provider of increasingly complete linear motion solutions, while strengthening its position in the industries of automation and robotics. For more information: ROLLON INDIA Pvt. Ltd. 1st floor, Regus Gem Business Centre 26/1 Hosur road, Bommanahalli Bangalore 560068, INDIA Tel: +91 80 67027066 Fax: +91 80 67027004
Information about Rollon Rollon Group has its headquarters
Email: info@rollonindia.in Website: www.rollonindia.in
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TECH TRENDS
Multi-dimensional automation
2D/3D laser scanners guarantee production quality using red and blue laser diodes As well as determining one-dimensional sizes (material thick-ness, vibrations and distance), processed multi-dimensional quality controls (profile and contour measurement) may also be required during the production process, where optical non-contact metrology is ideal due to its high precision, measure-ment speed and flexibility with respect to the surface of the measurement object. Laser scanners carry out complex 2D/3D measurement tasks.
T
he laser line triangulation principle is based on the light intersection method. The point-shaped laser beam is extended to a line via special lenses. Together with the distance information (z-axis), the integrated controller calculates the position of the measurement
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point along the laser line (x-axis) and outputs both values as 2D coordinates. If the measurement object or the sensor is moved, a 3D image of the object is provided. The scanCONTROL 2600/2900 series of laser scanners from Micro-Epsilon detect up to 2.56 million points per second.
The laser scanners owe their compact design to an integrated controller. The sensor is the size of a cigarette packet and stands out due to its comprehensive range of features. Up to 4,000 profiles per second can be transmitted to a PC for further processing. At the same time, digital inputs can be
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TECH TRENDS used for synchronisation, triggering or as encoder in-puts. 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 scan-CONTROL laser scanner is used for profile and contour measure-ments during running production processes of high volume, continu-ously produced goods (extrusion, milling, drawing, etc.) or single piec-es. An extremely powerful integrated controller unit and Ethernet inter-face make the laser scanner suitable for use with robots and for dy-namic production technologies e.g. in the automotive production when mounting the windscreens. A laser profile scanner serves to measure the height and position of the adhesive beading on the screen edges. The laser scanners that use a red laser diode are universally applica-ble. This proven technology is widespread,
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and the components used are therefore produced in large volumes and at relatively low cost. For extremely difficult surfaces, Micro-Epsilon offers its scanCONTROL 2600/2900 BL series of laser profile scanners that use a blue laser di-ode. These laser profile scanners are used, for example, in steel forg-ing plants in order to measure redhot glowing rail tracks and bogies. The red glow normally “dazzles” red profile scanners, but blue scanners remain unaffected. Of course, such an application requires spe-cial protection measures (cooling, protection housing) that can with-stand the high ambient temperatures in a forging plant. In the case of (semi-) transparent materials, the blue laser line penetrates significant-ly less into the surface than the red laser. Particularly with white plas-tics, the red laser point penetrates into the measurement surface. When penetrating the material, the measurement line expands, result-ing in
a blurred laser line. Also with organic materials, the slight pene-tration behaviour of the blue laser results in higher measurement ac-curacy. There is an increasing demand for high precision measurements in automated processes, and optical measurement methods are becom-ing increasingly popular. They can perform dimensional measure-ments, capture measuring points much faster, and measurement data is typically available in real time in digital format. This enables the au-tomatic correction and control of live processes, of which the aim is to produce “good parts” only.
For more information, Website: www.micro-epsilon.in
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TECH TRENDS
Vibration measurement in process monitoring
M
easurement of vibrations and accelerations plays an important role in process monitoring on machine tools. Vibration measurements are used in different ways for the safeguarding and stabilization of processes: as signals from the machine control or from external sensors. Vibration measurement is made as close to the process as possible. Sensors are integrated directly into the spindle or placed on the workpiece holder. How is acceleration measured? Acceleration can be measured with a sensor integrated into the spindle or with external sensors placed in the machine. A transducer then converts the values for the process monitoring system into information about the vibration speed. ARTIS offers sensors in the measurement range between 10 Hz and 5 kHz for acceleration measurement on one to three axes. Acoustic emission, a special form of vibration, is measured with external sensors and transmitted over a separate fieldbus. The sensors for acoustic emission cover the measurement range of 10 to 250 kHz. With learning curve In mass production, monitoring
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is performed using a comparison procedure. A learning curve is generated over one or more machining processes; signal peaks and troughs are used to monitor breaks; and the area under the curve (cutting work) is used to monitor wear and missing. Collision monitoring as well Acceleration sensors can be used for collision monitoring. When tool and workpiece collide, which the sensor detects from the sudden change in material vibration, the machine shuts off immediately. Here, the measurement means a gain of approx. 200 milliseconds until the machineâ&#x20AC;&#x2122;s overload protection would take hold. It is exactly during this time after a collision that serious damage results, because the machine at first â&#x20AC;&#x153;reactsâ&#x20AC;? to resistance with increased power. Not detectable with the naked eye Run-out errors in the workpiece, e. g. during centerless grinding, cannot be detected with the naked eye, but generate clear signal peaks, which provide an early warning of problems and which schedule the workpiece for rework. Vibration measurement thus contributes to quality assurance, supported by
process monitoring systems. Optimization in the ongoing process Vibration measurement is also used for process optimization, such as in gear cutting with profile milling cutters. Tool wear here depends on the vibration speed of the tool. Experiments show that an increase in cutting speed of only 10 % results in a significant decrease in the vibration speed. So here, optimization can be achieved by simple means. Additionally, with Adaptive Control, the vibration behavior at the milling head can be optimized in the ongoing process. Comprehensive Process monitoring looks at the entire process complete with workpiece, machine tool and peripheral equipment. The knowledge gained can be used in many ways for safeguarding production. The examples described show the benefits of vibration measurement for process monitoring, machine protection and process optimization.
For more information, Website: www.marposs.com
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TECH TRENDS
Global Manufacturing sector: The changing paradigm
H
istory has manifested that technology moves faster than management. Past few decades have been phenomenal not just in bringing new technologies but also the speed of adoption, assimilation and application of these technologies in multiple areas. The technological changes have brought in multiple opportunities for exponential growth for organizations but with risks associated with it. The life span of companies has significantly reduced and hence it has become important for companies to adapt these technological changes but be very cautious of the risk associated with it. Global manufacturing sector is on the verge of mammoth industrial revolution. The changes are generally based on the adoption of new technologies aiding progressive automation of the production processes for prototyping and mass customization. As industry leaders compete to drive change in their organizations to take advantage of this technological revolution, it is advisable to be insightful and evaluate the risk associated with each strategic commitment. Manufacturing industries are diverse by their inherent nature. While some are more labour intensive others are more knowledge- intensive. For some of the organizations, proximity to the customers is the key for success while others are dependent on efficient transportation. Organizations need to evaluate the technologies that are suitable for them. While 3D printing has been very successful for aerospace sector, advanced robotics is yet to prove its importance. Globally manufacturing contributes to 16-18% of the world GDP & 1415% of the employment. However,
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the contribution of manufacturing sector to the growth of any economy depends on the phase of development of its manufacturing sector. As countries industrialize, the output and employment grows exponentially but as they reach a particular threshold, they tend to dampen the growth. Growth fuels spending power of the consumer, wages increase and hence intention to spend on services rather than products in isolation thus blurring the boundaries between products and services associated with it (aftersales/ repair/ logistics etc). Chinese manufacturing sector has entered this phase with moderate growth and increase in unemployment due to rise in income levels. At an advance stage of development, manufacturing sector contributes more to innovation, efficiency and research rather than growth and employment. Organizations operating in multinational environment must plan implementation of new technologies considering the stage at of development of the economy in the geographical area (nation) they operate. The economic power of the world is shifting towards East. Manufacturing sector is entering a dynamic phase where developing economies of Asia fuel the growth emanating from increase in number of consumers. Rapid urbanization and growing middle class in these economies spark a plethora of opportunities but with substantial risk. Companies must base their decisions on scenario planning rather than forecasts to handle economic volatility in developing economies. With changing technologies and quest to boost productivity and efficiency, the most critical assets are the human resource. Qualified,
tech savvy workforce with relevant skills sets will be necessary for sustenance for organizations but the ability to accelerate learning curve and adapt new technologies faster than competitors will become a key differentiator for winning. Hence developing an ecosystem that equips skill sets and hone them is a key priority for nation and policy makers. The ecosystem must strengthen public education on one hand and build a seamless network of educational institutes and industry in parallel. One vital area, often neglected, but of paramount importance is to bridge the skillsets gap in organizations where there is dearth of expertise (more particularly Micro, Small and Medium Enterprises- MSMEs in manufacturing sector). These MSMEs are backbone of any economy and crucial for growth and development. Innovators must come up with business models and technologies to address this gap in order to enhance their contribution to global manufacturing sector. SolutionBuggy is an exclusive online platform that aims to truncate the skill deficit in MSMEs operating in manufacturing sector.
Author Vikas Manral Chief Strategy & Marketing Officer SolBuggy Connect Pvt Ltd Email: info@solutionbuggy.co.in, Phone: +91 80 42171111 Website: www.solutionbuggy.com
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TECH TRENDS
PMI : ACTUATOR-CKM series
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Special design to reduce the friction Fixed the strip to the table & combined with the roller design, so that the trip can be drived directly while moving the table and reduce the friction.
• Saving Space CKM SERIES continue the structure and characteristic of KM, as performance it can save the installation space and suit for clean room.
Characteristics • Low dust structure Fully cover design combine pneumatic component and lubrication reduce the dust generating, it will be reach ISO14644-1 and CLASS 4. (equivalent to FED209E CLASS 10) • Various of the product option 1. According to the space used and equipment size. PMI provided the model CKM20, CKM26, CKM33, CKM46. The length and lead equivalent to KM series. If you have special request, please contact PMI for details. 2. PMI provided connecting bracket, the unit is able to mounted from either top or bottom face.
• High Rigidity Base on the optimal analysis of FEM for the shape of U rail, it has the balance between light weight and high rigidity.
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Description of Specification CKM33 05 A +400 P 0 - 0 30 0 AA 1 2 3 4 5 6 7 8 9 10 1. Model 2. Ball screw Lead 3. Carriage-Nut type A:a single carriage with standard length C:a single carriage with short length 4. Rail length(mm) 5. Accuracy grade 6. With/Without a Motor 7. Sensor Specification 8. Type of Motor Bracket Type 9. With/Without a connecting bracket 10. Code of special type Specification Compare
• High Accuracy The design of two rows with Gothic-arch groove and stable manufacturing technology can control the variation by load at the minimum. It can provide the smooth feed with high accuracy.
Web:www.pmi-amt.com
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TECH TRENDS
Engineering innovation brings hope for a Parkinson’s cure Global engineering company Renishaw has built a device that has been used in a groundbreaking clinical trial
M
anufactured by Renishaw on behalf of the North Bristol NHS Trust, the deviceenabled the precise delivery of a new drug candidate, Glial Cell Line Derived Neurotrophic Factor (GDNF) with the hope of regenerating dying dopamine brain cells in people with Parkinson’s and thereby improve their symptoms. The results of the trial feature in a two-part BBC Two documentary, The Parkinson’s Drug Trial: A Miracle Cure? Renishaw worked with Consultant Neurosurgeon, Professor Steven Gill, to manufacture the novel drug delivery system, which offers a practical method to bypass the blood-brain barrier. During the trial, 42 patients had the additively manufactured titanium port embedded into their skull through which GDNF could be delivered via micro-catheters to the putamen, a critical region of the brain for motor function. The device is implanted using the RenishawneuromateTM surgical robot, which positions four catheters into the brain. The trial was funded by Parkinson’s UK with support fromthe Cure Parkinson’s Trust and in association with the North Bristol NHS Trust. Results announced on February 27th showed that the drug delivery system performed effectively and reliablyand a similar device, developed by Renishaw called ‘neuroinfuse™’, is now being used in other clinical trials. “This trial has shown that we can safely and repeatedly infuse drugs directly into patient’s brains over months
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or years through a small implanted port that emerges through the skin behind the ear,” explained Professor Steven Gill.“This is a significant breakthrough in our ability to treat neurological conditions, such as Parkinson’s because most drugs that might work cannot cross from the bloodstream into the brain due to a natural protective barrier. “Even at a low dose we have seen evidence of patient improvement, which is incredibly encouraging,” added Professor Gill.“Now we need to move towards a definitive clinical trial using higher doses and this work urgently needs funding. I believe that this approach could be the first neurorestorative treatment for people living with Parkinson’s which is, of course, an extremely exciting prospect.”
“It has been a privilege to work alongside the study team and with the participants in this ambitious trial,” explained Paul Skinner, General Manager for Neurological Products at Renishaw. “We are very encouraged that there were changes in the brain scans, demonstrating that GDNF is having an effect, and that the delivery system achieved precision administration of drugs into the brain. “This provides great potential for using the drug delivery system, being developed by Renishaw, for future Parkinson’s studies and experimental treatments for other neurodegenerative diseases and brain tumours.”
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Taming power quality is now child's play
When you use DigiVolt Stabilizers, Tranquil Ultra Isolation Transformers and Powercon Power Conditioners from Unity Controls, power quality is under total control and would no more hamper your production and product quality. These silent sentinels protect your sophisticated, high precision production equipment from the ill-effects of voltage, spikes, surges, transients, sags, noise and harmonics affecting AC power lines. Thus ensuring continuous uptime and enhanced productivity and consistent quality.
Intelligent Microprocessor-based, High Efficiency, Energy Savers specially designed for CNC machines
Our equipment are approved by major OEMs and exported (up to 2000 KVA) to countries in Europe, Middle East, Africa
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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!
Contact us for Power Quality & Harmonic Audits to Conserve Energy and Save Costs.
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
l l
vijayshreyaarts@gmail.com
UNITY CONTROLS PVT. LTD
TECH TRENDS
Use of TIP-TIG Technology in Process Equipment Plants by Rakesh Choudhary, Head WAPS, Ador Welding Ltd. (with inputs from Plasch, TiP-TiG, Austria)
T
IP-TIG welding is a new advanced innovation of the common GTAW Process. This process uses new, patent-pending technology (TiPTiG), that delivers the highest possible weld energy with the lowest possible weld heat, all while still being user-friendly. What is TIP-TIG welding? TiPTiG new welding with a hot wire process can be used in every industry. It is very simple to learn, use and simple to teach. This process is so unique that higher travel speed, lower heat input, reduced cycle time, and an overall better-quality welding advantage can easily be achieved. The Process The TIG weld receptivity for higher weld deposition rates is done by decreasing the speeds for the weld solidification process and increasing the fluid weld area. This allows for a 100%-400% increase in TIG wire feed rates, increasing the overall weld deposits. All these attributes like faster speeds and higher than normal weld energy, increase the resulting TIG weld quality and overall process productivity. The process is also slag-free and
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uses the lowest possible heat input of any welding process, producing a Heat Affected Zone (HAZ), all of which help to reduce distortion and weld stress. It produces some of the highest quality products with the best metallurgical and mechanical properties on all alloys, but also increases production up to four times the normal speed. There is also no inter- pass cleaning, creating availability for an increased Arc on time and weld quality. The TIP TIG process is available in manual and automated capability to attain weld and clad quality levels way beyond the conventional TIG – Hot – Cold Wire TIG – Pulsed MIG and the Flux-Cored process.
Fig.3
How it Works A TIP TIG welding system uses a wire fed GTAW system just like a typical TIG system, but it’s distinctive for the vibratory effect on wire at weld pool which is achieved by a linear forward and backward mechanical motion created by the customised wire feeder system. The forward and backward motion of the filler wire creates an oscillation that is then transferred to the weld, agitating the molten weld pool and ultimately disrupting the surface tension. In addition to this vibratory
Fig.1
Fig.2
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TECH TRENDS effect on the wire, a hotwire current (powered by a secondary power source) is also applied to the filler metal, prior to entering the weld puddle. The two pictures (fig. 1 & 2) describe the weld finish with Manual GTAW & Manual TIP-TIG process. ChampTig 400P Power source from Ador Welding with the TipTig wire feeder. Benefits of the TIG-TIP process • Increased fluidity of the weld pool • Greater tolerance to joint fit-up • Significantly reduced joint sensitivity • Greater ability to accept more wire into the weld pool, results in a higher deposition • 4-6 times increased travel times • Reduced cycle time and heat input • Cleaner welds with agitated weld pool • Reduced weld stress with the reduced heat input Approved Alloys TiPTiG welding can work on a wide range of alloys such as carbon steel, stainless steel, duplex and super duplex stainless steels, inconel, titanium, aluminium, copper, nickel, and many other critical materials like P-91, which are used in process plant production. Heat Exchangers Heat Exchangers are commonly constructed from low Carbon Steel, Copper, Copper-Nickel, Stainless Steel, Hastelloy, Inconel, or
Fig.4
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Titanium. There are certainly some unique applications and challenges associated with the welding of heat exchangers, such as the position and access for the popular circumferential welding of Tube to sheet welds or the half tube shell welding. A trained TIP-TIG welder can typically weld a 50mm tube in 30 seconds… or less with the highest quality and lowest heat input. Our typical travel speed for fillet welds will be between 300 to 500 mm/min on most applications. Compared with 80 to 150 mm/ min with conventional GTAW. TiPTiG manual system is a low cost semi-automatic solution to tackle any job by selecting a wide variety of torches for different applications, with modified 180 deg torch it allows a complete tube sheet welds without repositioning the wire or stopping, allowing for defect free welds. The typical customers in the manufacturing and repair of various sized heat exchangers are in power plants, chemical plants, petrochemical plants, petroleum refineries, natural gas processing, and sewage treatment. INCONEL CLADDING Normally, when you manually clad the end of a pipe ID with Inconelusing Pulsed MIG as shown in the picture and result is often not so good. However when we use TIPTIG, the results are visible as shown on the mentioned pictures. In the pictureTIP-TIG cladded Job, TIP -TIG Inconel 800 pipe was welded with Inconel 82 wire on 10 inch pipe 3/4 Wall. The TIP TIG weld cycle time for the Inconel pipe was 40 – 50 minutes, whereas the customer used to take around 4 hrs with regular TIG. When your weld process can weld a complex incoloy*
Fig.5
pipe and make the welds look simple, that’s a process that should be given consideration. With TIP-TIG, no brushing, no grinding, no spatter, no weld rework, no feeding of wire, no foot control, less skills. Note weld smoke prep machining lubricants. (*Incoloy refers to a range of superalloys produced by the Special Metals Corporation group of companies. They are mostly nickelbased, and designed for excellent corrosion resistance as well as strength at high temperatures; there are specific alloys for resistance to chemical attacks)
Fig.6
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TECH TRENDS Duplex Steel Welding Applications Application The picture (fig.5) is of a very thin Gage Duplex Boiler. Traditional automated TIG process with cold wire may result in sluggish duplex welds. The customer typically attained a maximum Hot Wire TIG weld travel speeds from 12 – 15 inch/min. Then the customer switched over from Hot Wire TIG to the TIP-TIG process. The TIP TIG weld parameters and speeds were achieved using an 0.035 (1mm) 2205 Duplex wire, with TIP-TIG travel speed of 35 inch/min was achieved providing 200% increase in weld travel. The welds had a superior, less sluggish weld bead appearance and the parts had a dramatic reduction in weld distortion, (note the much smaller HAZ). Also the TIP-TIG process was much more stable and consistent. TIP-TIG produces the cleanest welds from lowest possible oxidation. The welds will have the lowest possible weld pores and inclusions and the smallest possible weld HAZ. Welding of P-91 Material Welding of Grade 91 (9Cr-1Mo-V) chromium-molybdenum steel has presented numerous challenges since its introduction inthe 1970s. The gas tungsten-arc (GTAW) process can produce welds of high quality;
however, manual welding can be expensive and labour intensive, requiring skilled welders with extreme hand-eye coordination and dexterity. Grade 91 productivity can beincreased in either shop or field fabrication by introducing a semiautomatic high deposition metal transfer (HDMT) GTAWwelding process that combines controlled excitation of wire with a hot wire addition. This technique is costeffective and can beused for the entire weld from root to cap while producing high quality welds that industry expects from the GTAW process. With TiP-TiG weld study, it indicates that semiautomatic HDMT GTAW welding process is capable of producing toughness valuescomparable to or exceeding manual GTAW and that the process provides an attractive alternative for welding P91 root and hotpasses or the entire weld from root to cap.Results of this study indicates that semiautomatic HDMT GTAW welding process is capable of producing impact valuescomparable to or exceeding manual GTAWT. The process also provides an attractive alternative for welding P91 root and hotpasses or the entire weld from root to cap. The semiautomatic HDMT GTAW welding process permits an increase in energy(heat input), larger weld puddle and increased deposition rate while still
Fig.7
Fig.8
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providing tempering of the previously deposited weldbeads or layers. TIP-TIG HDMT (HIGH DYNAMIC METAL TRANSFER) FOCUS TIP-TIG HDMT FOCUS is a unique TIP-TIG welding process. Its precision and reliability make the TIPTIG HDMT FOCUS welding process particularly suitable for automatedapplications in combination with linear axles, robots and other guiding systems. Nearly all steels, non-ferrousmetals or galvanized sheets can be welded in one layer with filler material; e.g. CrNi-steels with a material thickness of up to 10 to 12 mm can be welded in single pass without any Joint preparation. Some of the welded examples are listed below. it has resulted in elimination of backing gas in austenitic stainless steel welds using high deposition metal transfer gas tungsten-arc welding(HDMTGTAW) TIP-TIG HDMT FOCUS PROCESS Example • Material: CrNi 8+8mm • Weld current: 500A • Weld speed: 46 cm/min • Wire feed speed: 2,0m/min Details of Welded Samples • Material: CrNi 10+10mm • Weld current: 500A • Weld speed: 32 cm/min • Wire feed speed: 1,8m/min TIP-TIG REDUCED COSTS BY OVER 60%, WHEN COMPARED WITH CONVENTIONAL TIG PROCESS TIP-TIG Cost Comparison The following comparison shows the actual savings calculated on a real stainless-steel welding application comparing conventional TIG and TIP-TIG on a pipe application (2” Sch 80 Stainless) in the 5G position.
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HIGH QUALITY FOR YOUR HIGH QUALITY FOR YOUR MACHINERY MACHINERY
MGM brake motor main features • TEFC 3-ph asynchronous brake motor (0.09kW-130kW)
MGM motor main orfeatures • ACbrake 3-ph brake (no rectifier) DC brake on request
• TEFC 3-ph asynchronous brake motor (0.09kW-130kW) • Oversized brake disc for higher brake torque, longer life and • AC reduced 3-ph brake (no rectifier) or DC brake on request maintenance • Oversized brake fortorque higher adjustment brake torque, life and • Fine and easydisc brake (aslonger standard) reduced maintenance • Very quick brake reaction time • Fine and easySTART/STOP brake torquecycle adjustment (as standard) • Frequent applications • Very quick brake timestandard) • Manual brake reaction release (as • Frequent START/STOP cycle applications • Hexagonal hole on non drive end of the shaft for manual rotation • Manual brake release (asspeeds standard) • Single speed or two motors • Hexagonal holedesigned on non drive end of the shaft for manual rotation • All motors for inverter duty • Single speed or two speeds motors • All motors designed for inverter duty
VARVEL production lines • RS-RT worm gearboxes: 28 to 150 mm centres.
VARVEL production lines and double worm. One stage worm, helical/worm
• RS-RT mmNm. centres. • RD worm helicalgearboxes: gearboxes:2850toto150 2300 Two and three stages. One stage worm, and double • RN parallel shafthelical/worm gearboxes: 180 to 3300 Nm.worm. Two and three stages. • RD helical gearboxes: to 2300 Nm. andNm. three stages. • RO-RV bevel/helical50 gearboxes: 180 Two to 3300 Three stages. • RN shaft gearboxes: to 3300 Nm. and three • parallel RG precision planetary180 gearboxes: 10Two to 230 Nm. stages. • RO-RV gearboxes: 180 to 3300 Nm. Three stages. Onebevel/helical and two stages. • RG precision planetary 10 to 230 Nm. • VR dry friction speedgearboxes: variators: IEC63 to IEC90 One1and stages. to 5two stepless speed range, 300 to 1500 rpm. • VR• dry friction speed variators: IEC63 to to IEC90 VS planetary speed variators: IEC71 IEC112 1 to15tostepless speed range, 300200 to 1500 rpm.rpm. 5 stepless speed range, to 1000 • VS planetary speed variators: IEC71 to IEC112 1 to 5 stepless speed range, 200 to 1000 rpm.
agency.com
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A new generation of electric motors and gearboxes for power transmission quality from the alliance of two dynamic italian companies. A new of electric motors and gearboxes for power transmission For generation those who want quality. quality from the alliance of two dynamic italian companies. For those who want quality.
MGM-VARVEL Power Transmission Pvt Ltd Ware House No.No. G3 G3 and and G4 •G4 Ground Floor •Floor Indus •Valley’s • Unit 3Park • Mel Ayanambakkam • Vellala Street •Chennai - 600 095 Ware House •Transmission Ground Indus Valley'sPark Logistic • Unit 3 • Mel Ayanambakkam • Vellala Street MGM-VARVEL Power Pvt Logistic Ltd • Tamil Nadu, Phone: +91 INDIA 44 26533665 / 9629691777 • info@mgmvarvelindia.com • www.mgmvarvelindia.com Chennai - 600INDIA 095 ••Tamil Nadu, • Phone: +91 44 64627008 • info@mgmvarvelindia.com • www.mgmvarvelindia.com Ware House No. G3 and G4 • Ground Floor • Indus Valley's Logistic Park • Unit 3 • Mel Ayanambakkam • Vellala Street th REGIONAL KOHLI TOWERS • 4+91 Floor, Dapodi •• info@mgmvarvelindia.com Near Bharat Petrol Pump ••Pune - 411012 Chennai - 600 095OFFICE: • Tamil Nadu, INDIA • Phone: 44 64627008 www.mgmvarvelindia.com th
TECH TRENDS
Variable / Results
Units
Conventional TIG
TIP TIG Process
Welding process
GTAW
GTAW
Wire type
ER308L
ER308L
Wire size
mm
2.4
0.9
Wire deposition speed
mm/min
100
1900
Melt off rate
g/h
200
580(3 times)
Deposition efficiency
%
100.00%
100.00%
Deposition rate
g/h
200
580(3 times)
Duty cycle
%
100.00%
100.00%
Final deposition rate
g/h
200
580(3 times)
Argon
Argon
Gas type Flow rate
cfh
30
30
Gas/Wire ratio
cf/g
63.05
23.62(60% Reduction in gas per gm of wire)
The above data shows, the deposition rates approx. 3 times to standard TIG process which reduces the production costs by 60%. Conclusion TIP-TIG is an innovative TIG process and good alternative to standard gas tungsten-arc (GTAW) process. Its versatility and simplicity makes the manual welder to give higher output. The Automated High Deposition Metal Transfer (HDMT) GTAW welding process that combines controlled excitation of wire with a hot wire addition and gives very
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promising results to challenging applications. Plant equipment manufacturing, wherever GTAW is applicable, is possible to be replaced by TIG-TIG process which gives very high output without compromising on quality. The success in P91 welding with TIP-TIG, also increases the application possibility in that area.
References: 1. Paper on ‘ACHIEVING TOUGHNESS IN P91 WELDS FROM ROOT TO CAP USING SEMIAUTOMATIC HIGH DEPOSITION METAL TRANSFER (HDMT) GTAW WELDING PROCESS ‘ by Charles W. “Pat” Patrick 2. Information from TiPTiG USA 3. Information from TiPTiG International AG .
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TECH TRENDS
Industrializing 4 Die and Mold Making: Grades, Methods, and Digital Options for Production Effectiveness
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or ISCAR, as for any cutting tool manufacturer, die and mold making is a highly important customer segment. This industrial branch not only consumes more and more tools but constantly puts forward new demands, which have a significant impact on advances in cutting tools. These demands are typical for every metalworking sector: the customer is always interested in more productive, reliable, and accurate tools. However, specific features of die and mold manufacturing necessitate special design considerations beyond the general requirements. Materials, machined shapes, and machining strategies are three distinctive hallmarks of die and mold making, and have a substantial influence on cutting tool demands. According to ISCAR, only a holistic tool development concept based on these features, combined with integration of Industry 4.0-inspired digitalization developments, will lead to successful solutions for the die & mold sector. Challenging Materials The main material for the die & mold industry is steel that is often hard. Workpiece hardness is a principal factor in influencing tool material and cutting geometry. Various repair methods for worn or damaged molds and dies use welding, thermal metal spraying, and laser treatment, etc., which are applied to the affected surfaces. Further machining of these surfaces requires a cutting tool to
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remove a material stock combining very hard and relatively soft layers. This condition significantly reduces tool life and requires tool manufacturers to make extra efforts to compensate and ensure the necessary durability. Intricate shapes Molds and dies feature complex shapes. A three-dimensional (3D) profile is typical for the working surfaces of a mold (die) set, and the ability to machine 3D surfaces effectively is an important requirement for cutting tools. A tool is expected to provide the required parameters for shape accuracy and surface finish, and to ensure the appropriate level of tool life needed to complete machining the shape or its pattern in one operation. Machining Manufacturing molds and dies requires various machining processes: turning, milling, drilling, reaming and others, although cutting tools for die and mold making are associated primarily with mills. The specific character of the die & mold industry - predominance of nonrotating parts, the complex shape of machined surfaces, the necessity to produce a lot of cavities that require considerable material stock removal, etc. - positions milling cutters in the first place among tools utilized by this branch. In their constant need to boost productivity in manufacturing molds and dies for new products, the die & mold industry was one of the first
adopters of advanced machining methods such as high speed milling (HSM) and high feed milling (HFM), and to develop efficient machining strategies. The progressive methods and techniques that were introduced impacted greatly on cutting tools, leading to new requirements for tool manufacturers. Over the years, these requirements have become increasingly tighter; today die and mold makers represent one of the most exacting cutting tool consumers and expect cutting tool manufacturers to be responsive to the industrial trends. ISCAR, a leading cutting tool producer, has cooperated successfully with the die & mold industry over the years, and constantly improves its solutions for die and mold manufacturing by introducing new products and upgrading the existing ones, as well as providing complex tooling projects and consultations. Cutting tool grades In die and mold making, indexable extended flute (also referenced as long-edge) milling cutters are often applied to rough machining cavities and wide edges. The cutters work in high-load conditions, and the material of the indexable insert is a key factor for improving tool life. In the last few years ISCAR has introduced IC845, a cemented carbide grade, that features a new tough substrate and a new nanolayer PVD coating with applied SUMO TEC post-coating
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TECH TRENDS treatment technology. The grade was designed especially for cutting at significant impact load. The inserts made from IC845 demonstrate substantially better tool life, which in turn improves performance of the extended flute cutters and slot milling cutters carrying the inserts. ISCAR’s solid carbide endmill line has been enhanced by adding the IC702 carbide grade, which is intended for efficient machining of hard materials (up to HRC 65).
introduced a new product targeted especially to this challenging market - the TOR6MILL family of indexable milling cutters. A TOR6MILL cutter (Fig. 1) can carry inserts in four different geometries. Mounting the appropriate insert in the cutter transforms it to a toroidal, 90°, 45° or high feed milling tool. The cutter can be applied to machining 3D surfaces, square shoulders, plane faces, chamfers, or use as a productive high feed rougher.
Advanced profiling In machining complex surfaces, the real workhorses are milling cutters of toroidal- (button-) and ball-nose shapes. ISCAR offers die and mold makers an extensive line of these cutters in the following designs: tools with indexable inserts, endmills with exchangeable cutting heads, and solid carbide endmills. They differ in nominal sizes, accuracy, mounting method (shank- or arbor-type) and application range, according to whether the workpiece hardness is low, moderate or hard. Mold and die making is characterized by a large proportion of small- and medium-size producers. For these manufacturers, tool versatility (multifunctionality) is an important factors in tool choice. ISCAR’s recent LOGIQ campaign
Innovative technologies High feed milling and high speed milling proved to be powerful methods for dramatically increasing machining productivity while reducing manual operations, consequently shortening production time significantly. Due in no small part to timely introduction of these efficient methods, the die & mold industry succeeded in filling the sharply increased demands for molds and dies that occurred in the 1990’s.
Fig. 1
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High Feed Milling Today, cutting tool producers provide a great choice of high feed milling cutters, and ISCAR’s range of high feed (also known as fast feed or FF) milling tools seems to be the widest. ISCAR’s standard high feed milling line comprises more than 10 tool families that differ in their design principle (indexable, solid, with replaceable heads), nominal diameter, cutting geometry, mounting method and applicability (machining faces, pockets, deep cavities). This diverse range enables die and mold makers to select the optimal cutter for their needs. ISCAR views high feed milling tools as important productivity boosters and continues to develop the line by introducing new families and improving the existing ones.
Not surprisingly, the leading milling products presented in ISCAR’s recent LOGIQ cutting tool marketing campaign were related directly to fast feed cutters. NAN3FEED and MICRO3FEED, two of the latest ISCAR families of indexable high feed milling tools, feature an 8-16 mm (.315.625 in) diameter range. Even though solid carbide endmills traditionally dominate this range, ISCAR’s specialists believe that the advantages of the indexable-insert concept for rough machining will position the families as serious costeffective alternatives to the solid carbide designs. The LOGIQ4FEED family of fast feed cutters (Fig. 2) features “boneshape” double-sided inserts. This unusual insert profile provides four cutting edges, with an exceptional ramp-down capability that defines the main application of the family: high-efficiency rough milling of cavities, particularly deep cavities. The cutters are suitable for machining workpieces with hardness up to HRC 50. Fig. 2
High Speed Milling Expanding the range of products intended for high speed milling, ISCAR introduced multi-flute solid carbide endmills in 2 - 20 mm diameters (.250-.750 in) for high
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TECH TRENDS speed finish and semi-finish milling. The endmills are produced from the ultra-fine IC902 carbide grade, which was developed to machine hard materials, and have a cutting-lengthto-diameter ratio of up to 6. They are operated at rotational speeds up to 20000 rpm. The application of solid carbide endmills for rough milling of slots and open pockets by trochoidal technique and at high metal removal rate (MRR) - has also reached the attention of die and mold makers. MULTI-MASTER options The need to customize molds and dies to products is why die and mold manufacturing is often low-volume or even single-piece, which results in a large number of small- to mediumsize shops involved in die and mold making. For these manufacturers, efficient utilization of cutting tools and well-run tool stock management is of key importance. However, customization often requires a specific tool configuration in order to machine hard-to-reach part areas. Not every cutting tool in a tool stock is optimal for this type of machining but “customizing” the tool by ordering a tailor-made design is far from the best solution. ISCAR’s MULTI-MASTER (Fig.3) family of assembled tools with Fig. 3
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exchangeable cutting heads helps to overcome these difficulties. According to the MULTI-MASTER concept, the head is suitable for mounting in different tool bodies (shanks), and the shank can carry different heads. The heads are varied in shape, cutting geometry and sizes and are designed for machining 3D surfaces and shoulders, faces and slots, chamfers and holes. The cylindrical and taper-neck shanks feature different dimensions for a broad-ranging overhang; their design options ensure clamping in toolholders, collet chucks or in a machine tool spindle directly. The MULTI-MASTER, with its rich variety of heads, shanks, reducers and extensions, enables over 40,000 possible tool configurations. The MULTI-MASTER tools wholly meet the requirements of the important “no-setup time” principle, as replacing a worn head does not require additional setup operations. The head can be changed without removing a tool from a machine, which significantly decreases downtime. These features make the MULTI-MASTER family extremely popular in the die & mold industry. Digital tool assembly The low-volume character of die and mold manufacturing and highly precise machined shapes make any deviation from die (mold) specifications an Achilles heel. Even a small error threatens rejecting a whole product. Driven by Industry 4.0 developments, digitalization in modern manufacturing is providing die and mold makers with an effective instrument for overcoming this obstacle - computer modelling of machining processes. This ensures the implementation of productive machining strategies, tool path and cutting data optimization, and
prevention of possible collisions. ISCAR expanded its world of digitalization by introducing a milling tool assemblies option in its electronic catalog, which contains accessible and accurate tool data for digital pre-machining. Creating a digital tool representation of a tool assembly, based on standard ISO 13399, facilitates accurate communication of tool information between software systems. Integrating this new function into the CAD/CAM system of a die and mold manufacturer can prevent errors on the shop floor during machining, while the ability to plan multiple assemblies saves time and costs in the planning process. The company plans to expand its Industry 4.0 datadriven products and to connect the digital and virtual worlds of modern manufacturing for die and mold makers. Many products around us are manufactured using molds and dies, and demand for these products grows constantly. Advances in industrial branches such as the automotive industry, a leading consumer of molds and dies, have a great impact on die and mold making. More requests for molds and dies will lead to a new level of requirements for the cutting tools that die and mold makers need. ISCAR holds that cutting tool manufacturers should anticipate these demands and act accordingly by providing the necessary solutions.
For more information, Website: www.iscar.in
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TECH TRENDS
Complete analysis of heterogeneous data from TwinCAT controllers and third-party components TwinCAT Scope meets OPC UA In the context of Industrie 4.0 and big data applications, machine data acquisition and analytics are becoming increasingly important. The information must be presented in a clear and efficient manner, and the machine control system also has to cover a wide range of other smart components. TwinCAT Scope software provides optimum support for such integrated data acquisition across heterogeneous system environments. A standardised OPC UA communication channel enables this charting tool to analyse data from diverse sources such as TwinCAT controllers and third-party components.
T
winCAT 3 Scope consists of Scope View for the graphical display of signal curves and Scope Server for the actual data logging. The Scope Server can be installed on a target device for autonomous logging (without the View component if desired) or on the corresponding engineering system together with Scope View for remote logging. The latter solution offers the advantage that no additional software has to be installed on the target device. As a result, no updates to TwinCAT controllers are required, and devices without TwinCAT do not have to be modified in order to display their data graphically in Scope View. Vendor-independent, secure data collection via OPC UA For logging measured signals, the Scope Server now not only features a TwinCAT-specific ADS channel, but it also offers support for another standardised communication channel, which is realised as an OPC UA client. The widespread use of OPC UA in automation technology enables TwinCAT Scope to acquire and display measured data in a vendorindependent way. With OPC UA, this can be achieved reliably and securely, especially if certificates are used.
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With an OPC UA communication channel, the high-performance TwinCAT Scope multi-core oscilloscope can be used as a charting tool for diverse data sources such as Beckhoff control technology & third-party components in heterogeneous control systems.
The TwinCAT Target Browser, which is used for managing the connected data sources in TwinCAT Engineering, has also been expanded with OPC UA support. It enables browsing in the namespaces of connected OPC UA servers. This feature can be used to select the desired variables for logging by the Scope Server with configuration options for certificate-protected access. A TwinCAT 3 Engineering installation always includes a Scope View and a local Scope Server. Both software components are included free of charge in the basic version, which enables testing of the OPC UA
communication. With a rich set of features including multi-core support, triggers, chart synchronisation and numerous zoom functions, the tried and tested charting tool is now perfectly suited for an even larger group of users and even more diverse application scenarios with these latest communication enhancements.
For more information, www.beckhoff.co.in/twincat-3-scope Email: info@beckhoff.co.in
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DIGITALIZATION OF MANUFACTURING
JUNE
14 19 21
The Oberoi, New Delhi Taj Connemara, Chennai
DIGITIZATION of MANUFACTURING The Fourth Industrial Revolution As the technology adoption evolves at an exponential speed and disrupts almost every industry in every country, the breadth and depth of these changes herald the transformation of entire systems of production, management, and governance. At the NASSCOM COE & The Economic Times Industry 4.0 Summit, we will discuss the below topics with leading industry experts, technology users, SMEs, global experts and technology providers.
DISCUSSION HIGHLIGHTS
Sheraton Grand, Pune
from 9:00 am onwards
For Marketing Alliances: 86920 09966 | enquiry@et-edge.com
Global stories within your reach
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Autonomous Robots
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Cybersecurity
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Simulation
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The cloud
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Horizontal and vertical system integration
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Additive manufacturing
Key takeaways and new perspectives The forum will give insight into new technologies and conversations that will make possible many aspirations of the market.
Global stories within your reach Hear global success stories shared by the leaders themselves in your backyard. An unmatched global experience at your fingertips.
Power packed panels Witness first-hand the innovations that the industry is adopting to bring the best possible technical support to the market.
Industrial Internet of Things
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Live Interviews Hear global success stories shared by the leaders themselves in your backyard. An unmatched global experience at your fingertips.
Idea CafĂŠ One on one meetings, industry focused tracks that will enable a perfect environment to initiate new business ideas.
Think Tanks Focused and exclusive decision with a set-of cohorts to initiate strategic business/technology discussions and initiate new business talks.
To register, log on to www.et-edge.com/conferences/et-industry4 Platinum Partners
Supporting Partner
Gold Partner
Security Partners
Exhibitor
Media Partner
TECH TRENDS
Jetstream Tooling provides operational stability & improved surface finishes Toolholders Pinpoint Coolant and Eliminate Turning Operation Interference
C
oolant-through tooling components and connectors that interfere with grooving, parting off and other turning operations become a thing of the past with the new additions to JETI (Jetstream Integrated) tooling from Seco Tools. Expansions to the range of MDT (Multi-Directional Turning), X4 (grooving and parting off) and 150.10 (parting-off) tool holders offer interference-free internal coolant capabilities and the choice to switch the underside stream channel on and off as the application requires. Jetstream Tooling provides operational stability, reliability and improved surface finishes as well as application flexibility and the productive convenience of coolant delivery without external hoses, fittings and spare parts that can diminish productivity and raise costs.
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Square-shanked MDT, X4 and 150.10 holders are available in 20 mm x 20 mm (0.787” x 0.787”) and 25 mm x 25 mm (0.984” x 0.984”) sizes. MDT holders accept inserts in 2, 3, 4, 5, 6 and 8 mm (0.0787”, 0.118”, 0.157”, 0.197”, 0.236” and 0.315”). 105.10 holders accept 15size blades. For optimized machining, chip control and process reliability, Jetstream Tooling aims high-pressure coolant directly into the cutting zone through internal channels in the toolholder. Unlike other tool holders, Jetstream Tooling® Duo provides upper and lower cooling channels with the ability to switch the underside stream channel on and off as needed. With coolant connections on the side and back of these holders, they also function on machines with conventional coolant supplies.
About Seco Tools Headquartered in Fagersta, Sweden and present in more than 75 countries, Seco Tools is a leading global provider of metal cutting solutions for milling, stationary tools, holemaking and tooling systems. For more than 80 years, the company has provided the technologies, processes and support that manufacturers depend on for maximum productivity and profitability. For more information on how Seco’s innovative products and expert services bring success to manufacturers across all industry segments
For more information, Website: www.secotools.com
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Meet existing and new potential customers
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Engaging demonstrations, live displays and workshops
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TECH TRENDS
What does robotics mean for the cutting tools industry
Friend or foe? Helper or fiend? Here’s what robotics really mean for the cutting tools industry and what are the pitfalls to watch out for. By Thomson Mathews
T
he rise of the robots is pervasive across all verticals, including the cutting tools industry. As more and more manufacturers turn to leaner processes robotics have been seen as a way to increase productivity, improve precision and reduce labor costs. It’s led to some asking whether robotics will replace humans completely. It’s also led others to ask if the benefits are just too good to be true. The use of robots is steadily growing. In the United States alone more than 34,000 robotic systems were introduced in 2016. And while upfront costs can seem prohibitive
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to many, the reduction in operating costs, ease of programming and potential for increased productivity is enough for many to fully automate their machining. In particular the cutting tools industry has been using robotics to take over the repetitive tasks once done by humans. Tasks such as manual loading, checking and removal of tools and materials. Some manufacturers are even using robotics to work 24/7, taking their production to a ‘lights out’ level with minimal input from humans. But, as with any advancement in technology, there are manufacturers who are doing it well and others who are not.
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TECH TRENDS manual processes. It has meant less shift work, more family friendly work hours and a win-win-win for customers, the business and their workers. Fraisa’s success comes from ensuring their machines are fully connected to their ERP systems, so that efficiencies can be monitored throughout their entire supply chain.
When robots go wrong Probably the most famous case of robotics not meeting expectations are at Tesla, with a fully robotic system managing the production of Tesla’s Model 3. The process simply didn’t work and Tesla was unable to deliver the volume of cars they had promised. After a dismal first quarter in 2018, Elon Musk was forced to bring in humans to replace the robots. In Musk’s own words, “Excessive automation at Tesla was a mistake… humans are underrated.” Tesla’s big mistake was not in automating, but in not considering their whole supply chain and planning appropriately. While parts of their automated processes were increasing their production as promised, the chain as a whole was not. In the end there were production bottlenecks down the supply chain. It didn’t matter how fast one part of the process was completed, if the next part of the process couldn’t keep up. What we, in the cutting tools industry, can learn from Tesla is that consideration needs to be given to how the entire system works; what connects with what and where the dependencies are. There’s no point being faster at one end of the process if the next step can’t keep up. Get the cadence right before jumping in. When robots go right In contrast Fraisa – a Swiss based business that offers its customer a complete range of solid round tools with endmills, drills and taps – shifted to lights out production for 50 hours a week with surprising results. Not only did they increase their productive hours from 105 per week to 150 per week (per machine) they reduced their operation costs by half. Workers retained their salary and the business invested more time in upskilling them in other manufacturing processes. They now have a more engaged and skilled workforce who focus on value-added work rather than monitoring
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It’s not set and forget Other bottlenecks may occur through lack of in-house programming skills. Whilst your general labor costs may be cut, extra hours need to be allowed for programming. Either you need to employ specialized robotic programmers or invest in a system that translates your requirements. You tell the application what you need, it tells the robots how to do it. Robots are here to support the humans in the cutting tool industry and beyond. In return robots need planning, monitoring and programming support from us humans to be their best. For more information, Website: www.anca.com
THE S.BHANDARI GROUP EST. 1951
PRODUCTS : New Launch
Solid Carbide End Mills
CNC TOOL HOLDERS
High Performance End Mills Solid Carbide Drills. Through Coolant Drills Solid Carbide Reamers & Centre Drills Solid Carbide Special Tools Re sharpening services of Solid Carbide Tools HSS Drills & Taps HSS Centre Drills & Spotting Drills CNC Tool Holders
Agents / Distributors Wanted
HITTCO TOOLS LIMITED
#78, III PHASE PEENYA INDUSTRIAL AREA, BANGLORE - 560 058. INDIA Tel : +91 80 28394327 / 28392265 | Mobile : +91 9886781458 / 9845740887 E-mail : roy@hittco.com | Website : www.hittco.com
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TECH TRENDS
VL 1 TWIN Line from EMAG A Pioneer for the Production of Planetary and Sun Gears, Cams, and more!
Two VL 1 TWINs can be linked with TrackMotion to form the VL 1 TWIN Line. Machining is then performed from two sides.
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he challenges in the automotive industry are growing—and fast. Take transmissions for instance: Existing systems such as automatic torque converters and dualclutch transmissions are constantly being enhanced. These are being supplemented by unique hybrid drives and assistance systems, which increase the complexity of the overall system. In this context, the main goal of quality managers is “zero fault tolerance,” now more than ever. Each component must flawless when they leave the production area - and at the lowest possible unit costs. With its new VL 1 TWIN, EMAG shows how a highly specialized machinery manufacturer is able to master the challenge. The twin-spindle pick-up turning center for components up to 75 millimeters (3 inches) in diameter simultaneously machines two identical components in a single machining area. At the same time, equipment such as the innovative linear motor and the direct distance measuring system
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in the X-axis provide precision and long-term accuracy. This makes the production of essential transmission components, such as planetary and sun gears, significantly more efficient. It also improves the manufacturing of cam parts, flanges, sleeves, and roller bearing rings at every level. “Quantity and quality” are shaping transmission manufacturing more than ever: Considering the increasing number of gears in transmissions, the quantity of gears and other toothed components produced is undeniably on the rise. At the same time, the quality of the components must also increase in order to achieve the power density required in modern transmissions. The performance features expected of transmissions, such as a long service life with optimal dynamic response, also still apply. Is it at all possible to reconcile growing quality and productivity requirements with generally increasing pressure on costs? “That was precisely our goal,” says Björn Svatek, Sales & Marketing Director
Modular Solutions at EMAG. “We have developed a low-cost machine, that enables high output volumes with short lead times due to its two pick-up spindles and also ensures dynamics as well as repeatability and long-term accuracy with its direct distance measuring systems in the X-axis, size 45 recirculating roller guide rails, and innovative linear motor. It is the perfect solution for turned parts with diameters of up to 75 millimeters (3 inches).” Minimizing Cycle Times The possibilities made possible by this approach become clear from a simple description of the production sequence: A simultaneous process (OP10/OP10) is performed on two identical workpieces, quickly, within the machine. Both components are picked up from the conveyor belt by the two pick-up spindles (9.9 kW/136 Nm at 40% duty cycle), transported to the machining area, and machined in a single clamping operation—the diameter and length (X/Z directions)
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Register at ow.com www.aes-sh to visit
An exhibition on technologies for automotive manufacturing
4 – 6 July 2019 Hall No. 1, Chennai Trade Centre, Chennai
Product displays from 90+ auto technology brands! Aukua MGA2510 which is a powerful Ethernet Test system supporting IEEE standards-based automotive Ethernet microScan3 Safety Laser Scanners, which comes with innovative safeHDDM® scanning technology equipped with onboard Core Input/Ouput, EtherNet/ IP™ and PROFINET for safe machine integration Wipro 3D’s Steering Bracket which is one of its largest 3D printed automotive components optimized through additive engineering principles and FEA resulting in weight reduction and geometry optimised for the stress path Precision reduction gears used in the joints of industrial robots to support their accurate and powerful motion Register to visit
For other details, contact Nikita Pires +91 22 6144 5900 Nikita.pires@india.messefrankfurt.com
Scan the QR code Supporting associations
Strategic Media Partner: All India Council for Robotics & Automation
TECH TRENDS of the two components can be adjusted independently, since the movement of the spindles is entirely autonomous. The linear motor in the X-axis combined with the direct distance measuring system also increase the speed in the simultaneous sequence. What cycle times are possible with these features? “It obviously depends on the component and process,” says Björn Svatek. “Generally, the average chip-to-chip time is just under five seconds. VL 1 TWIN Line EMAG uses the productive twin approach for advanced manufacturing solutions. For example with the VL 1 TWIN Line:two VL 1 TWIN machines are linked together using the TrackMotion automation system. Machining is then performed simultaneously on two sides of two components in OP10 and OP20. This allows for cycle times of less than 20 seconds to be achieved for the
entire OP10/OP10 and OP20/OP20 sequence—an incredibly low figure, ensuring significantly lower unit costs for the soft machining of planetary gears. The system is also equipped with an extensive parts storage area for raw and finished parts. The use of space optimized stacker pallets allows for a large number of components to be accommodated in a very small space. Doing so, by stacking the parts as the name already implies. With the TrackMotion automation system linking machines, EMAG is able to deliver multi-technology production lines. Let’s take gearwheels as an example: After machining two sides of the blank using two VL 1 TWINs, an EMAG hobbing machine cuts the gear teeth on the component. Finally, deburring is performed with EMAG technology in OP40. The TrackMotion automation system allows for a fast pace between operations with a maximum travel speed of 150 m/min (5905 in/min).
Short cycle times as a result of simultaneous machining: Planetary Gear Example: 12 second cycle times for a total machining time of 24 seconds (two working spindles are used).
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High Quality— Low Cost A goal during the development of the VL 1 TWIN was to achieve consistent, high quality workpieces – as evident by various configuration details. For instance, there is a direct and extremely precise distance measuring system in the X-axis, the recirculating roller guides ensure high rigidity as well as guidance precision, and the MINERALIT® polymer concrete machine base reduces vibrations during the turning process. An optional measuring system between the machining area and the pick-up stations continue to increase the process reliability. “Extreme precision and long-term accuracy are always an integral part of this machine,” says Svatek. However, the fact that these high requirements are achieved with low investment costs for the user may be the most surprising highlight of this technology. EMAG is committed to rigorous cost control during the entire development process and also uses standardized high-performance components. This is how the price per spindle was significantly reduced. The basic machine (without chip conveyor and automation system) has a footprint of only 4.59 square meters (50 square feet) —and this will naturally cuts costs even further when establishing a new production process. “With this turning center, we really bring all the decisive factors together,” concludes Björn Svatek. “The VL 1 TWIN ensures extremely low cycle times, guarantees high component quality, and minimizes investment costs. Additionally, we’re able to configure highly flexible system solutions for both sub-processes and complete processes. At the end of the day, our customers benefit from significantly lower unit costs.” For more information, Website: www.emag.com
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TWO MEGA EVENTS, ONE PLATFORM
February 13-15, 2020 Auto Cluster Exhibition Center, Pune, India
Explore the Great Collaboration between
Gear and Grinding Technology EXHIBITION PROFILE: IPTEX
GRINDEX
• Mechanical Power Transmission • Electrical Power Transmission • Linear Motion Drives
• • • • •
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FACE TO FACE
YASKAWA: Magnifying Opportunities in Automation robot are among the many significant achievements; it is easy to see that we place quality innovations first. Our social responsibility takes into account the impact of our work on our immediate and global environments. From instituting a comprehensive internal environment management system to ensuring that we are a green company from procurement through product functioning, we aim to minimise the burden on a rapidly declining ecological balance.
Mr. Ajay Gurjar, Deputy COO & Head of Business Operations, Yaskawa India (Robotic Division)
Q. Being the key player in the industry, Please brief us company’s journey from inception & share some of the milestones achieved? YASKAWA is India’s most advanced and world class manufacturer of motion control products for industrial automation and OEMs. As an Indian subsidiary of more than 100 years old Yaskawa Electric Corporation- Japan, it has established itself firmly in the Indian Robotic market. In India, Yaskawa started its journey with the business of PLC in 1980 and AC drives in 1990 and steadily expanded its Robotics applications presence since 2005, to accommodate growing customer needs. Today, our India operations span the length and breadth of the country becoming a central hub for our future goals, which is headed by a vigorous team. At YASKAWA, with a continuous focus on R&D, we are constantly trying to outperform our benchmarks. Our patents for the world’s fastest
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Q. Please brief us about company’s infrastructure & what are the technology alliances that has been made in order to out-front the competition? Equipped with the latest technology, Yaskawa has facilities across India viz. Gurgaon, Bangalore, Gujarat, Chennai, Pune to serve its customers better. Having said that we have in house testing and warehousing facilities along with proficient professional’s in their respective fields. Looking at the current usage of automation applications and customers demand Yaskawa has embarked on various expansion projects. With our extremely qualified experienced Employees and System Integrators serving diversified markets across India truly has right mix of people and offerings to delight our customers. Being a world leader in motion control products for industrial automation and OEMs, we always strive for innovation and providing cutting edge trainings to serve our business partners better at all times. In addition to this, Yaskawa is consistently contributing to skill development
program by founding various training centres in collaboration with educational institutes making future generation ready. Q. What are the products manufactured by your company? To satisfy the current automation industry requirement, Yaskawa has a comprehensive line of Robotic solutions with core strengths majorly in applications like Arc welding, Spot welding, Handling ( General Purpose series), Pick, pack & palletizing, foundry & forging, Painting and many more. Integrated power sources, torches and peripherals, and our extensive family of fully integrated welding cells, we provide building block solutions that are simple to integrate and operate. Needless to mention, World’s ¬first dual-arm industrial robot for volume production is from Yaskawa range. To specifically deal in machine tools industry for handling purpose, Yaskawa General Purpose Series is more popular which has Payload capacity ranging from 7kg to 400 kg and Horizontal reach from approx. 927mm to 3518 mm. Yaskawa Globally came up with products like AR, GP & SP Series Robot with next generation YRC1000 Controller for reducing the foot print of Robot & Controller. Also Yaskawa has collaborative robot HC10 in its range and has recently launched prototype of HC20 with can work together with human during the operation. Yaskawa YRC1000 robot controller on industrial platform IV to gratify the market need of IOT with the help of Motoman Cockpit & Motoman Cloud software, can analyse & observe the robot remotely.
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FACE TO FACE Q. What is your marketing strategy for India? To contribute to the development of industry and society in India with world’s top class products and technologies, we are making efforts to create new value through the deployment of our business based on our core technology, and strengthening our business foundation to ensure maximum return. Yaskawa is focussed towards development of organizational capabilities, progress in global network; develop individual capabilities, sustainable growth and creating social value. We are leveraging the business capital that has been nurtured from past few years for value creation in Indian industry. Other than this, we have collaborated with a league of top educational institutes and opened various training centres to prepare the NextGen for future by giving them industrial exposure during their curriculum. Q. Product innovation through R&D is vital to be a leader in the competition, as per your opinion, how does R&D plays the role of catalyst in the success process? Since Yaskawa India was established, our spirit and drive for innovation has continued. We try our best to develop new technology that is good for people and the earth with the creation of Eco-mechatronics. Recently, Yaskawa has also been awarded with “Top 100 Global Innovator” by Clarivate Analytics for the 3rd successive year. With a current focus on the themes of human assistance, social well –being, environment friendly technology, our aim is to create high-value added products through conjugation and optimization of application based functions, and pursuing ultra-precision control technology. Also we contribute to the environmental protection by making high-efficient mechatronics
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products for energy-saving effects and using power conversion technology. Yaskawa three-dimensional digital data solutions: Integrated, Intelligent & Innovative named as I3-Mechatronics created by synthesizing our knowledge of mechatronics is a technology with which we are empowering the next generation where industry is looking to work in future. Q. Quality standards are benchmarked by the product performance; please brief us how do you maintain the quality norms since from solution development to implementation? In order to make sure that our customers use our products with confidence, the most important thing for us is product quality assurance from the very beginning. The causes for market defects in products are largely broken down to two factors: issues involving the design and issues involving parts, and are said to comprise 60 to 80 percent of all causes. In order to build in quality and reliability from the start of its development, Yaskawa sets up environmental resistance levels for each product to meet market/usage conditions at planning stage, and makes efforts to design and evaluate its products by leveraging tools and methods such as simulations, quality engineering, and HALT. Additionally, it pursues appropriate quality in the parts and materials. Q. What are the key technological trends that are driving the industry? Automation Robotics, Industry 4.0 and IIOT is actually a melange of many futuristic and advanced concepts and technologies which have the potential of transmuting the production scenario in the twenty first century mainly comprising of a ‘connected shop floor’ where data is collected from various sensors and other input devices to be
used for predictive maintenance, better control and long term analysis. Q. How do you perceive the future of the industry? Industry 4.0 is expected to be led by MNCs and large professionally managed Indian companies. Smart machines, robots, and other forms of automation could either be an economic poison or cure in a developing country like India and this change will affect how businesses worldwide outsource work. Businesses impacting top-line growth exploring evolution into intelligent automation that includes more advanced artificial intelligence (AI), and transforms the workplace and the workforce to enhance human potential, delivering exponential value by learning and adapting as it automates and reshape the manufacturing operations. Q. What is your vision for your company for near future? Rapid change in product variants led Yaskawa to make available highly flexible robot technologies and automation solutions to its OEM’s, system integrators and Tier 1 & Tier 2 suppliers and meet consumers’ expectations for customization and drive continuous product innovation while consistently lowering costs. Having said that to serve its customers with best possible solutions and reduce proximity, Yaskawa India has expansion plans for the advanced state- of -the -art- facility to be near to its customers. Yaskawa has the robust capabilities to strengthen the market reach with diverse nature of marketing activities and also to develop skills in workforce and future generation.
For more information, Email: arshleen.ahluwalia@yaskawa.in
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PRODUCTS SHOWCASE
PRODUCT SHOWCASE Edge protection profiles
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 Email: info@elesaganter-india.com Web: www.elesa-ganter.in
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Elesa+Ganter is expanding its range of products once again. Edge protections profiles and edge protection seal profiles ensure secure front-side finishes on covers, cable ducts or openings, for ex- ample. Elesa+Ganter are thereby offering everything that constitutes perfect sheet metal working from one source â&#x20AC;&#x201C; even for smaller or occasional use. The edge protection profiles are delivered on rolls of 20 or 50 metres in length, without a minimum order value. The edge protection profiles build not only an optically clean finish, they also protect surfaces from damage and prevent cables or tubes from being worn down in their encasing. In addition, they speed up the production phase as the burring or chamfering of edges is largely eliminated. GN 2184 is available in two sizes, is made of extruded PVC and can be assembled manually. The metal clamp insert prevents it from detaching. The edge protection seal profiles GN 2180 and GN 2182 cater for edge protection and sealing in one. They are available in separate sizes and are made up of the clamping profile and the additionally extruded hollow chamber sealing profile with a softer finish. By applying the correct pressure, the profiles prevent dust, warm air or water spray from entering, while also reducing noise emissions. The clamp insert is made of a steel wire polyester combination, enabling a comparatively low minimum placement radius without the risk of an uneven profile fit or detachment. The seal profile is affixed to the top or the side of the clamping profile. The profiles are available in a choice of EPDM or NBR, or in a combination of PVC and EPDM. NBR are particularly ideal for applications where contact with fuels or oils can occur. The con- sistently high-quality materials are permanently elastic and have good resilience, making their sealing properties particularly long lasting. All profiles fulfil the RoHS and Reach requirements. The EPDM profiles of GN2180 are additionally certified according to UL 50 and UL 94-HB, rendering exports to the US-American and Canadian market problem-free.
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PRODUCTS SHOWCASE
“Ninja” High Performance Range Indian Tool Manufacturers “ITM” – (A division of Birla Precision Technologies Ltd.) has newly launched NINJA Taps, Drills and End Mills. ITM focuses on its R&D department to continuously develop exceptional quality products for its customers. As a result of this extensive study and continuous efforts, we proudly introduce ITM “NINJA” High Performance Series a new range of products to compete with international standards to ensure Superior Performance, Extra Tool Life and Guaranteed Results. I) NINJA series Taps trare made out of the finest grades of HSS materials. These High Performance Taps are manufactured on our latest CNC Machines, with special geometries to suit different machining applications, based on work materials. ITM NINJA series Taps consists of Spiral Flute, Spiral Point, Roll Form, and Straight Flute-Cast Iron. To get enhance the performance of taps, we can supply theses taps with surface treatment like TiN, TiAlN, TiCN etc., 1. Spiral Flute Taps are best Suited for Blind Hole applications and are specially designed to eliminate chip clogging, they are available in size range of (Size Range: M3 to M16). 2. Spiral Point Taps are specially designed for Through-Hole application and are suitable for higher cutting speed for higher productivity. Size range is from M3 to M16. 3. Roll Form Taps is best suitable for both Blind and Through-Hole application. Roll forming operation is chip-less operation, forming a thread by displacement of materials and not by cutting, hence these taps are best suitable for soft materials like Aluminum, Brass, Bronze etc., the size range is from M6 to M16. 4. Straight Flute - Cast Iron Taps are best suitable for Cast Iron material and size range is from M3 to M16. II) NINJA series of Drills are also made out of the advanced grades of HSS premium materials. These Drills are produced on our latest CNC Machines, with unique geometries to give better accuracy holes and best performance. These drills are developed to machine hardened steel materials like Stainless Steel, Nickel Chromium Steel and Forged Steel etc. These NINJA High Performance Drills are designed having Special point geometry to reduce thrust forces while drilling. Ninja drills are made with special Surface treatment for maximum wear resistance. Size range in metric as per IS 5101 Metric Size 3.0mm to 13.0 mm Inch size as per BS 328 Inch Series: 1/8”to ½.”
For Product Enquiry Contact Birla Precision Technologies Limited Email: itmth@indiantool.com
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III) NINJA Series of End Mills are made out of best quality of HSS grade of Materials. These High Performance End Mills are manufactured from our latest CNC Machines, with special geometry to give better performance with higher productivity. These End Mills best suitable for materials like Stainless Steels, Nickel Chromium steels and tougher machining applications. These new series of our “NINJA” range of Products are new generation tools which will work at higher cutting parameters on latest CNC Machines and we are very confident that these products are best solutions for your higher productivity.
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PRODUCTS SHOWCASE
Nylon / Polyamide Knitted Seamless Features & Benefits Made Synthetic Nylon or Polyamide texturised/ stretch yarn for more wearing comfort & soft feel. The Nylon offers more sensitivity & ease at finger tips & less lint reduces the chance of contamination of material handled. The gloves in 13 & 15 gauge offer more lighter & sensitivity of finger tips recommended for precision work. These gloves are available in different colours options like White, Blue, Black, Grey etc.. & sizes options from M to XL. The Nylon/Cotton Plated Gloves made to increase protection & also to provide wearing comfort to absorbe perspiration.
For Product Enquiry Contact Marvel Gloves Industries Manufacturers, Exporters & Importers of Gloves & PPEs 187/188, 2nd Floor, Ashoka Shopping Centre, G.T. Hospital Complex, L. T. Marg, Mumbai 400 001 INDIA Phone : +91 22 2262 6546 / 2262 6876 Email : marvelgloves@gmail.com www.marvelgloves.com
Application • Mechanical Protection • Cleaning • Paint Shop • Packing • Precision Handling- Assembly • Automotive Assembly • Pharmaceutical
VARIMETER RCM: Reliably identify current faults! Increased availability of machines and devices
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
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The residual current monitor RN 5883 of the VARIMETER RCM family from DOLD, sensitive to all universal currents, records current faults either with DC or AC components in earthed supply systems (type B). Through early recognition of insulation faults, the RN 5883 provides a preventative service and maintains machines and devices. System downtime and production disruptions can consequently be avoided. The residual current measurement takes place over an external current transformer. The residual current monitor RN 5883 provides an informational advantage for specific and cost-effective maintenance - before the machine stop working. As well as the clearly visible LED chain for measured residual current, the LEDs indicate operational status, pre-alarm and alarm. In addition, the device indicates test functions and optional analogue output through breakage. This residual current monitor finds its place in fourfold usage, and increases the availability of energy supply whilst simultaneously minimising the risk of fire. Devices, in which current faults can occur due to porous cables, moisture or dust deposits, will be reliably monitored with the RN 5883. Examples of application include building automation, data centres, traffic engineering, climate & air conditioning devices.
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PRODUCTS SHOWCASE
GEM’s Bottle Type FRP Cooling Tower GEM’s Nexgen Bottle type FRP Cooling Tower is known for the benefits it offers like low maintenance, high efficiency, noiseless operation, minimum water loss and long service life.
For Product Enquiry Contact GEM Equipments (P) Ltd. SF No.103, Avinashi Road, Arasur, Coimbatore 641 407 Tel : 0422-2363800 / E-mail: sales@gemindia.com
Following are some of the constructional features of this trendsetting product: • Superior extended shaft flange mounted frame, waterproof with aluminium body, epoxy painting, SS shaft and EPDM sealing; saves power; highly reliable and built to last. • RTM Mould body, UV protected and with glossy finish • FRP Louver profile reduces water spillage loss, prevents entry of foreign particles and extends cycle for blow down. Also proper L/G reduces evaporation loss. • High Efficiency Aero Dynamic Fan: Axial flow, direct driven, low noise, long life, corrosion -free aluminium, computerized balanced and wind tunnel tested. • Revolutionary Spiral Fills: Rigid PVC – with long life, clogg-free and ease of assembly. UV stabilized • The product is offered to the customer with a 5-year warranty – for the first time in India.
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.
For Product Enquiry Contact Unity Controls Pvt. Ltd 405, Sapphire Arcade, 42 M.G. Road, Ghatkopar (E), Mumbai 400 077 Phone: 022- 2501 3832 / 33 E-mail: sales@unitycontrols.in Web: www.unitycontrols.in
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Following are some of its unique features: • 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.
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PRODUCTS SHOWCASE
Welding Fume Extractor, King Extractor-II-MU 3 Welding Fume Extractor, King Extractor-II-MU 3 is a mobile mechanical high efficiency self-cleaning filter designed for workplaces. The filter cleans air from different kinds of dry dust, welding aerosols and other dry contaminants from most industrial processes. The filter cartridge is cleaned automatically without interrupting the filtration process. The cleaning extends the cartridge service periods and minimizes maintenance.
For Product Enquiry Contact Ador Welding Limited Akurdi Chowk, Chinchwad, Pune 411 019 Tel.: 020- 4070 6000 Email: cmo@adorians.com Web: www.adorwelding.com
The Filter is designed for continuous indoor operation under the following climatic conditions: • Air temperature from +10 deg. C to +45 deg. C. • Relative humidity : 80% at 25 deg. C • The compact construction integrates the filter, extraction arm and fan • The filter can be used at workplaces unreachable to other ventilating equipment, and • The filter requires connection to a general compressed air supply. The standard delivery set includes Built-in fan, Control console, Filtering cartridge of respective type, Spark arrester, Oil separator with reduction box for compressed air system, & Electrical grounded cable L= 5 m with plug.
Price-attractive gripper for small components
For Product Enquiry Contact SCHUNK INTEC INDIA PRIVATE LIMITED No 80 B, Yeshwanthpur Industrial Suburbs, Bangalore – 560022, India Ph.: 080-40538999, Fax: 080-40538998 Email: info@in.schunk.com Web: www.in.schunk.com
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For the production of small parts, there is often an enormous margin pressure. This is why over engineering should be consistently avoided in systems engineering, especially due to the fact that a lot of systems are only used temporarily. In order to expand the scope for designers within the SCHUNK gripper portfolio, the competence leader for gripping systems and clamping technology is therefore expanding its range of grippers for small components with an attractively priced basic gripper for simple applications. The pneumatically controlled SCHUNK MPC offers an attractive price/ performance ratio whilst at the same time ensuring excellent performance and attractive construction size staggering, which covers a wide range of applications in assembly automation and for automation in plastics processing. The quickly available basic gripper in SCHUNK quality is available in six sizes between 16 N and 270 N, and maximum jaw strokes between 2.5 mm and 15 mm. Even the smallest size with a weight of only 50 g, allows handling of components weighing up to 80 g. At the top end of the size scale, part weights of up to 1.3 kg are possible. The repeat accuracy amounts to 0.02 mm. Despite the entry level price, the warranty is 12 months or 7 million cycles. The gripper is rounded off by the newly developed and also attractively priced SCHUNK J02 magnetic switch, meaning solutions from a single source are possible. For applications with higher requirements when it comes to cycle times, precision, and service life, SCHUNK also recommends the proven universal SCHUNK MPG-plus gripper for small components or the mechatronic SCHUNK EGP.
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ADVERTISERS INDEX COMPANY NAME
PG. NO.
A ACCUSHARP CUTTING TOOLS PVT. LTD.
93
ACE MANUFACTURING SYSTEMS LTD.
BACK PAGE
ANCA MACHINE TOOLS PRIVATE LTD
PG. NO.
COMPANY NAME
PG. NO.
DOWEL ENGINEERING WORKS
185
GEDEE WEILER PRIVATE LIMITED
19
DVS TECHNOLOGY GROUP
20 - 21
GIFU ENTERPRISE CO., LTD.
57
GP PETROLEUMS LTD.
119
E ELECTROTHERM (INDIA) LTD.
15
H
ELESA AND GANTER INDIA PVT. LTD.
37
HANGSTERFER'S
153
ELGI EQUIPMENTS LTD.
27
HEXAGON
80 - 81
EMO HANNOVER - 2019
99
HITTCO TOOLS LIMITED
205
EMUGE-FRANKEN INDIA PVT. LTD.
79
HOSABETTU HEAVY MACHINERY LLP
33
ENGIMACH - 2019
29
HURCO INDIA PVT. LTD.
154
EPPINGER TOOLING ASIA PVT. LTD.
166 - 167
7
APEX PRECISION MECHATRONIX PVT. LTD.
191
ASIAN MACHINE TOOL CORPORATION PVT. LTD.
131
AUTOMOTIVE ENGINEERING SHOW - 2019
207
B BECKHOFF AUTOMATION PVT. LTD.
COMPANY NAME
13
I
BETTINELLI AUTOMATION COMPONENTS PVT. LTD.
103
ERWIN JUNKER MASCHINENFABRIK GMBH
31
BIRLA PRECISION TECHNOLOGIES LIMITED
129
EXXONMOBIL LUBRICANTS PRIVATE LIMITED
11
C CHENNAI MACHINE TOOL EXPO - 2019
IMTEX FORMING - 2020
111
IMTOS - 2019
17
INDUSTRY 4.0
201
IPTEX + GRINDEX- 2020
209
ISCAR INDIA LIMITED
INNER INSIDE FRONT COVER
F 107
D
FACCIN S. P. A.
51
FATTY TUNA INDIA PVT. LTD.
69
DAHANUKAR MACHINE TOOLS
71
FIBRO INDIA PRECISION PRODUCTS PVT. LTD.
123
DELHI MACHINE TOOL EXPO - 2019
109
FLIR SYSTEMS INDIA PVT. LTD.
77
DELTA ELECTRONICS INDIA PVT. LTD.
9
FUCHS LUBRICANTS (INDIA) PVT. LTD.
75
DIEMOULD INDIA - 2020
41
DMG MORI INDIA
25
G GALA PRECISION ENGINEERING PVT LTD
135
J JAY-SHREE MACHINES PVT. LTD.
189
JYOTI CNC AUTOMATION LTD.
137
K K-1 ENTERPRISES
195
KTR COUPLINGS (INDIA) PVT. LTD.
133
JUNE 2019
MACHINE TOOLS WORLD
217
ADVERTISERS INDEX COMPANY NAME
PG. NO.
L LUBECO
165
COMPANY NAME
PG. NO.
OPEN MIND CADCAM TECHNOLOGIES INDIA PVT. LTD.
121
P
M MACHINE TOOLS, MANUFACTURING & TECHNOLOGY EXPO 2020
203
55
PILZ INDIA PVT. LTD.
171
101
MARPOSS INDIA PVT. LTD.
127
MARVEL GLOVES INDUSTRIES
PRECIHOLE MACHINE TOOLS PVT. LTD.
139
175, 177, 179, 181
PRECISION MOTION INDUSTRIES, INC. ( PMI )
95
INSIDE BACK COVER
Q
THE ASSOCIATION FOR MANUFACTURING TECHNOLOGY
151
TRUCUT PRECISION TOOLS PVT. LTD.
FALSE COVER
158
R
MGM-VARVEL POWER TRANSMISSION PVT LTD
193
MICRO-EPSILON INDIA PRIVATE LIMITED
169
MILLENIA TECHNOLOGIES
125
MITSUBISHI ELECTRIC INDIA PVT. LTD.
45
MMC HARDMETAL INDIA PVT. LTD.
INSIDE FRONT COVER
V V M TRADERS
WOHLHAUPTER / ALLIED MACHINE & ENGINEERING COMPANY
Y YAMAZAKI MAZAK INDIA
34 - 35
RENISHAW INDIA
43
YG-1 INDUSTRIES INDIA PVT. LTD.
FRONT GATEFOLD
RK CNC SOLUTIONS
97
RK POWER SOLUTIONS
96
ROLLON INDIA PVT. LTD. - INDIA
173
RR KABEL LIMITED
161
S
NIDEC MINSTER
157
SEW-EURODRIVE INDIA PRIVATE LIMITED
59 - 66
83 - 90
105 113 - 116
O
OKUMA INDIA PVT LTD
23
MACHINE TOOLS WORLD JUNE 2019
152
133, 139
47
99
183
RAVIK ENGINEERS PVT. LTD.
NICOLAS CORREA, S. A.
OCTAGON MANUFACTURING TECHNOLOGY
187
W
199
N
218
T
UNITY CONTROLS PVT. LTD.
QVI INDIA PVT. LTD. MEERA CASTING
PG. NO.
U
MACO CORPORATION (INDIA) PVT. LTD.
MASTERCAM INDIA
PARAGON MACHINERY CO. LTD.
COMPANY NAME
SOLBUGGY CONNECT PVT LTD
73
SUGINO MACHINE INDIA PVT. LTD.
39
141 - 150
ANCA MACHINE TOOLS PRIVATE LTD
FLIR SYSTEMS INDIA PVT. LTD.
MASTER FLUID SOLUTIONS
ADOR WELDING LIMITED
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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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