Volume 04 No. 11 | April 2019 | ` 150
Pages 124 | RNI No. MAHENG/2015/64267
Whatever industry sector you’re in? Aerospace, Automotive, Electronics, Medical or woodworking
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
Machine Tools Industry : The vision 2020
Assistant Editor Shweta Nanda
Marketing Team
The Indian machine tools industry, though highly fragmented, is projected to grow at 5.5 per cent annually through 2019, driven particularly by expanding demand in China and other developing countries.
Ladoji Pendurkar, Amol Powle, Bhavin Shah, Bharat Shah, Vinod Surve, Kamlesh Balkrishna, Kavita Chaudhari
Digital Marketing Kailash P.
Designer & Layout Arun P. Shinde, Nandan S. Moghe, Dinesh S. Gawade
Process automation, additive manufacturing and the rise of electric vehicles are the three core trends that are changing the dimensions of the machine tool industry, Stating that the industry is growing at an exponential rate and is presently estimated at around 6,000 crore, manufacturers will need to develop capabilities to cater to the demand and investments in this area could yield long-term benefits.
Online Division Ganesh Mahale
Circulation Executive Satish Kadam, Amol Ranshur Branch Offices (Zonal)
NORTH (Delhi & NCR regions) Sandesh Jain : 09810837877 / 09871602777
SOUTH (Chennai & Coimbatore) Y. V. Raghu : 09566141224 Bangalore E Vikram : +91 9591488434 Vaman : +91 9686721340
The industry has advanced significantly in hardware and software applications. The future includes automation of processes into manufacturing and engineering sectors. Reduced manual intervention in process control using machine tool control system and smart tooling would be the key to optimise cost, reduce scrap and improved machine utilisation. Machine tool exports from India reached about 55.3 million dollars in the past. Indian machines are price competitive in their range making them suitable for exports. Indian companies have grown rapidly over the last decade and have marked their presence across all the broad product categories of machine tools. Many of them are also exporting to countries such as Germany, Turkey, China, Middle East, Russia, South Korea, etc.
Hyderabad E Vikram : +91 9591488434
EAST (Kolkata & Other regions) Kamlesh B. - 09819464242
The global machine tool industry is predicted to exceed 120 billion dollars by 2020, according to a report. Experts are optimistic about the market but the emergence of certain disruptive technologies may change the future of this sector. Some of the core trends that are altering the dimensions of the current machine tool industry include process automation, additive manufacturing and the rise of electric vehicles.
WEST (Maharashtra & Gujarat) Pune Shilpa K. - 09833373371 Nashik Abhijit B. Joshi : 09890002333 Rajkot (Saurashtra) Swapnil Bhatia: 09227909005
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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
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Contents
APRIL 2019
COVER STORY
GP PETROLEUMS: Extending horizons through quality in lubricants arena Hari Prakash M Chief Executive Officer GP Petroleums Ltd.
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BUSINESS NEWS
22
Yaskawa India, Robotics Customer Seminar, Gurugram – 2019
METALWORKING FLUID INDUSTRY VIEW
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Oerlikon Balzers continues expansion with new customer centre in China
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New alignment laser system increases Renishaw’s range of machine calibration solutions
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LANXESS announces capacity expansion for corrosion inhibitor products
The Evolving Landscape of Metalworking Fluid Industry
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Leadership in Specialty Naphthenic Oils
IN FOCUS
ADVERTORIAL
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53
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ANCA announces Daniel Shepley as Apprentice of the Year
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Anthony Machine and Kennametal Teamup to Reduce Setup Times 10
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Contents
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TECH UPDATE
COMPANY PROFILE
EVENT PROFILE
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56
64
60 AMT SECTION
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70
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TECH TRENDS
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78 Floating Wind Turbines, promising future
The smallest draw-wire sensor the world has ever seen
PRODUCTS SHOWCASE
92 The e-commerce boom & intralogistics: Rollon presents its warehouse automation solutions 12
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117“ENGINEERING FILES” 118 Cross Roller Bearing 118 FLIR Ex-Series™ 119 Cotton Knitted Seamless
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Editorial Board
Editorial Index A Ador Welding
104, 116
ANCA
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Masters
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Micro-Epsilon
82
Millenia Technologies
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B
N
Birla Precision
Nynas
Technologies
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117 O
D Mr. Arun Mahajan General Manager AMT- The Association For Manufacturing Technology
Mr. A.P. Jayanthram Ex-Managing Director, Heidenhain India
Mr. GK Pillai Managing Director & CEO
Oerlikon Balzers
DOLD Electric
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120 Q
Walchandnagar Industries Ltd
E
Quaker Chemical India
ExxonMobil Lubricants
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48 R
F Faccin SPA
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FLIR Systems India
Renishaw
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ROLLON INDIA
92
118 S
G Mr. Arjun Prakash Managing Director Effica Automation Ltd.
Ms.Samina Khalid Marketing Manager Renishaw Metrology Systems Ltd.
Mr. Rupesh Paparaju Director, Bettinelli Automation Components Pvt. Ltd.
Shavo Technologies
GEM Equipments GP Petroleums
120 36, 122
Solitaire Machine Tools 88 Spraymet Surface Technologies
K
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69
Superslides &
Kennametal
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Kinefac Corporation
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ÂŽ
Ballscrews
118
U L
Unity Controls
LANXESS
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LMT Tools
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W Wohlhaupter India
Mr. Dinesh Khambhayta President MTMA-RAJKOT
Manjit Singh Matharoo General Secretary Association of Ludhiana Machine Tool Industries
Mr. Suhas Belapurkar Director - Sales & Marketing ( Industrial Products) Sanjay Tools & Adhesives
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66
M Y
Marvel Gloves Industries
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Yaskawa India
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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
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Mr. B.P. Poddar Vice President - Sales & Marketing FEMCO Fatty Tuna India Pvt. Ltd.
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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
Yaskawa India, Robotics Customer Seminar, Gurugram – 2019 On 25th Feb’19, Robotic Division of Yaskawa India Pvt Ltd., an Indian Subsidiary of Yaskawa Electric Corporation, Japan organized its Customer Seminar at Hotel Hyatt Regency, Manesar to strengthen its bonds with customers and strategic business partners and to show its appreciation for their support in jointly achieving 2018 goals. With fortitude to always act as an efficiency partner to its customers, the theme of the seminar “your productivity partner” concluded the whole event making the aura flourishing and keeping the determination and enthusiasm of the gathering high to achieve 2020 vision. The event theme talked about how Yaskawa is trying to be a productivity partner of Indian industry by offering world’s best products, excellence in engineering, innovation, after sales support and proximity. A huge audience of 350 plus customers and strategic business partners showcased their trust and relationship with Yaskawa in its long journey of growth. The event commenced with an auspicious lamp lighting ceremony which was attended by who’s who of Indian industry and representatives from
Embassy of Japan and Japan Plus along with Mr. Akinori Urakawa – President & CEO of Yaskawa India Pvt Ltd. The dignitaries include Mr. P. Soni – Director & CEO of SKH Group, Mr. Sanjay Bassi – Head of Corporate Sourcing of JBM Group, Mr. Yuichi Koshikawa – Second Secretary, Embassy of Japan and Mr. Tomoyoshi Hisamori- Japan Plus, Department of Industrial Policy & Promotion.
As the event moved further, an audience was amazed when Mr. Ajay Gurjar – Dy. COO Yaskawa India (Robotic Division), arrived on stage with MOTOMINI, the world’s smallest and lightest robot to address the audience. During his presentation on “Yaskawa - your productivity partner” he talked about entire range
of robotic offerings, AC Drives and Servo & Motion control products, Industry 4.0, i3 Mechatronics, System engineering, After sales and regional support model of Yaskawa. Initiatives taken by Yaskawa in establishing Robotic Centre of Excellence in various engineering institutions and acknowledgement by Indian media was appreciated by the customers. Distinguished clients, to name a few, who were present, include automotive giants like Suzuki Motorcycles, Hero MotoCorp, Honda Cars, Honda Motorcycles & Scooters and T-1 suppliers like JBM, SKH, Hema Engineering, KML, Minda, SIAC and many more. General Industry customers like Samsung, LG, Havel’s and strategic business partners like Yaskawa-Doolim, Taikisha, Techanvia, Nexgen, PAPL who are specialized in various robotics applications and do business with Yaskawa robotics, were also in attendance. Through customer voice, representatives from SKH (Mr. Sanjay Koul-– Head of Corporate Sourcing) & JBM (Mr. M.S.Rawat- Plant Head) validated Yaskawa India Robotics for their services, products & 24x7 support. The evening was followed by the Lucky Draw anonymously, having two winners of Lenovo tabs and further the gala dinner wherein all the participants enjoyed the music, fun and Yaskawa MOTOMINI serving Tequila shots, creating a great deal of bonhomie and energy to work towards the 2019 and beyond goals. The customer meet in Gurugram allowed us to share the best in motion control technology across the length and breadth of the NCR Region!!
For more information Website: www.yaskawaindia.in
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BUSINESS NEWS
Oerlikon Balzers continues expansion with new customer centre in China Recently, Oerlikon Balzers, a leading global provider of surface technologies, held the Grand Opening Ceremony with guests of honour and customers to inaugurate its new coating centre in Dongguan, China. A much larger production space was required in Dongguan in order to process the rapidly growing order volume of recent years. Oerlikon Balzers started its coating business in China in 2004. The new customer centre is now the second largest in China. It is one of 111 coating centres in 35 countries worldwide. Oerlikon Balzers began production in Dongguan, one of eleven customer centres in China, in 2008. As the existing production centre had insufficient capacity to
From L to R: Ian Howe (Head of Precision Components), David Franz (Regional Executive North East Asia), Peter Liu (General Manager Oerlikon Surface Solutions China), Marc Desrayaud (Head of Oerlikon Balzers), Ye Kunhong (Governor Representative), Henry Guo (Director of Sales & Operations Balzers Industrial Solutions, China), Wolfgang Kalss (Head of ThinFilm Cutting Tools) and Pravin Shirse (Managing Director Oerlikon Balzers India) cut the ribbon.
meet the high demand for Oerlikon Balzers’ solutions for cutting and forming tools, and now for precision components as well, the company decided to relocate the
Marc Desrayaud (Head of Oerlikon Balzers) and Ye Kunhong (Governor Representative) unveil the traditional inauguration plaque.
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customer centre to provide a production area three times the previous size. This new facility will allow the company to fulfil the growing number of new orders from a wide range of industries and offer enhanced services to its customers in this heavily industrial region of China. Marc Desrayaud, Head of Oerlikon Balzers, explained in his speech at the opening ceremony: “Since 2008, when we began production in Dongguan, our customers have placed more and more orders every year, a clear demonstration of their confidence in our technologies and services. We feel honoured by this
strong relationship and will not let our customers down. Relocating to these new premises is part of our long-term growth strategy: establishing this new customer centre in Dongguan allows us to continue serving our customers while also expanding the range of services we provide. We have invested in the latest coating equipment and technologies and have recruited new staff in order to provide our customers with first-class environmentally-friendly coatings combined with an excellent service.”
For more information www.oerlikon.com/balzers
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BUSINESS NEWS
New alignment laser system increases Renishaw’s range of machine calibration solutions Renishaw’s new XK10 alignment laser system has been developed for use during the build and alignment of machine tools, replacing the need for artefacts. It can be used on linear rails to ensure that they are straight, square, flat and level, as well as to assess spindle direction and coaxiality of rotary machines. These factors can be measured and aligned with the XK10 during build, using the systems live display. The XK10 is also a powerful tool for diagnosing the source of errors following a collision or as part of regular maintenance.
XK10 can measure and align geometric and rotational components for machines with axis lengths up to 30 m. It replaces the need for artefacts such as granite squares and test bars, that need to be calibrated and transported
at considerable cost. With simple mounting onto machine guideways, this single modular system can perform faster setup and measurement of the machine when compared with traditional methods. The XK10’s intuitive
software reduces reliance on highly skilled operators. Measurements are digitally recorded and can be exported, providing traceability to international standards, or can be viewed directly on the robust display unit. Renishaw’s new XK10 alignment laser system resolves the challenges found when using traditional artefacts and offers a single digital solution, across a range of machine tools. For more information, www.renishaw.com
LANXESS announces capacity expansion for corrosion inhibitor products Specialty chemicals company LANXESS has successfully completed a debottlenecking project resulting in a 15 percent increase in global production capacity of its Additin RC 4000 series of corrosion inhibition additives. The additional capacities are a result of process synergies identified and realized following LANXESS’s 2017 acquisition of Chemtura Corporation, which expanded its lubricant additives portfolio and global production network. “With LANXESS’s in26
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creased footprint from the Chemtura acquisition, we were able to unlock process synergies between our production sites in Mannheim, Germany and West Hill, Canada to increase output of our corrosion inhibitors products to meet market demand and further enhance our global production network,” said Martin Saewe, Head of the Lubricant Additives business line in LANXESS’s Additives (ADD) business unit. “The global corrosion inhibitor market is growing and we have
APRIL 2019
seen increasing demand for LANXESS specialty additives products due to their unique performance and technical advantages relative to other product offerings in the market,” Saewe adds. “While we are committed to supply security for our customers, we are also looking toward the future with new product developments in the pipeline to meet new performance requirements and stricter regulations.” LANXESS’s Additin Corrosion Inhibition (CI) product range includes
calcium sulfonate, carboxylate, succinic acid, and phosphoric acid-based specialty products. They work by being adsorbed on the polar metal surface to form a water-repellent and protective film that protects against corrosion. Main applications include power transmission oils, industrial oils, metalworking fluids, anti-corrosion oils, and greases.
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BUSINESS NEWS
ANCA announces Daniel Shepley as Apprentice of the Year ANCA, a privately owned global exporter of advanced technology headquartered in Bayswater, Melbourne was struggling to recruit young engineers and trades people to join their team. With over 1,000 people around the world, a turnover of $250 million and being the dominant player in its sector, searching for skilled people was becoming a major business issue. In response ANCA decided to train its own and in January 2011 they established an apprenticeship program which has been successfully training highly skilled technicians since. Set up by co-founder Pat McCluskey, the program has been designed to offer participants a range of technical training paths in CNC machining; machine building; fault finding
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and analytical skills; machine commissioning and customer service. ANCA currently has 15 apprentices and recently celebrated the graduation of four of these from the program. Daniel Shepley, Commissioning Technician graduated the ANCA Apprentice 2019 program this month and took out the Apprentice of the Year award by the company at the celebration evening. Of participating in the program Daniel said: “It feels great to finish my
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apprenticeship after four years, I have worked in multiple parts of production learnt different skills in different areas and met heaps of great people. My proudest achievement over the time of my apprenticeship would probably be the first time I was sent overseas. I was sent to Weinheim in Germany for three months to support ANCA’s German branch. It was a challenge working on some unfamiliar tasks but I learnt lots and was happy with the job I did.”
“The biggest challenge of the program would have to be being sent over to America for six weeks to install new machines and service some older machines out in the field, I worked in various parts of Michigan, Ohio and Indiana. Although it was challenging it was really rewarding to travel to customers and work on their machines resulting in good outcomes,” Daniel concluded. Stuart Gurney, Apprentice Master said: “ANCA has a proud history of investing in its people to develop a highly skilled and engaged workforce. My apprentices get exposure to CNC machining, precision fitting, electrical testing and grinding applications throughout their four-year program.”
For more information, Website: www.anca.com
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BUSINESS NEWS
Anthony Machine and Kennametal Team-up to Reduce Setup Times Anthony Machine Inc has served a variety of industries, including oil and gas, mining, transportation and power generation. With all that precision machining experience, there’s little this San Antonio job shop can’t handle. However, after the company purchased a pair of NLX 3000 1250 universal turning centers from CNC machine builder DMG Mori—the shop’s first Y-axis, live-tool lathes— Anthony’s manufacturing team was challenged with making the most of that new investment. Kennametal senior sales engineer Mark Davis was there to help, just as he’s been for the past decade. He explained to Anthony that the best way to reduce setup times and maximize the new machines’ potential would be to
equip them with Turret Adapted Clamping Units (TACU) and KM quickchange toolholders. “The TACU system supports everything from KM32 up to KM63,” Davis says. “We offer blocks for both static and driven tools, and can tool up lathes from Okuma, Haas, Mazak, Doosan, and of course DMG Mori—pretty much all of the major machine tool builders, with more coming online all the time. This makes it both easy and cost-effective for our customers to equip more than 80 models of CNC turning centers with a fast, flexible and accurate quick-change toolholding system.”According to Anthony Machine manufacturing technologist Daniel Goller, the decision to adopt TACU and KM for the new machines was an easy one. “Over
Anthony Machine has been using KM throughout the shop for years, so when the time came to equip their new Y-axis lathes from DMG Mori with quick-change tooling, the choice was clear.
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Mohsen Saleh and CNC machinist setter Mark Garland discuss a workpiece produced on one of Anthony Machine’s DMG Mori NLX 3000 1250 universal turning centers.
the years, we’ve built a number of KM-equipped custom toolholders for deep boring and other machining operations on our CNC lathes and machining centers, and we use Kennametal? on several of the shop’s manual turret lathes to overcome limitations with available tool positions,” he says. “On more than one occasion, we’ve earned new business because KM was able to achieve tolerances and surface finishes that others couldn’t do with conventional tooling.” Anthony’s operations manager Mohsen Saleh agrees. “The differences are striking,” he says. “Compared to the traditional wedge and screw-style blocks that come standard on most machines, the KMequipped TACU units are both faster and more
accurate. We routinely hold tolerances of 0.0005” (0.013 mm) and I’m told that part size doesn’t change from one clamping to the next. The turret’s less crowded, everything’s easier to get at, and you don’t have the chatter and deflection that you often find with your typical straight shank tools and set-screw type boring bar holders.” “Anthony’s experience with TACU is what we’ve come to expect from KM,” notes Kennametal’s Davis. “Considering the breadth of the platform, its accuracy, and especially its flexibility, it’s quickly become the de facto industry standard in quickchange tooling.”
For more information, Web: www.kennametal.com
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IN FOCUS
GP PETROLEUMS: Extending horizons through quality in lubricants arena Q. Please brief us about recent initiatives undertaken in machine tools space? Which are your focus areas? IPOL brand has strong roots in the machine tools space with wide range of products in the metal working applications facilitating productivity with desired precision of work. The focus is to enhance the performance, reduce downtime, increase tool life, better machine upkeep and delivering operator and environment friendly products. Q. What are the market opportunities for your products in India? How do you plan to position these products? This market offers tremendous opportunities for Metal Working Fluids as these are integral part of any production process. We offer wide range of products like Water Soluble cutting fluids, Neat Cutting fluids, Semi- Synthetic Cutting Fluids, Quenching Oils, Rust Preventives and Cleaners. IPOL has a significant presence in the Industrial lubricants segment for Metal working fluids, Corrosion prevention, Quenching oils, Gear oils, Process oils and Greases since last four decades. A wide range of products and services have helped us to become a dominant player in the manufacturing segment with the
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agility to offer customized solutions. We see an increased opportunity in the growing automotive sector and also new opportunities through development in bio degradable lubricants. Q. What is your marketing strategy for India? Our strategy is to focus on value added products and services which will optimize the ‘Total Cost of Operations’ for our customers. GP Petroleums Limited is geared up to offer complete solution to the customers and not just a product offer. Our approach is to work closely with the customers by understanding their application, usage, pain points and offer a composite solution. This approach ensures end user confidence on the performance and the reliability of the product. The usage of the right product for the right application, following good maintenance practices will help the customer to have extended tool life, less machine downtime and low top up consumption of the machine lubricants or metal working fluids. Q. According you what are the factors affecting to your business? The key factor affecting our business is the socio- economic conditions which drive the Industrial
productivity and in turn drives the demand for the metal working fluids. 1. Budget Outlay on Infrastructure development 2. Credit availability in the market driving growth of Auto sector 3. Migration from BS IV TO BS VI 4. Stringent emission norms 5. Environment and safety concerns Q. What are the key technological trends that are driving machine tools industry? The machine tool industry is evolving with developments in both hardware technology and software applications this has resulted in machines becoming faster, intelligent and versatile. The emergence of Industry 4.0 demands much more reliable and consistent productivity and output. This in turn puts increasing responsibility on the Metal working Fluids to be very consistent in performance and longevity. The modern metal working fluids are based on high performance chemicals and stable base fluids. Some recent trends in Metal Working Fluids are a) Bio Based Lubricants, b) recycle or reuse, c) MQL or Minimum Quantity Lubrication. 1. Environmentally Adapted Lubricants-MWF systems has focused on Environmentally
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IN FOCUS
Hari Prakash M Chief Executive Officer GP Petroleums Ltd.
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IN FOCUS
Adapted Lubricants (EALs). EALs have been defined in the European Union as lubricants that have high biodegradability and low toxicity with performance equal to or better than conventional alternatives. Several classes of EALs have been developed, including vegetable oil based ingredients which are being substituted into traditional waterbased and straight-oil formulations as renewable and biodegradable alternatives to conventional fluids, primarily as vegetable-based
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formulations, and their market share is growing 2. Minimum Quantity Lubrication (MQL) techniques represent another growing class of EALs. MQL typically involves sprays of compressed air and a small amount of oil to provide the function of a MWF without the large volumes of aqueous waste. However, air is an inefficient coolant and today’s oil-in-air MQL systems are only suitable for mild machining operations that do not require
significant heat removal. Q. What is your vision for your company? Our vision is to be the preferred partner for providing world class metal working fluids and services by applying technology and creating innovative business solutions. IPOL is fast getting recognition as a solution provider and we are keen to build our brand IPOL as the first call for any lubricant requirement in the manufacturing sector.
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INDUSTRY VIEW
The Evolving Landscape of Metalworking Fluid Industry A lot of innovation is happening in the metalworking fluid (MWF) industry in the direction of balancing performance needs and environmental impact. Major players are continually working towards developing sustainable and more eco-friendly formulations. Shweta Nanda of Machine Tools World takes a comprehensive look at the growth drivers, impact of rising trend of dry machining and the way ahead for the industry
T
he MWF segment has been on the steady rise and doesn’t show any signs of slowing down soon. Several market reports also point to the rapid growth prospects of the industry. As per a report by research firm, Global Market Insights, the global market for MWF is pegged to exceed $15 billion by 2025. When we look closer home, India is one of the key regions contributing to the growth of the segment, with promising future prospects. As MWFs are used across a spectrum of manufacturing processes to cool or lubricate workpieces when they are being machined, they play a critical role in machining. With rapid growth in manufacturing activities in India, metalworking fluid industry too is riding the tide. Auto sector, undoubtedly, is the prime driver of MWF growth in the
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country, with India moving towards becoming global sourcing hub for many auto companies, leading to more auto component production in India. That said, some other sectors are also adding to the demand rise. Experts believe that India still has big head room to grow on aviation component, which could be future growth engine in India for MWF. “While, most of the growth comes from automotive and auto component manufacturing, aerospace, defence, infrastructure and FMCG also contribute to this growth. India is a huge market and one of the major consumer of MWF in the world and we are seeing lots of new investments coming to India, which will further improve the potential for MWF,” shares Yatendra Kumar, Business Head – MotulTech India.
Echoing similar emotions, Rebecca Samotra, Marketing Manager, D.A. Stuart India Pvt Ltd. (A Houghton Company) says, “The market is expected to be driven by the rapidly growing automotive sector for which the metalworking fluids are used during the manufacturing of automotive parts and other equipment. The metalworking fluids market has been segmented based on end-use industry into transport equipment, primary ferrous, primary non-ferrous, machinery and metal fabrication industry. The main industries linked with transport equipment are automotive and fabricated metal industries which are involved in the manufacturing of boilers, radiators, engines, and other equipment, hence driving the overall metalworking fluids market.” In the recent years, MWF technology has advanced considerably so much
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INDUSTRY VIEW so that the right fluid for a particular process has the potential to significantly increase efficiency and process productivity. “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,” asserts Shankar Karnik, General Manager, Industrial Lubricants, ExxonMobil Lubricants. MFWs are segmented into four different product types, namely, removal fluids, forming fluids, protection fluids, and quenching fluids. The removal fluids are used to remove the metal chips produced during the drilling and milling of metal pieces. The forming fluids are used as rolling oils, forging fluids, and hydroforming fluids and are used in metal fabrication and machinery industries. “Removal fluids are currently dominating the market share and the dominance will continue due to the high use of coolants, cutting fluids, and grinding fluids during the various machine processes in manufacturing, says Samotra. The Increasing Shift towards Dry Machining While MWFs continue to be extensively used in machining industries, advanced processing technique, such as dry machining are also gaining popularity. MWFs are expensive to use and even dispose and have been under constant scrutiny for safety and environmental hazards. Thus, the discussions around dry machining and near dry machining come to the fore
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time and again. Dry machining works well in applications, such as milling, where the tool only makes intermittent intervention in the material. “Dry Machining provides a cleaner, hassle-free working environment. Manufacturers use vacuums to remove chips and air to clean fixtures, leaving no coolant mist or waste to dispose of,” shares Samotra. On the flip side, dry machining does not offer all the advantages of MWFs and they are acceptable only
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 Shankar Karnik, General Manager, Industrial Lubricants, ExxonMobil Lubricants.
when the part quality and machining times achieved in wet machining are equalled or surpassed. According to industry experts, dry machining does offer advantages for niche markets but it won’t replace traditional metalworking fluid technology anytime soon. Sustainable MWFs: Need of the Hour A lot of innovation is happening in the MWF industry in the direction of balancing performance needs and environmental impact. Regulations and safety and health concerns are fuelling the need for chemical reformulation in MWFs. Regions, such as North America and Europe, have already laid down strict policies to ensure the usage of ecofriendly products. Stringent regulations ensure that only manufacturers that have the ability to develop sustainable fluids are allowed to operate. Given the rising awareness, other regions too are expected to tighten regulatory norms. Thus, sustainable MWFs are the way forward. For maximum impact, the whole value chain needs to be taken care of. This essentially means that not only oil but other components used in MWF need to be eco-friendly. “End users give due consideration on the composition of metalworking fluids as altering it may change the range of functions these fluids can perform. In addition, it is imperative for manufacturers in the global metalworking fluids market to give attention to the safety profile of the base oil used in metalworking fluids, such as evaluating their allergen content, compatibility with humans, and emission behaviour. These factors are expected to drive advancement in products,” elaborates Samotra. MWFs today are available in three broad categories, including non-watermiscible oils, water-miscible (emulsifiable) concentrates and fully synthetic, oil-free products. Given the ever-grow-
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INDUSTRY VIEW ing thrust on utilizing green solutions that reduce environmental impact, market is drifting towards semi-synthetic and synthetic products. MWF producers are also showing inclination in developing semi-synthetic/synthetic formulation as they get better value for their product. Given the market demand, experts predict that synthetic fluids from the entire metalworking fluids range will be the fastest growing segment by 2025. Kumar from MotulTech asserts that sustainable products are the need of
End users give due consideration on the composition of metalworking fluids as altering it may change the range of functions these fluids can perform. In addition, it is imperative for manufacturers in the global metalworking fluids market to give attention to the safety profile of the base oil used in metalworking fluids, such as evaluating their allergen content, compatibility with humans, and emission behaviour. These factors are expected to drive advancement in products Rebecca Samotra, Marketing Manager, D.A. Stuart India Pvt Ltd. (A Houghton Company)
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the hour and we need to work on this with sense of high urgency. “Customers should also look to work with the lubricants manufacturers, who has such technologies and ready to invest further to make the world sustainable. Since sustainable products are high in cost, not many peoples in India, are ready to accept these products and we need to change this for our own survival,” he says. Kumar stresses on the importance to innovate products which not only enhance performance but also reduce the fluid consumption. “MWFs needs to be disposed very effectively with minimum harm to environment. Hence, it is most important for us to innovate the products that not only give optimum performance in machining or any other metalworking operation but also help in reducing overall consumption. This saves the cost of disposal as lowest quantity needs to be disposed, as well as reduces carbon footprint and environmental hazards,” he says. “Rigorous environmental regulations have compelled manufacturers to implement recycling programs. Cost reduction from recycling fluids can be significant,” agrees Samotra. More and more companies are continuously focusing on R&D to prepare environmentally friendly formulations for metalworking fluids. A case in point is MotulTech, which has a fully biodegradable MWF to be used as minimum quantity lubricants (MQL) used in near dry machining. Similarly, Houghton is developing new products using novel chemistry and state of the art tribology equipment, guided by the principles of Design of Experiment (DOE) statistical analysis. “Houghton continuously works with our supply chain and customers to identify safer and effective components for product formulations and to ensure that all identified hazards and properties of component ingredients are con-
MWFs needs to be disposed very effectively with minimum harm to environment. Hence, it is most important for us to innovate the products that not only give optimum performance in machining or any other metalworking operation but also help in reducing overall consumption. This saves the cost of disposal as lowest quantity needs to be disposed, as well as reduces carbon footprint and environmental hazards Yatendra Kumar, Business Head – MotulTech India sidered in the product risk assessment, classification and product end uses. Houghton’s risk assessment processes evaluate inherent chemical risks such as toxicity, corrosivity and flammability within the context of product end uses,” shares Samotra. So, what does the future look like for the MFW industry? Well, the opportunities are galore owing to rapid growth of the growing manufacturing and metal fabrication segments in the country. However, there is a strong need to not only develop environmentally friendly products but also to raise awareness in customers regarding their benefits.
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IN FOCUS
“Mobil’s perfect formula for machine tool industry” Shankar Karnik, General Manager, Industrial Lubricants, ExxonMobil Lubricants Private Limited
Shankar Karnik, General Manager, Industrial Lubricants, ExxonMobil Lubricants Private Limited, reveals how the right lubricant can improve productivity and increase profits for a manufacturing business Q. ExxonMobil 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 ExxonMobil 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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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. How important is oil analysis as part of the lubrication program? Technologically-advanced lubrication practice is one of the key factors for preventive maintenance. Lubricant is the lifeblood of machines and oil analysis is akin to a doctor testing a blood sample to assess one’s health and detect ailments that require treatment. A sample of oil provides crucial information that can help increase productivity, reduce unscheduled downtime, improve equipment durability and lessen lubricant consumption. Mobil ServSM Lubricant Analysis, bringing its thorough knowledge of applications and equipment built by working closely with original equipment manufacturers, delivers precise analysis and detailed, actionable recommendations, resulting in cost savings, strong pro-
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IN FOCUS ductivity and peace of mind. We also bring expertise through our Mobil ServSM Engineering Services to help plants optimize their lubrication programs, troubleshoot equipment issues and proactively inspect and monitor equipment for more efficient and profitable operations. 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 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.
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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. What are Mobil’s key products for the Indian manufacturing sector? Mobil offers a complete range of lubricants for the Manufacturing sector, including OEM-approved products with years of proven performance, as well as advanced problem-solving synthetic oils, industrial oils and greases. Our range for the Manufacturing sector includes Mobil DTE 10 Excel™ Series, our high performance anti-wear hydraulic oils specifically designed to meet the needs of modern, high pressure, industrial and mobile equipment hydraulic systems; Mobilcut™ series – the aqueous metal working fluids that deliver a dependable performance in a wide array of metal removal processes; Mobil Vactra™ Oil Numbered Series – the premium-quality slideway lubricants specifically designed to meet the requirements for accuracy, aqueous coolant separability, and equipment protection of precision machine tools; Mobil SHC™ 600 – the exceptional performance gear and bearing oils designed to provide outstanding service in terms of equipment protection, oil life and problem-free operations; Mobil SHC Gear™ – the synthetic industrial gear oils designed to provide outstanding protection of gears and bearings; Mobil SHC Rarus™ – the supreme-performance air compressor lubricants; Mobil SHC Polyrex™ - the specifically designed greases to improve productivity in high temperature conditions; Mobilith SHC™- the superior performance greases designed for a wide variety of
applications; Mobilgrease XHP™ - the extended-service lithium complex greases designed for a wide variety of heavy duty applications and operating conditions and Mobilgear™ 600 XP – the extra high-performance gear oils having outstanding extreme-pressure characteristics and load-carrying properties. Q. ExxonMobil is known for its cutting-edge innovations and customisations. Can you share an example of how Mobil Serv created a solution for an Indian manufacturer? In terms of customization, let me share an example of a recent engagement with Modern Mould Limited, a leading organization in the plastics industry. The injection moulding major charged a new hydraulic oil in their machine and a heat exchanger malfunction resulted in water entering the oil. To manage the high production demand, the machine could not be stopped for oil replacement and running with contaminated oil would damage the pump and machine components. Offering a solution to Modern Mould Limited, Mobil’s Field Engineering team proposed to opt for online water removal with a low vacuum dehydrator. After completing the water removal procedure, the oil’s suitability for use was tested under Mobil Serv Lubricant Analysis program and it was found fit for further use. Thanks to Mobil Serv’s predictive maintenance and corrective action, the damage to the machine components was averted, the oil disposal was avoided and the high productivity was maintained, potentially saving 36 hours, 2200 litre of oil and revenue of INR 670,800!
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INDUSTRY VIEW
Leadership in Specialty Naphthenic Oils Nynas is a different kind of oil company – we want to use oil, not burn it. With around 1000 employees, two independent production facilities in Europe as well as offices in over 30 countries, Nynas is dedicated to researching, producing and supplying specialty naphthenic oils and bitumen for a growing global market. Together with our customers, we have the know-how to find new applications and meet new challenges that can help shape society. We take oil further to bring value to customers and the world we live in. Nynas is a key global supplier of highly refined, hydrotreated naphthenic base oils. These Naphthenic Specialty Products (NSP) are applied as base oils for industrial lubricants and lubricating greases, or as process oils for rubber and plastics
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(and many other uses). The naphthenic base oils have many attractive properties for the formulation of industrial lubricants, and have found widespread application due to the following properties: • Wide viscosity range, 3 to 700 cSt (at 40 °C) • Higher solvency power than paraffinic base oils of the same viscosity • Low PAH aromatic content • Low toxicity and IP 346 label free • Very good low temperature properties • Very high emulsion stability • Good heat transfer capacity • Effective convective cooling efficiency • Globally available base oil supply On average, Industrial Gear Oils account for almost 3% of the global
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NYNASÂŽ base oil. Bringing industry to life
At Nynas, we see oil as a high-tech tool for creating sustainable value. We use our knowledge to produce naphthenic base oils for metalworking fluids, lubricants, and greases, designed to keep the cogs and wheels of society turning smoothly. www.nynas.com > base oils Nynas Naphthenics Pvt. Ltd, #2203 - 2205 Kesar Solitaire, Plot No. 5, Sector 19, Palm Beach Road, Navi Mumbai 400 705, Maharashtra, INDIA. Telephone: +91-22-6815 1900
INDUSTRY VIEW lubricants market. Total global consumption is expected to reach well over 1 million tonnes by 2020, with Naphthenic oils poised to increase their market share in this application. Industrial gear oils are generally formulated with 95-98% of base oil. The other 2-5% often consists of an industrial gear oil additive package. A traditional Industrial Gear oil in the VG range 150 to 460 is typically formulated from paraffinic Bright Stock and SN 500/600 in different proportions according to the needs of the different Viscosity Grades. For the upper viscosity grades, ISO VG 680, 1000 and 1500, Viscosity Modifiers (VM) like PIB, or Viscosity Index Improvers (VII:s) are employed to create viscosities above what can be reached using typical paraffinic Bright Stock (KV at 40 °C ca 500 cSt) Naphthenic base oils for industrial lubricants offer benefits with regards to high additive solvency and low temperature properties. Naphthenic base oils do not, however, on their own have the required Viscosity Index (VI) required in the common ISO VG grades for many industrial lubricants. In, for example, Industrial Gear Oil standards such as ISO 12925-1 and DIN 51517-3, a minimum viscosity index of 90 or 85 is required. Therefore, to be able to formulate gear oils based on NYNAS® Naphthenic specialty base oils, we
Table 2. Select model systems reaching the KV and VI of the ISO VG class indicated Base Oil
Additive
Treat rate (%)
ISO VG
NYNAS® T 400
#1 OPAG
43
150
NYNAS® T 110
#3 PAMA
7
220
NYNAS T 110
#2 BIO
12
320
NYNAS BT 150
#3 PAMA
12
320
NYNAS T 400
#4 OCP
11
460
NYNAS® T 400
#3 PAMA
10
680
NYNAS T 600
#5 EEB
27
680
NYNAS T 400
#2 BIO
15
1000
NYNAS T 600
#2 BIO
15
1500
® ® ®
® ® ®
have created a set of model base fluids meeting these Kinematic Viscosity (KV) and Viscosity Index (VI) requirements. We have shown that all ISO VG classes relevant for industrial gear oils indeed can be formulated from NYNAS® T 110, BT 150, T 400 and T 600 with the addition of Viscosity Index Improvers (VII), Viscosity Modifiers (VM) or high VI base fluids. We managed to meet KV and VI requirements for seven ISO VG classes: 150, 220, 320, 460, 680, 1000 and 1500 in least one of the model base fluid formulations in each ISO VG class. Five (5) different commercially available viscosity modifiers were successfully employed, Table 1. The required content of VII, VM or high VI base fluid needed in each model formulation varied from 7% to 43%,
Table 1. An overview of viscosity modifiers investigated.
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and the average treat rate level was around 10-15%. Some examples of successful formulations are: • NYNAS® T 110 and #2 BIO, 12%, makes ISO VG 320 • NYNAS® BT 150 and #3 PAMA, 12%, makes ISO VG 320 • NYNAS® T 400 and #4 OCP; 11%, makes ISO VG 460 • NYNAS® T 600 and #2 BIO, 15%, makes ISO VG 1500 Please see Table 2 for more examples We thus can propose starting formulations for industrial gear oils, and other industrial lubricant and greases needing high base oil viscosity. A wide viscosity range, 150 to 1500 cSt, utilizing four different high viscosity NYNAS® Naphthenic base oils and five different VI Improvers representing different chemical compositions, have been made. We are now ready to share these results with formulator eager to explore the span of opportunities offered by NYNAS® Naphthenic base oils in industrial lubricant applications.
VII or VM Name
Polymer or Fluid Type
#1 OPAG
PAG base fluid, liquid. Fatty alcohol poly-glycol ether. KV 90 cSt at 40 °C, VI 191.
2# BIO
Complex ester, KV 40 000 cSt at 40 °C, VI 290
#3 PAMA
PAMA, liquid. Dissolved in highly refined mineral oil. (PSSI): 43. KV 30 000 cSt at 40 °C, VI 240.
- Thomas Norrby
#4 OCP
OCP, liquid. Ethylene/propylene co-oligomer. KV 37 500 cSt at 40 °C, VI 300.
Please contact your Nynas representative
#5 EEB
Synthetic base stock, KV 1000 cSt at 40 °C, VI 227.
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for further details and tips! Website: www.nynas.com
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ADVERTORIAL
Quaker Chemical Corporation inaugurates its state-of-the art new manufacturing facility in India
Q
uaker Chemical Corporation today held the grand opening of its state-ofthe-art manufacturing facility in Dahej, Gujarat, India. The site will be used to produce rolling oils and metalworking fluids for the steel and metalworking market in India, the Middle East, and east Africa. This is the latest operations expansion for Quaker, whose India headquarters were established in 1997 in Kolkata. Since that time, the company has continued to build a strong brand presence in the country supporting the metalworking fluids industry. “We are very proud of this achievement – the opening of a special facility in a special place. This major milestone is happening as Quaker celebrates more than 20 years in India. Today’s inauguration of the Dahej Manufacturing Facility, a truly world-class and world-scale
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manufacturing facility, begins yet another chapter in Quaker India’s already successful journey,” said Gulshan Kumar Sachdev, Managing Director, Quaker Chemical India. The newly built plant combines state-of-the-art technology with Quaker’s long history of manufacturing excellence and safety. The site incorporates unique features in its design, such as high efficiency induction motors to reduce energy, a water condensation recovery system, and wastewater treatment technology that supports Quaker’s environmental goals. The Dahej facility will add between 7,000 and 12,000 metric tons of capacity to the company’s operations by the end of 2019, with plans to increase that capacity to 20,000 metric tons over the next few years. “Quaker is truly proud to add this new production capability for the benefit of our regional customers.
In particular, this site strengthens Quaker’s supply chain in western India, the Middle East, and eastern Africa,” said Wilbert Platzer, Vice President Global Operations, EH&S and Procurement. “Together with our existing manufacturing partner, Asianol Lubricants based in Kolkata, and our warehousing infrastructure around India, Quaker is able to provide customers with an efficient, secure, and reliable supply chain they can count on.”
For more information, Quaker Chemical India Private Ltd 11/3, 11th Floor, ACROPOLIS, 1858/1, Rajdanga Main Road, Kolkata, 700107 INDIA Office: +91.33.40464500, Cell: +91.70300 64545, Fax: +91.33.46010839 Web: www.quakerchem.com
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TECH UPDATE
Robust, accurate & non-contact measurement of vertical surfaces How to measure flanks with more than 90°
S
o far, geometries such as the bore holes of e.g. injection valves in the automotive industry could hardly be measured optically. Lateral probing of components with vertical surfaces was limited to tactile measuring systems, CT solutions or complex special solutions. This changes with a new function of the optical coordinate measuring system µCMM, which Bruker Alicona will present at this year’s Control show in Germany, Stuttgart. Vertical surfaces of more than 90° can now also be measured optically. Coordinate measuring machine µCMM enables optical hole measurement µCMM is the first purely optical coordinate measuring machine that enables the measurement of dimension, position, shape and roughness of smallest tolerances contact-free and with only one sensor. Now, a new feature of this coordinate measuring system also allows the lateral probing of components. Component features such as holes, bores, reference surfaces, contours, lengths etc. can thus be optically measured with high accuracy, high resolution and in short measurement times. The diameter-depth ratio of holes ranges from 1:3 to 1:10, the measurable diameter is 0.1 mm to 2 mm. Users measure parameters such as outside and inside diameter and opening angle. In combination with an automatic rotation unit “µCMM
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Real3D”, turning the 3-axis CMM into a 5-axis system, multiple holes including their orientation to each other can be measured. One application which can be achieved using the µCMM in combination with Real3D is the measurement of injection nozzles including diameter, K-factor, injection angle and side angle.
Focus-Variation technology and is based on the use of a partial light cone. Individual light rays diffusely reflected from vertical surfaces are captured by the lens. Flanks with more than 90° are traceably measured in high-resolution and high repeatability. Vertical flanks measured in this way can be used, for example, to fit a workpiece coordinate system. First purely optical coordinate measuring system µCMM µCMM allows highly accurate measurement of smallest tolerances, even on large components. 3D data is captured areal based and in high measurement point density, which, in addition to measuring dimensional parameters, also enables the measurement of roughness according to EN ISO 4287/88 (Ra, Rq, Rz...) and 25178 (Sa, Sq, Sz...). Due to the high accuracy of the axes, individual measurements are precisely related to each other. Users can also verify the position of their components in this way. Therefore, it is no longer necessary to measure the entire component optically as it is sufficient to measure only those areas that are relevant. For a user, this means a significant reduction in overall measuring time.
New “Vertical Focus Probing” technology The patent pending method for hole measurement “Vertical Focus Probing” is an extension of the
For more information, www.alicona.com
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COMPANY PROFILE
LMT Tools India at IMTEX 2019 is a huge success At IMTEX 2019, LMT Tools India received a great response from its visitors with more than 91,000 people visiting the show over a span of 7 days Using this machine customers were able to see Live-Up & Close, the various benefit of Thread Rolling Tools. This includes • Increase in Efficiency • Reduced Cycle Times • Cost Savings
T
he year 2019 started off with a bang for LMT Tools India at IMTEX 2019. The firm entered the show this year, with an intention of becoming the Go-To-InnovativeTechnology-Partner for its customers. The “Exactly Yours” experts of the LMT Tools Group promised to offer exactly the solution as per customer needs. This promise encompasses customized tooling solutions which stand out against standard solutions and at the same time feature the latest tool research innovations. This guarantees customers that their production is operating at top efficiency. IMTEX 2019 received great response from its visitors, more than 91,000 people visiting the show over a span of 7 days. For LMT Tools, it was one of the best trade shows with a rich customer interaction
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showcasing the passion for precision and being top solution providers to meet customer needs. The team showcased its latest innovations in the field of Gear Cutting, Advanced Tooling, Milling &Tapping and Thread Rolling with live machine display on how threads can be rolled in seconds! The firm also launched its 30 Printed Thread RollingTangential Attachment at the International Seminaron Machining Technologies at the IMTEX2019. Last but not the least, LMT Tools India has been recognized by Economic Times as the Best Metal Cutting Brand 2018! A quick glance at some of the latest highlights from LMT Tools at IMTEX: 1 .Thread Rolling on CNC Live Demo: This proved to be a show stopper at IMTEX 2019. With the live demonstration, the firm showed how threads could be rolled in seconds.
2. EVOLine Tangential Rolling Head: 3-DPrinted For More Stability Rolling systems allow extremely fast product ion of external threads with high fatigue strength. The thread rolling heads used and a rapid, reliable tool change are crucial. The new EVOilne tangential rolling head makes your processes even more efficient and user-friendly. It can be installed and removed without any
tools. Labeling on the components facilitates assembly and the identification of spare parts. LMT Tools produces the roller head hinges using 3D printing methods to optimize the volume flow and distribution 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.
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COMPANY PROFILE 3. UNIFY lndexible Insert Hob: Newsingle-part design has created a compact and robust base plate. The new UNIFY Indexable insert hob came to founding, as it was created to enable even more users to utilize carbide with economic efficiency. It strengthens the field of applications of the proven Carbideline-1 (Indexable) hob family in the module range 6-i2. The new single-part base plate allows a compact design (diafrom 150 mm) and thus also brings the benefits of using 4-edged indexable inserts onto smaller machines.
Longer tool life, shorter processing times and increased operational reliability significantly improve its economic efficiency. A robust and very precise working tool has been created by minimizing the interfaces on the carrier body. 4. HPFMax: The LMT Fette modular HPF forming tap has a unique selling point: this tool combines all the advantages of a wear resist ant carbide head and a durable steel shaft - thanks to a patented coupling joint. This enables high cutting speeds andmaxi mum tool life. Furthermore, users no longer have to change the whole tool because of wear, but only the forming head. LMT Fette is expanding its standard range for the HPF Max grade, which is immediately available up to size M33. Features include a micrograin carbide substrate (LCP25G), optimized geometry and an especially wear resistant
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TiCNcoating. These factors guarantee improved cost-effectiveness in mass production and in mechanical engineering compared to one-piece HSS forming taps 5. Tools for Turbocharger: Downsizing in Drive Technology In auto motive production, “downsizing” has been a trend for a number of years: engines are getting smaller and lighter, while delivering a higher performance. For this requirement, the turbocharger comes into its own: as extreme temperatures are generated inside, manufacturers use highly heat resistant materials. Users employ various methods for machining these materials. The specialists at LMT Tools have thought about this, too: with a single tool, users can perform boring, face and circular milling. Time-consuming tool changes are eliminated, secondary processing times are reduced. This is how the tooling solutions from LMT Tools increase the profitability of turbo charger production. 6. ChamferCut : Definition of a New Standard Chamfering with the patented ChamferCut process is economical, precise and reliable. The precise chamfer profile is machined by chamfering. This process, as opposed to conventional transforming methods, does not affect the material structure. The qual-
ity of the generated chamfer defines a new standard, while, all the while, maintaining top repetition accuracy. The process advantages combined with the low tool costs make deburring and chamfering with the ChamferCutthe most economical process on the market. 7. CopyMax2 : One Insert - TwoMissions The CopyMax®2 indexable insert that features can entirely new design by LMT Kieningerguarantees top performance in mold and die making: Apart from improved cutting and material properties, the copy milling plate has a fully functional second cutting edge. When the first cutting edge is worn down, the second cutting edge can be turned over and used with the same service life. In cases of practical applications it was possible to quadruple service life. Another new feature is that the milling plate is manufactured using the High Quality Sintering (HOS) process. Here, increased pressure and special forming ensure stabler cutting edges on the tool. This facilitates highly consistent and reliable cutting of the material over large material surfaces.
The world’s first double-sided ballnose insert with well proven performance of LMT Tools Kieninger. • Absolutely stable cutting edge due to the modified HOS- Process. • Highly economic solution for more than 70% of your roughing and semi-finishing applications. • Fully functional second cutting insert.
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Machine tool automation Machine calibration
Additive manufacturing / 3D printing
Material analysis
Gauging
Motion control
Dimensional measurement
Renishaw has supplied manufacturers in India and around the world with products that help to make products in less time, with more accuracy, higher levels of productivity, and with less waste. Today, our engineering and science based technologies are used in applications as diverse as jet engine, TV and solar-panel manufacture, through to 3D printing, dentistry and brain surgery. Contact one of our 6 Indian offices to find out more.
For more information visit www.renishaw.com
Renishaw India G.K Arcade, 3rd Floor, #125/1-18, T. Mariappa Road, Jayanagar 1st Block, Bangalore 560 011 T +91 80 6623 6000 F +91 80 6623 6060 E india@renishaw.com
www.renishaw.com
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COMPANY PROFILE
Shavo’s tailor-made technology solutions 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.
F
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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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
Mr. Rushil Shah, Managing Director, Shavo Technologies Pvt. Ltd.
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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COMPANY PROFILE
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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Solitaire No. 2 - 10" (250 mm) Precision Centerless Grinder
INDIAN ENTERPRISE
AMERICAN RIGIDITY
ITALIAN INNOVATION
Combined to give you Customized Centerless Grinders Solitaire Machine Tools Ltd. 292, Dharamsinh Desai Marg, Chhani Road, Vadodara - 390002, Gujarat, India Tel.: +91-265-2761776, +91-265-2773585 Email: sales@smtgrinders.com www.smtgrinders.com
EVENT PROFILE
IPTEX and Grindex 20 : Apt platform for gear & grinding technology Explore the great collaboration between gear and grinding technology
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he International Power Transmission Expo-2020, India’s exclusive expo for the Power Transmission Industry, is organized by Virgo Communication & Exhibitions (P) Ltd. IPTEX is emerging as one of the most promising platforms for the Gears and Power Transmission Equipment industry members to network with peers and potential buyers and market their products, services and capabilities to a diverse and significant audience. The 6th Edition is to be held between 13-15 February at the Auto Cluster Exhibition Center, Pune, India. IPTEX has been created with the mission to provide a consistent channel of communication to the members of the industry. It allows them to come together under one roof, share their knowledge & expertise with fellow members & participate in discussions on latest technology & process, industry practices, safety & standard and quality control. The ‘Make in India’ campaign has been a significant step towards making India the manufacturing hub of the world and has had a substantial impact on the overall economy. In the last 4 years, since the launch of the initiative, it has received a good response and has seen several large global brands coming forward to express support. India stands 12th in production and 8th in consumption of machine tools in the world as per the 2017 Gardner Business Media survey. The country is set to become a key player in the global machine tools industry and is likely to see substantial high-end machine tool manufacturing. • India’s manufacturing sector presently contributes about 16% to its GDP
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• India plans to create as many as 100 million skilled jobs in the manufacturing sector by raising its share of GDP from 16% to 25% • India’s manufacturing sector could reach US$ 1 TRILLION by 2025 as per a study by McKinsey and Company Ever since it was first held, more than a decade ago, IPTEX Expo has established itself as India’s leading event for power transmission industry. The only exhibition dedicated to this vital sector of engineering and manufacturing every two years, over 100 of the leading manufacturers, suppliers of technologies such as mechanical power transmission equipment including gearboxes, gear drives, gears, chains, belts, bearings, couplings, variable speed drives, electric motors and testing equipment manufacturer exhibit at the expo. Grindex Grindex is an exclusive expo on Tool Grinding & Surface finishing technology. It’s a best opportunity for Grinding industry player to come under one roof and to showcase latest products &
technology. Grindex will be held along with the IPTEX’20. As manufacturing industry needs to adopt new high-end technology, solutions and applications, the prime focus is on increasing the cost effectiveness and process efficiency. Grindex is specifically designed to meet the resultant demand for precision driven applications that serve these prime objectives. Grindex 2020 will focus on delivering:• Enhanced Productivity • Achieving increased level of precision • Improved aesthetics and design • Sharing best practices and ideas by companies that have adopted cutting edge technologies. The event is being organized by Virgo, India’s leading B2B exhibition organiser, publication & media house, creating highly effective business networking and interacting platforms for various niche market segments. Since 2004, Virgo has a strong presence in various niche segments of Adhesives & Sealants, Elevators & Escalators, Gears & Power Transmission, Grinding, Beer & Breweing and many more.
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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
TECH TRENDS
Wohlhaupter India Offers New Indexable Carbide Insert Drill – 4TEX The 4TEX drill is engineered to excel in drilling high temperature alloys and stainless steels.
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ohlhaupter India, an Allied Machine & Engineering company, announces the availability of their new 4TEX indexable carbide insert drilling system. Engineered to create optimal chip formation for efficient evacuation in holemaking processes, the drill outperforms other standard drills by delivering higher penetration rates in light duty machines. 4TEX excels in challenging applications that include interrupted cuts or drilling high temperature alloys and stainless steels. The indexable insert drill is ideal for making shallow 2xD, 3xD, and 4xD holes in the 0.472” – 1.850”
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(12mm - 47mm) range. The 4TEX drill’s unique design increases core strength, improving hole size and straightness. The flute space of the internal cutting edge side, where chips often cluster, is 1.6 times larger than typical IC drills. Dual twisted coolant outlets improve
penetration rates by enhancing coolant flow and generating superior chip evacuation. The insert geometries are optimized for wear resistance and are available in geometry/coating combinations for all ISO materials including steel, stainless steel, high temperature alloys, non-ferrous, and iron. The distinctive insert shape improves surface finish, hole quality and penetration rates, while eliminating issues from chips winding around the tool. The drills are stocked in both imperial and metric shanks with standard fractional diameters, as well as every ½ mm diameter up to 26mm and every 1 mm up to 47 mm assuring fast delivery. For more information on 4TEX or other holemaking solutions, visit www.wohlhaupterindia.in/
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Need more versatility?
WOHLHAUPTER® VARIOBORE The Wohlhaupter® VarioBore head offers precision, versatility, and an optional 3ETECH docking port for easy adjustments. Experience precision boring for yourself.
Put us to the test, and give us a call. DRILLING BORING
REAMING
BURNISHING
THREADING SPECIALS
Email: info.in@wohlhaupter.com | Phone: +91 11 41827044 Holemaking Solutions for Today’s Manufacturing www.wohlhaupterindia.in
AMT SECTION
TECH TRENDS
Kinefac® Corporation
K
inefac® Corporation, founded in 1962 to develop cylindrical die rolling equipment, is recognized as a world leader in the development and manufacture of specialized precision metal forming machinery and processing technology to meet the demands of the global aerospace, automotive, energy, medical, power generation and precision fastener industries. The company operates under six separate corporate divisions offering the most advanced CNC metal forming and metal cutting systems with interactive HMI user experience, process control and monitoring features, and fully integrated automatic parts handling systems including robotic and servo-mechanical control. All Kinefac products are designed and manufactured in the United States with high quality parts and workmanship at the 55,000 SQ-FT Kinefac World Headquarters in Worcester, Massachusetts. Kinefac is an ISO 9001:2015 registered company. Kinefac offers a wide range of machinery including CNC and conventional Two-Cylindrical Die and ThreeCylindrical Die High-Precision Rolling Systems under the KINEROLLER™ product to produce precision threads, worms, knurls, splines, and other helical and annular forms at high speed. The KINEFORM™ division provides high-precision cylindrical rolling dies for all makes and models. Additional Kinefac product lines and technology include KINETURN™ CNC CenterDrive Double-End Lathes allowing simultaneous turning operations on both ends of a shaft; KINEXTRUDE™ CNC Double-End and Single-End Extrusion Systems for high-speed forming of solid and hollow precision shaft forms; KINESPIN™ Centrifugal Machinery allowing fluid recovery, chip cleaning,
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and parts cleaning; KINECOIL™ Helical Spring Forming Machinery on the Nano and Macro scale for the medical device and industrial spring industries, and KINEPOWER™ Fluid Power Motion for hydraulic, pneumatic, and other mechanical linear motion devices. The KINEPRO™ prototyping and production services division meets the needs of those customers who desire an outside source for unusual or difficult rolling, coiling, and extrusion operations. Throughout its 56-year history, the continued success of Kinefac has been built on a cohesive team of engineers, designers, assemblers, and supporting staff who are all committed to establishing worldwide leadership in the company’s various niche markets. Kinefac machines can be found operating on all seven continents of the globe thanks to its internationally expanded footprint. The company has sales and service offices in Shanghai-China, Chennai-India, and Monterrey-Mexico through the Association for Manufacturing Technology (AMT) where it has achieved considerable success servicing our global partners. The achievements of Kinefac and
its employees have been recognized by several organizations including the U.S. Small Business Association from which it received the Exporter of the Year Award, and the Massachusetts Manufacturing Extension Partnership which named Kinefac as Small Manufacturer of the Year. Kinefac was recognized by Fastener Technology International with a Technical Achievement Award for innovations in thread rolling. Kinefac received a Certificate of Machine Performance in End User in China. The company is a member of AMT, NCMS, NAM, AIM, PMPA, CASMI and MASS MEDIC Associations. Kinefac Corporation is committed to total excellence and customer service. Please contact us for your precision metal forming and metal cutting needs! For more information, Kinefac Corporation Mobile: +91 9003075035 Email : Kinefac@amtindia.org Website: www.kinefac.com
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S-CARB APR
Kyocera SGS Precision Tools Case Study INDUSTRY Aerospace MATERIAL 7075 ALUMINUM PRODUCT KSPT S-CARB APR APPLICATION MILLING
GOALS The goals of this study were to significantly reduce cost through an increase tool life.
COMPETITOR INDEXABLE CUTTER COOLANT Flood TOOL INFORMATION 25mm DIA / 35mm LOC / 140mm OAL
STRATEGY KSPT approached this job with the S-Carb Advanced Productivity Rougher (APR). KSPT’s S-Carb APR, engineered for high power, high-efficiency machining of aluminum aerospace structural parts. Material removal rates of 550 cubic inches is achievable with remarkable tool life and product finish. KSPT
COMPETITOR
TOOL DIAMETER
.9840
2.0
SPEED
21,900 RPM
12,000 RPM
FEED
175.5 IPM
24.0 IPM
RADIAL CUT (AE)
.9840
2.0
AXIAL CUT (AP)
.6250
.100
CYCLE TIME
185 minutes
300 minutes
TOOL CHANGE TIME 15
kyocera-sgstool.com
15
MINUTES
KSPT’s S-Carb APR reduced the tool change time by 66%!!
5
10 5 0
KSPT
COMPETITOR
1
VALUE AT THE SPINDLE
100%
SPINDLE CAPACITY WHILE ACHIEVING MAX SPEED & FEED RATE
SETS THE STANDARD FOR 3 FLUTE END MILLS IN ALUMINUM
MAXIMUM RIGIDITY
OPTIMAL CHIP REMOVAL AT HIGH SPEEDS
IDEAL FOR CYCLE TIME REDUCTION
AVAILABLE IN VARIOUS END CONFIGURATIONS
AMT SECTION
TECH TRENDS
Enter the 2019 Masters of CAM Wildest Parts Competition for Students and Professionals
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astercam is pleased to announce the 2019 Masters of CAM Wildest Parts Competition. This year, the competition has been expanded and prizes are even bigger. New for 2019, in addition to the three divisions for students that were available in previous years, a division has been created for professional Mastercam users to enter the competition. If you are a student or professional using Mastercam, this competition is a great opportunity to show off your creativity to win cash and prizes. The contest is open to Mastercam users from around the world. Teachers can enter the competition in the professional division and should encourage students to enter at their educational level in both the individual and team categories. The challenge is simple. Create a bold, original item using Mastercam that shows off your design and machining skills. The Masters of CAM Wildest Parts Competition accepts entries in the following four divisions: • Secondary – The secondary division is open to individual students at a high school level of education. • Postsecondary – The postsecondary
division is open to individual students at a college or university level of education. • Teams – The team division is open to groups of students at any level of education; teams participating with SAE, FIRST Robotics, WorldSkills, and other similar organizations are encouraged to enter parts in this division. • Professional (NEW FOR 2019!) – The professional division is open to anyone with professional manufacturing experience; instructors are encouraged to enter parts in this division. Also new for 2019, at least one Masters of CAM story submission is required
for each part entered. Masters of CAM is a place for manufacturing professionals, students, and educators to share their Mastercam stories. The site features user-generated content, and members receive exclusive Masters of CAM merchandise when their stories are published. To join the Masters of CAM, simply log in with your Mastercam account. If you do not have a Mastercam account already, you will be prompted to create one for free. Next, choose one of the available story templates to share a story about your manufacturing experience. For the Wildest Parts Competition, choose the template that matches the division you are entering. Learn more about Masters of CAM here: https://mastersofcam.com/ aboutmc.aspx. Visit the site often to view stories submitted by others in the worldwide manufacturing community. Entry forms, additional contest information, and support materials for the Masters of CAM Wildest Parts Competition are available here: https://www.mastercam.com/en-us/ Competitions/WildestParts. Entries must be postmarked by June 28, 2019 and sent to: Wildest Parts Competition, CNC Software, Inc., 671 Old Post Road, Tolland, CT 06084. An entry form must accompany each part entered in the competition.
For more information: Mastercam Phone: +91 7378 55 2000 (India) Email: marketing@mastercam.com Website: www.mastercam.com
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MEASUREMENT ERROR
MEASUREMENT PRECISION
The non-contact Mida ML75P laser tool pre-setting and verification system is the key to maintaining the micrometric accuracy required by the most demanding machining applications, as in the aerospace field. You get consistent quality, less waste and more profit. Marposs means precision.
www.marposs.com
Y O U R G L O B A L M E T R O L O G Y PA R T N E R
MARPOSS INDIA Pvt. Ltd. 147, Sector 7, IMT Manesar 122 050 - Tel. +91 124 4735700 | sales@in.marposs.com
TECH TRENDS
Floating Wind Turbines, promising future
Mr. Javier Lanfranchi – Sales Manager – Faccin SPA
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ceans are an incredible source of energy and till now has been under-utilised due to the high-cost involved, technical and environmental challenges. Floating offshore wind power may have a significant role in upcoming years providing energy to power our households and industrial facilities.
The Hywind Scotland Pilot Park, which has five 6MV turbines with a total installed capacity of 30 MW, and a transmission voltage of 33 kV., has been developed and operated by Hywind Limited owned by Statoil whose principal activity is the development of renewable energy projects in the United Kingdom.
What are the challenges These giant full-scaled floating wind turbines are massive conical steel structures, which can measure up to 254 m (846 feet). Investment along with collaboration between the different sectors that are involved in the different steps of the construction are needed, these not only helps to down costs but also to improve efficiency. This emerging technology in the wind industry has been successfully tested in a full-scaled floating farm located 15 miles (25 km) off the coast of Peterhead in Aberdeenshire, Scotland.
The future The resource potential is believed to be in deep waters where wind speeds are typically faster than on land. Just small increases in speed result in large increases of energy production. In so far, as this new technology evolves, much larger areas of the ocean could be used to install floating wind farms and not just along the coast. More developers recognise the optimistic future for the wind industry and are involved in floating wind demos around the world. The technology has been tested for a couple of years now and the costs have
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started to come down so it is expected soon more locations will be added including the northern part of UK, US, and Japan. Driven by this scenario, wind tower manufacturers can trust Faccin’s experience and successful track record of installed wind tower automation systems for their most exigent wind tower projects. Customized cost-effective solutions Bending hundreds of cans every month can only be accomplished with a rolling package like the innovative ‘Faccin’s Wind Tower Automation System’ designed to provide manufacturers with the reliability, precision and automation required in this type of manufacturing processes. The system is able to reach the floor to floor production time of 20min per rolled tube. It combines a powerful super-sized plate-rolling machine with key components like a strong side support, a sturdy top support
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TECH TRENDS and a feeding table with alignment device, all accessories controlled by a highly advanced fully programmable CNC designed to automate the most complex rolling projects. 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 of the wind tower cans 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
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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.
Learn more about us and discover our latest developments by visiting our website www.faccin.com
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23 - 28 January 2020, Bangalore, India
TECH TRENDS
The smallest draw-wire sensor the world has ever seen
The new wireSENSOR MT19 from MicroEpsilon is particularly well suited to crash tests. The deformation values of the crash test dummies give vital clues about the safety of the tested vehicle.
Draw-wire sensors precisely detect displacements and distances in a variety of R&D and industrial applications. Reliable & easy to install, they are also ideally suited to serial applications due to their relatively low cost. Offering a broad range of draw-wire sensors, Micro-Epsilon now reveals another highlight - the smallest draw-wire sensor in the world, which is specially designed for high speed measurements.
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aintenance-free, draw-wire sensors operate reliably and can be installed easily. Furthermore, complex alignment work is not required. Even the tightest of installation space is no match for these versatile displacement and distance sensors. Depending on the model, they measure displacement and distance in high acceleration applications and OEM tasks. These positive characteristics enable their use in versatile industrial applications, test rigs, mobile machinery and medical engineering. The application possibilities are numerous, whether it is measuring lift height for the maintenance of bridges, training monitoring in rehab devices, positioning of operating tables and ca-
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tering vehicles, or measurement tasks in machine tools. Small sensors achieve big things Among the numerous models available, the new wireSENSOR MT19 miniature sensor from Micro-Epsilon is a stand-out. It’s as small as a 1 cent coin, and is therefore the smallest draw-wire sensor in the world. This model is specially designed for test applications with high wire accelerations covering measuring ranges up to 40mm. The MT19 is used, for example, in test applications for aircraft and racing cars. Furthermore, the miniature draw-wire sensor is particularly well suited to crash tests. The deformation values of the crash test dummies give vital clues
about the safety of the tested vehicle. The exact determination of this deformation enables the engineers to optimize design of interior or passenger compartments and consequently, to increase passenger safety. A crash test dummy is equipped with numerous sensors. Special attention is given to the head, chest, spinal column, pelvis and legs. In order to receive deformation values that are as realistic as possible, draw-wire sensors are directly installed in the dummy on the parts of the body concerned. But the installation space is rather limited here. However, due to their compact design and through-bores in the housing, the MT19 miniature draw-sensors from Micro-Epsilon can be easily
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TECH TRENDS installed in extremely tight spaces. The MT draw-wire sensors are protected with a robust aluminum housing. As the draw-wire sensor is specially designed for extremely high acceleration tasks, the draw-wire is able to follow these high speed movements. The wireSENSOR MT19 withstands these stresses, since it’s designed for accelerations up to 60g. Based on a well-conceived concept, it provides precise displacement and distance values to fulfill the very high requirements placed on sensors in crash tests. For high-speed measurements in confined spaces, Micro-Epsilon has also launched two further miniature MT sensors. The wireSENSOR MT33 measures displacement and distance at measuring ranges up to 80mm, whereas the MT56 enables measurements up to 130mm. All of these are equipped with an aluminum housing, stainless steel measuring wire and potentiometer. Robust draw-wire sensors for industrial applications As an expert in the field of industrial measurement technologies, MicroEpsilon has developed a broad, highquality product range of draw-wire displacement sensors over 50 years of company history. Various models cover measuring ranges from 40mm to 50m. As well as sensors designed for
Among the numerous models available, the new miniature wireSENSOR MT19 from Micro-Epsilon is a stand-out. It’s as small as a 1 cent coin, & is therefore the smallest draw-wire sensor in the world.
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MK sensors from Micro-Epsilon are used in sectors where high cycle rates are required, e.g. in logistics and for forklift trucks
high-speed measurements, the sensor specialist also offers wireSENSOR P draw-wire sensors which are specially designed for industrial applications. These sensors are used in elevator construction, crane systems, forklift trucks and high-bay warehouses. Their robust and compact aluminum housing protects the sensors from mechanical influences. In addition, Micro-Epsilon draw-wire sensors are available as analog versions with potentiometer, current or voltage output, or as digital versions with incremental or absolute encoders. Load tests on rotor blades wireSENSOR P draw-wire sensors are used when performing stress tests on wind turbine rotor blades. Therefore, test rigs have been developed that simulate the real loads caused by winds and storms. These expensive rotors made from fiber-reinforced plastics are manufactured according to the half-shell sandwich construction. They are usually between 40m and 60m long. The Fraunhofer Institute IWES in Bremerhaven has developed a test rig that can be used to test rotor blades up to 70m in length. In the test rig, the rotor blade is mounted horizontally. Steel cables are routed to the rotor
using guide pulleys and attached to the rotor blade at various positions either directly or via mechanical clamps. The tip of the rotor blade can be distorted by up to 10m due to mechanical loads. Twelve draw-wire sensors are used for measuring the distortion. Two sensors per traction point measure the deflection and torsion of the rotor blade. For this, the sensors are mounted on rails on the ground and the measuring wire is attached to pre-fabricated eyes on the terminals. Here, the sensors impress with their ease of use and robust design while covering measuring ranges between 3m and 10m. The digital signal provided is used for further simulations. Lift height measurement for twocolumn lifts Draw-wire P sensors ensure also in two-column lifts that the vehicles are lifted evenly. Modern two-post lifting systems are normally designed without a base frame. Unlike lifts that have a chain between the two lifting columns, these modern systems no longer require a mechanical connection. Therefore, the threshold between the lift columns is no longer required. This makes the user’s daily work much easier since no “obstacle” has
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TECH TRENDS to be overcome during entry and exit and so it is much easier to position the vehicle. However, “automatic” lift height synchronization, which was previously provided by the mechanical connection of the two columns, is now missing. The lift therefore requires a synchronization controller or lift height monitoring system in order to ensure that the vehicle is raised evenly on both sides. Draw-wire sensors are the preferred choice for this type of height measurement as they are easy to integrate, very compact and provide a very attractive price/performance ratio relative to the measuring range, as well as high accuracy. Versatile draw-wire sensors for OEM and serial applications In applications where high quantities are required, draw-wire MK sensors from Micro-Epsilon are ideal, as they are specially designed for serial applications. Particular advantages are their low cost combined with a compact design, as well as easy integration – even in confined spaces. The MK sensors from Micro-Epsilon combine a favorable price with high performance, compact design and robustness – ideal characteristics for serial applications. 8 times longer service life with WPS-MK88 Compared to draw-wire sensors based on a conventional potentiometer, the new wireSENSOR WPS-MK88 U45R with a non-contact potentiometer achieves 8 times more working cycles which prolongs the sensor’s service life to a maximum. This new technology combined with a robust plastic housing and a favorable price/performance ratio, sets new standards in terms of economic efficiency. Those positive characteristics were achieved by replacing the conventional, analog hybrid potentiometer with a non-contact potentiometer. With common potentiometers, a
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sliding contact (wiper) moves along a resistive element. However, this wiper quickly wears. In contrast, the new, non-contact potentiometer is based on magnetic field sensors that significantly increase its service life. Safety in forklift trucks MK sensors are used in sectors where high cycle rates are required, e.g. in logistics and for forklift trucks. When lowering the load, normally large safety margins have to be observed, so that when rounding a corner or braking and accelerating, the truck is not put into a dangerous tilted position. Since the lift height of the load can now be measured using draw-wire sensors, the optimum driving speed can be determined from this. In addition, the system is protected against erroneous operation, i.e. the operator cannot knowingly or unintentionally cause critical driving conditions. Determining the position of the tailstock in machine tools Another common measurement task is determining the position of the tailstock in machine tools. Here, drawwire MK sensors from Micro-Epsilon are used. Although this measurement has no direct impact on the precision or safety of the machine, it poses many challenges for designers. Thus, the position of the center point of the tailstock often has to be determined over a very large area up to a few meters. To make matters worse, the space for the corresponding measuring system is limited. Due to their compact design, Micro-Epsilon sensors can be easily mounted even in confined spaces. The sensor does not have to be installed directly in the vicinity of the tailstock, as the measuring rope can be guided very flexibly in different-to-access places over different pulleys. Typical drawwire sensor models for machine tools offer measuring ranges from 300mm
wireSENSOR P draw-wire sensors are used when performing stress tests on wind turbine rotor blades. Two sensors per traction point measure the deflection and torsion of the rotor blade.
to 2,100mm, although larger ranges are also available. Their robust plastic housing protects the sensors from mechanical and thermal loads and stress which ensures long-term stable application in machine tools. Box: How does a draw-wire sensor work? Draw-wire sensors are composed of a drum, spring, measuring wire and potentiometer or encoder. The spring tensions the measuring wire during extension and retraction to prevent the wire from sagging. This ensures that the displacement the wire has travelled can be detected correctly to provide precise measurement values. The highly flexible stainless steel measuring wire is wound onto a drum, where the potentiometer or encoder is mounted. When the wire is wound up or unwound, this drum rotates. Therefore, the potentiometer or encoder rotates proportionally to the drum as soon as the measuring object, where the measuring wire is mounted, moves. The rotation of drum and potentiometer/encoder caused by the distance change can then be converted into a proportional, electrical signal. The potentiometer is used for analog output signals, whereas the encoder is used for digital output signals. The signals determined can finally be transmitted via different outputs and then be evaluated. For more information, Website: www.micro-epsilon.in
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Shavo Technologies Pvt. Ltd. 29/2 Kharadi, Off Pune Nagar Road, Old Kharadi Mundhwa Road, Pune: 411 014 Tel. No.: +(91) (0) 7030938211, 7410004817, Fax No.: +(91) (080) 28395963 Email: shavogroup@vsnl.com | Website : www.shavogroup.com
TECH TRENDS
Innovations in centerless grinding machine & its operations
C
enterless Grinding operation is a mass production process in which cylindrical components are ground without reference to center. This operation is used as the final process in majority of the components where the tolerances and the quality parameter are stringent. The grinding process is basically designed for mass production. As the cost of manufacturing is increasing, the users are trying to extract more & more production from a grinder in order to lower the cost per piece. The user feedback and experiences highlighted the problems faced during day to day work, and solutions need to be implemented for future expansion projects and existing machinery.
Below are some suggestions, to improve the quality level and productivity, while bringing down costs in Centerless grinding: • Land costs are at an all-time high, which necessitates the reduction of machine foot print and floor space dedicated to a single machine. • In any centerless grinding operation, the major non-productive time is the dressing time. Hence, a method needs to be devised so that the dressing time also can be used productively. • As the working cost is increasing, more automation is required so that an operator can run more than one machine. • With cost of power increasing all around the world, more energy efficient motors should be explored. • The fuel prices are increasing at a phenomenal rate and it is essential to produce fuel efficient vehicles.
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This calls for components with higher quality standards and a need to explore different materials to reduce vehicle weight. Consequently, machines with capability to grind these components efficiently need to be devised. To resolve the above issues, our engineers did brain storming and devised various options: 1. To reduce the floor space there should not be any compromise in terms of the rigidity and stock removal capabilities of the grinder. We designed a grinder similar in size to our smallest model. At the same time, we increased its rigidity by adding weight to make it equivalent to our bigger sized model. The center of gravity was kept constant at the working area so that the vibrations would always be at that point. The vibration analysis was conducted to ensure that it was maintained at a very low level. 2. Total Usage Time = Productive Time + Non-Productive Time (Dressing Time) The challenge for us was to convert the non-
productive time into productive time. To achieve the same, we designed a diamond roll dresser for the machine. The CNC controls were programmed in a manner that when the dressing is done on the wheel, grinding of the component is also in process. Therefore, the total usage time is now equal to the productive time. This enables the customer to grind more components. The savings was substantial in terms of productivity. 3. Working Cost = Running Cost (Power + Employees + Overheads) + Consumables (Hydraulic Oil + Coolant + Grinding wheel + Regulating Wheel + Diamond Dresser) To reduce the working cost of a machine, it is important to reduce all the above costs to an optimum level. a. Power Cost: The maximum power consuming motor is the grinding wheel motor. We procure the motor such that during idling time of grinder in each cycle it would draw very low current, while providing full torque during the grinding process. Such motors
Diamond Roll Dresser
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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
TECH TRENDS
Linear Guideway
have rating of Eff 1 or better. The other options include soft start for grinding wheel motor or Variable Frequency Drive for regulating and grinding wheel motor. These options avoid peak current required for start-up of the motor. b. Employees Cost: Machine automation is designed in such a way that the operator can run more than one machine at a time. In mass production plants, the focus is to have one skilled person to look after the setting and inspection of finished components for all grinders. Loading, unloading and other routine operations are done by unskilled employees. CNC options also reduce the operator intervention to a large extent and thereby reduce the cost. At the time when customer sends the plant layout, we give suggestions and inputs to reduce material handling and make it ergonomically convenient in order to reduce operator fatigue. Variable Frequency Drive is installed to achieve Constant Surface Speed for Grinding Wheel. This helps in reducing the dressing frequency even when the wheel diameter is
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reduced. Hence, the grinding wheel is used to its optimum level. c. The other consumables like oil, coolant, diamonds and wheels are selected with the help of various manufacturers’ input and expertise, to suit each application. 4. The increase in fuel prices and depreciation of Indian currency has put a lot of burden on manufacturers to improve the fuel efficiency of vehicles. This calls for more close tolerance in manufacturing parts. Quality Parameters are a combination of Size Tolerance, Roundness, Cylindricity and Surface Finish. We use Precision Linear Guideways to achieve practically friction free movement. This enables the slide to move with high accuracy, as close as 0.25 microns and helps in maintaining size in close tolerance. To achieve roundness in 1 to less than 1 micron, it is necessary to have rigid spindles and vibration free grinding. We mount Automatic Wheel balancers, which balance wheel with vibration level less than 1 micron. This also helps improve Cylindricity. Coolant supply while dressing the
Servo Regulating Wheel Drive
wheel has to be forced at the point of contact of diamond and wheel. Proper forced coolant supply helps to dress well, which in turn helps in improving surface finish on component. Coolant supply during grinding is conventionally done by free flow of coolant on the part. Due to air turbulence because of wheel rotation, most of the coolant does not reach the actual grinding area. With redesigned nozzles and flapper to stop air turbulence, the coolant now reaches grinding hot spot to almost 90% level. The overheating of parts and burning marks are reduced and surface finish improved. The above are some of the innovations & adaptations incorporated in the machine to meet the demand of the industry for better & greener tomorrow.
by Harsh Badani, Technical Director, Solitaire Machine Tools Ltd., Vadodara
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More Precision Sensors for displacement, distance & position Draw-wire displacement sensors Easy, precise and accurate Different models with measuring ranges from 50mm to 50m Customer-specific OEM series For harsh, industrial environments Different outputs: encoder, potentiometer, current, voltage
Magneto-inductive displacement sensors Ideal alternative to inductive sensors and proximity sensors Linear output signal, high basic sensitivity and temperature stability Selectable measuring ranges up to 55mm with different magnets Long-life sensor due to non-contact measurement
Inductive sensors (LVDT) and gages More than 250 different models with measuring ranges from 1 to 630mm High accuracy Integrated or separate controller Standardized and customer-specific sensor designs also for integration into hydraulic cylinders
+91 20 2674 1009 | info@micro-epsilon.in | www.micro-epsilon.in
TECH TRENDS
The e-commerce boom & intralogistics: Rollon presents its warehouse automation solutions
F
ast and reliable in increasingly smaller spaces: Rollon’s components and complete mechanical solutions make shuttles and stacker cranes more efficient, and sustain the growth of a quickly growing sector. In a market worth tens of billions of dollars, shaving off one second or one centimeter can make a big difference. Especially in the intralogistics sector, the root of the e-commerce revolution, growth in recent years has developed at the same rate as automated processes have improved warehouse efficiency. Reliability and speed in smaller spaces: this short phrase sums up the winning approach behind a truly efficient warehouse during this explosive era of e-commerce growth. Rollon can definitely achieve this result through its extremely wide range of products and specific know-
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how gained in customizing solutions to respond to the different needs of single applications in all areas of intralogistics. Let’s see how: Shuttles: Today, shuttles run unceasingly between the shelves of automated warehouses carrying Rollon telescopic rails to manage the extraction process, picking products from shelves and placing them elsewhere. This crucial process is repeated millions of times. Therefore, it is fundamental that these telescopic rails have the right characteristics. Which features do they need? • Cross-section dimensions: a difference of one centimeter on a single rail is multiplied by thousands of slots along shelves
that are hundreds of meters in length, and this turns into meters or tens of meters of space available for new slots. A properly sized rail, like ASN, means that the warehouse can store more objects in the same amount of space. • Rigidity: the extraction system must be extremely rigid. Telescopic rails used in these applications must have extremely limited play (two-place decimal tolerance) or a total absence of play. In this context, Rollon brand products are particularly efficient: for example, the ASN telescopic rails have induction hardened raceways that allow them to maintain coupling and preserve rigidity. • Double and over-extending strokes: shuttles need to extract products in two directions, and
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Linear solutions global provider.
Linear Line
Actuator Line
Telescopic Line
Actuator System Line
ROLLON India Pvt. Ltd. - INDIA 1st 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
Rollon solutions such as ASN and DE telescopic rails allow them to do that, thanks to the double stroke configuration option. Another issue is that, in order to reach more distant products, shuttles require a stroke with rails that are longer than the usual 50%. With Rollon rails, strokes can be extended up to 75%. If two pairs of two-stage extraction rails are used, a total extraction of 150% of the width of the shuttle is achieved. • Synchronization: to meet the needs of clients and offer a synchronized product, Rollon has proven that it is an expert at customization. Starting with the DE telescopic rails, the Group has created a personalized solution: the DEF43Z, a synchronized rail with a rack and pinion mechanism. However, Rollon’s customization abilities can even go further to provide mechanical systems integrated with personalized components that meet the client’s specific needs. These components range from belt mechanisms for synchronization to ground raceways for further improving sliding movements. They also include rails
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with ball bearings integrated into a special intermediate element that can guarantee maximum rigidity. Stacker Cranes: In the filed of intermediate rotation, stacker cranes are systems that run on both a horizontal and vertical axis to reach products on warehouse shelves. Due to evolutions in its product range and recent corporate acquisitions that have fostered its growth in the linear actuator sector, Rollon is now able to offer complete solutions for stacker cranes, formed by an X-axis and a Z-axis, ideal for managing small and medium-sized loads. In this case, the right products to use are belt-driven actuators from the Smart System family, which guarantee speed and high acceleration along with no need to lubricate the belt. This combination provides the perfect solution for stressful work cycles. Smart System actuators are also supplied with all mounting accessories and fasteners needed for simple, quick integration between products, to allow the fast, easy assembly of an efficient stacker cranes.
Vertical Warehouses: Over the years, Rollon products have been confirmed as reliable reference points also in vertical warehouses. This systems make it possible to store materials on different shelves and to move them with automated means to make them accessible to the ground. This is where Rollon’s DSS telescopic rails come in handy. Thanks to their high load (up to 500 kg per pair of rails) and low degree of bending, they allow the operator to extract the tray holding the materials and to re-insert it inside the drawer easily.
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 Email: info@rollonindia.in Web: www.rollonindia.in
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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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and Asia Pacific. So leave power quality and energy management to the experts – 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.
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Ahmedabad l Bangalore l Chennai l Delhi l Gurgaon l Hardwar Indore l Jalandhar l Jamshedpur l Kolkata l Kanpur l Mumbai l Pune l Rajkot
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TECH TRENDS
New Development in Hard Chrome Replacement: HVAF Flash Carbide Coating
Dr. Andrew Verstak, President. Vermetico Inc., USA
BACKGROUND • Traditional hard chrome plating produces Hexavalent chrome as effluent which is a known carcinogen. The process also produces large volumes of Toxic Waste. • The HVAF (High velocity Air Fuel) spray coating technology for deposition of high-quality carbide coatings developed by Kermetico, USA and Spraymet to replace hard chrome plating in critical engineering wear applications is a very important process breakthrough towards eliminating carcinogenic hexavalent chrome from shop floor. • The concept of “Flash Carbide” coating is developed, targeting deposition of high-quality coatings at low cost, duly meeting traditional chrome plating cost by reduction of coating thickness
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Mr. P T Bindagi echnical Director Spraymet Surface Technologies Pvt Ltd., Bangalore
and elimination of the need for dimensional grinding in the process. Issues With Hard Chrome Plating • The process produces large amounts of hydrogen gas in the gas bubbles burst throwing hexavalent chrome solution into the air as fine mist. • Hexavalent chrome is a known carcinogen. • The process produces large volumes of toxic waste. • EPA and OSHA have mandated more stringent stack emission levels and lowering of permissible exposure limits for workers. • This results in increased costs and business risks.
Combustion Breakthrough • Ability to use heating in long/ slowgas combustion chambers • long time for “soft” heating of spray powder • High pressure in the chamber =Better heat Transfer • Result: High energy efficiency leading to higher spray rates Particles Velocity Breakthrough • Kermetico HVAF: 1200-1800 mts/ sec • There is practically no restriction on the nozzle length thus and flame velocity • Higher acceleration of spray particles • Higher and Uniform acceleration means uniform coating structure and properties Breakthrough in Results : WC-10Co-4Cr Flash coating by HVAF A superior quality and performance of carbide Coatings deposited with HVAF has has been proven by multiple R&D and industrial applications.
Kermetico HVAF process: How and Why
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TECH TRENDS
After 150 Hours salt spray test (no corrosion)
After 150 Hours salt spray test (80% corrosion)
dense WC-10Co-4Cr powder • (30 micron) • Polish surface to needed roughness (remaining 22-25 micron of coating)
Flash Carbide: Salt Spray Corrosion Test
• Total cost of coating to 38 mm OD x 300 mm L rod, Ra 0.2 mm finish: <15 USD
Cavitation resistance of Wc-10Co4Cr of JP 5000 HVOF and Kermetico HVAF Coatings CPRI, Bangalore (India): Kermetico HVAF Wc-10Co-4Cr Coatings are: • Harder (related to cohesion strength) • More Ductile (related to Co-matrix properties) • More resistant to cavitation, erosion and abrasive wear
Hard Chrome Plating Microcracks
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HVAF FLASH CARIDE COATING: 25 µm (0.0010“) thickness as sprayed Comparison of Hard Chrome Plating to HVAF Flash Carbide Process • Dimension-grind the part to lowest tolerance, Ra 0.5 micron • One pre-heating/cleaning pass with the gun flame • Pass(es) of coating, HVAF fine/
Some Applications : Gas Compressor Piston Rod HVAF coated and super finished to 0.05 Ra
Micro porosity max 1 % (No through passage)
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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.
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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. G3 and G4 •Transmission Ground Floor • Indus Valley's Logistic Park • Unit 3 • Mel Ayanambakkam • Vellala Street MGM-VARVEL Power Pvt Ltd Chennai - 600 095 • Tamil Nadu, INDIA • 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 Earlier the rod was induction hardened and chrome plated Hydraulic cylinder: Biggest Single Application for Hard Chrome Replacement alternative by HVAF
This hydraulic cylinder rod with a diameter of 700mm and a length of 1,700mm is coated with WcCoCr by HVAF process CYLINDER BORE APPLICATIONS Flash Carbide as Economic Alternative to Hard Chrome Electroplating • The most economical coating is not the one sprayed with the highest DE. It’s the thinnest coating. • The HVAF Flash Carbide coating technology is based on the similar to Flash Chrome principles: a. The coating thickness is
comparable to tolerances for the final Coated part (i.e., 20-25 micron) b. The coating roughness is low – “ground-like” Ra 1.5-1.7 micron c. Such coating does not require dimensional grinding d. Polishing to Ra 0.2-0.3 micron removes only about 5 micron of “as- sprayed” thickness The final cost of Flash Carbide is 1/10 of conventional WC-coating
SUMMARY • Multiple data confirmed improved quality of HVAF-sprayed FLASH Carbide coatings as compared to Hard Chrome Plating. Herewith, in many industrial applications it is reasonable to sacrifice some quality to achieve higher DE and correspondingly lower cost with HVAF, still meeting the specified coating quality requirements. • A line of AK HVAF guns of different power is created to address the variety of industrial applications with the best efficiency. The hardware allows operation in different modes to balance the coating quality and cost. • The HVAF FLASH carbide coatings are developed to meet existing Chrome plating application requirements, while depositing lower cost coatings utilizing high spray rates and lower thickness. And most importantly doing away with hexavalent chrome all together. A major step toward “GREENER coatings”.
PROCESS BENEFITS: Comparison of Chrome Plating vs. HVAF FLASH carbide Hard Chrome Plating
HVAF FLASH carbide
Process of coating
Electroplating Bath
HVAF spray
HRC
55-60 HRc
70-74 ( 1150-1400Hv)
Typical Thickness to get Hardness and corrosion
60-100 microns
40-60 microns
Pre and Post treatments
Hydrogen Embrittlement tempering is required.
No post treatment.
Wear resistance ASTM G 65
Good
Very good (due to 72 HRC )
Corrosion resistance ASTM B 117
Typically 150-200 Hrs Salt spray
>700 Hours (salt spray test with sealer ~ 2000 Hours )
Temp resistance
Upto 450 deg C
Upto 450 deg C
Environmental factor
Hexavalent chrome ( carcinogenic) Difficult to control
No pollution except overspray dust ( only need dust collector)
Most of Industrial Hard chrome is now replaced by HVAF in the following applications : Hydraulic piston rods, Steel mill rolls, Corrugated rolls ,Ball valves ball and seat, plug valve , gate valve, pump plungers, etc.
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Grip with confidence in wet or oily environments NINJA® MAXIM Cool 360° breathable coating and liner for cool hands • • • •
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GRIPSMART
Wet, oily and dry grip
Contact:
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BREATHESMART
360° breathability
TECH TRENDS
Automation in sheet metal cutting and welding The paper examines welding and cutting process trends in the sheet metal and plates used in various industries like automobiles, infrastructure, ship building, aerospace industries, wind tower manufacturing etc. Productivity gains in arc welding are reviewed, and the increasing use of laser cutting and welding, as well as laser-arc hybrid welding, particularly in Europe, is discussed and explained. Some friction technologies are already widely adopted, but they could make more impact with further development. Electron beam welding could also be used with economic benefit in some situations, but as with all nonarc processes, it will only be adopted if significant gains in productivity and cost reduction can be created to justify the more specialist welding equipment required. Many productivity improvements can come from non-welding activities in the fabrication process. 1. INTRODUCTION Leadership in manufacturing (welding and Cutting) can come from addressing the factors of QUALITY, COST, PRODUCTIVITY, SAFETY and CONTINUAL UPGRADATION OF TECHNOLOGY. Inflection in Metal Fabrication Technology has taken place in the Manual / SemiAutomatic Welding Power Sources - (Digital control inverters), Welding Automation - (Developments in HNG SAW, HNG MIG, Tandem MIG / SAW, Friction Stir, Electron Beam, Saddle Welding Automation, Robotics, Laser spot welding, Hot wire TIG, Orbital systems, automation with hybrid welding systems like Plasma â&#x20AC;&#x201C; MIG, Laser - MIG) and major advances in the cutting processes (Precision Plasma, Laser Cutting, Water-jet cutting etc.). This paper reviews current trends in arc welding and cutting processes used for Sheet metal processing and will discuss some of the newer processes which are beginning to replace arc welding for such steels, or have potential to do so in the next 10 years. 2. ADVANTAGES OF AUTOMATION d. Consistency in weld result - Error Proofing: A welding supervisor can limit the amount of changes an operator can make during a program,
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e.
f.
g.
h.
preventing him from accessing the override screen through the use of a key switch or password. Multiple parameters for multiple weld-run: In addition to the ability to adjust parameters between weld passes, operators of microprocessorbased welding machines can also program changes to weld parameters during each pass, which offers distinct advantages for certain applications. Store parameter for sharing on other machines with same applications: A microprocessor-based power source can store programmed welding procedures on data cards. This allows the operator to easily transfer programs developed on one machine to other machines being used either in the same facility doing the same type of work. Quality control: Microprocessorbased machines can immediately alert the operator if weld parameters fall outside pre-selected limits. Parameters can be directly to a quality-control computer program for storage or statistical analysis. This eliminates time-consuming radiography in many applications. Date storage and records: It is now very easy to display a set of welding parameters and operator or supervi-
sor can observe the welding procedure. Moreover, the data can be printed in the form of reports, which can be presented to the customer as quality assurance procedure. i. Quicker Weld-Fault diagnostics lower repair time: The system can be stopped if the measured values cross a certain preset variation limit. It is possible to stop the machine in out-of-tolerance conditions. This enables the operator to perform timely functions and take necessary steps to prevent the deposit of faulty welds. 3. TANDEM MIG AND ROBOTIC WELDING Significant improvements in productivity are nowadays hard to gain in this mature process. In gas-shielded MIG/MAG processes, the growth of tubular wire over solid wire is still slow despite the deposition and bead shape benefits of the former although tubular wire usage is higher in the USA and Japan compared to other parts of the world. The lower price of solid filler wire, particularly in Europe, is still a dominant factor that continues to favour their use. Self-shielded cored wires are still widely used in the USA but less so in Europe because of the fall-off in fabrication of large offshore
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TECH TRENDS installations. Care is always needed in selecting self-shielded wires if weld metal toughness is a critical design factor. Schematic of Equipment for TANDEM MIG
new robot installations per annum, but generally robot take-up for welding is still majorly for the automobile sectors. Robots are being employed in situations where product repetition and/or tonnage throughput are high, combined with relatively standardised designs. Robot profile cutting is increasing in usage and in Japan, some building frames are now being welded on robot lines and agile robots are also used for site welding building column joints at height. The applications most suited to robot use involve butt and fillet welds in the fabrication of beams, welding of stiffeners to beams, welding of end plates and the assembly of panels or decking. A likely trend is to ‘take robots to the work’ and use them for large part and sub-assembly manufacture in cells which house autonomous vehicular robots. These robots, mounted on moving platforms are manoeuvred around the parts to be welded and are capable of all-positional welding using the MAG process with tubular wires, (Fig.2).
Fig. 1: TANDEM MIG
Advantages of TANDEM MIG: • Exceptional welding speeds • High weld metal deposition rate • Superior weld quality: » Reduced heat input » Resists burn-through on thin materials » Maintains low spatter levels » Produces good penetration on thick materials » Improves bead wetting at weld toes » Resists undercut • Bead profile control • Lowers production costs • Increases productivity The greatest potential for productivity improvements comes from using robots. Japan still leads the work in
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Fig.2. Schematic diagram showing autonomous robot vehicle navigated by vision system, being used for all positional MIG / MAG welding
4.NARROW GAP SAW In submerged arc welding, multi-wire, iron powder additions and narrow gaps are common ways to increase productivity. However, the use of tubular wires is increasing in popularity and can offer better weld quality compared to solid wires in some situations, e.g. when submerged arc welding of primed plate. In building and bridge construction MIG/MAG welding is
more suited to automation and is now beginning to replace submerged arc welding, reducing costs and distortion significantly. 5 . LASER – IN CUTTING AND WELDING Low power CO 2 lasers were originally developed in the late 60s for cutting and welding operations, while Nd: YAG lasers entered the market only in the early 1980s. In the shipbuilding and off-road vehicle sectors, higher power lasers (3-10kW CO 2 and 2-4kW Nd:YAG) have become popular in the last decade because their use brings more precision in dimensional control, and greater accuracy in assembly, as well as the additional advantages of high cutting and welding speeds, and cleaner working. Laser cutting is now an essential route to accurate assembly in steel fabrication. Parts can be cut to a precision of ±0.3mm in 10 metres compared to ±1-2mm for conventional plasma cutting. Sub assemblies can then be arc welded to tolerances of a few millimetres in 15 metres, with the same lasers being used for marking and hole drilling on the cutting table. Even though arc welding is still regularly used for assembly of laser cut parts, cost reductions can be dramatic because of the improved accuracy of assembly and the potential for eliminating distortion correction and other processing operations downstream from welding. Direct costs have been cut by up to 50% using lasers for cutting in many shipyards, and this shows the extent of benefit which could follow from more widespread use of laser cutting in building, bridge and public infrastructure construction.
Fig.3. A typical laser welded sandwich panel and advantages over conventionally stiffened panels
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Fig. 5.Schematic diagram of the FSW process: (A) Two discrete metal work-pieces butted together, along with the tool (with a probe). (B) The progress of the tool through the joint, also showing the weld zone and the region affected by the tool shoulder.
Fig.4a. Nd:YAG laser - MAG hybrid process being developed for land pipeline girth welding. Picture of the welding head
Fig.4b. macro section showing MAG root and cap beads & central hybrid weld bead
6. LASER-ARC HYBRID WELDING There is tremendous interest in the use of CO 2 laser-arc or Nd: YAG laser-arc for steel construction at the present time. The concept has been around since 1978 and was actively developed in Aachen in the late 90s using high power CO 2 lasers in combination with one or two MAG torches directed into the same weld pool in series with the laser. Already one shipyard in Germany has such a system in production on a panel line, the process replacing submerged arc welding. The advantages of moving from simple arc processes to a hybrid laser-arc system include higher joint completion rates and associated control of distortion. As noted above, laser systems alone are usually not suf-
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ficient to cope with variations in joint gap in large structures. However, where plates are thin, it is possible to produce stiffened panels successfully by laser welding. 7. FRICTION TECHNOLOGIES There have been many exciting developments in friction welding and probably more process innovation in the last decade than in the previous 40 years when friction welding first came on the scene. In the context of metal joining and construction, friction stud, radial friction and friction stir welding are good examples of more recent approaches, with friction stud already being used in the production of sandwich structures comprising steel skins and a concrete core and for welding attachments in high volume such as shear connectors and reinforcing bars to end plates. Attachment of anodes under water to offshore installations using steel studs and electrical connections to railway lines are other applications of friction stud welding.
Automotive, Railway Rolling Stock, Fabrication 8. ELECTRON BEAM TECHNOLOGY There have been several key improvements in this process in the last decade which have made EB welding increasingly attractive for large-scale fabrication of steel structures such as buildings and bridges. The two main areas of improvement are in gun development and reduced pressure technology.
Reduced pressure electron beam welding system Reduced pressure EB welding using
APPLICATIONS Shipbuilding and Offshore, Aerospace,
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TECH TRENDS
chamber pressures of around 1mbar has been another major step forward in simplifying EB welding operations. The beam shape and beam penetration at, say 5mbar, is identical to that at the more conventional pressure for EB welding of 5 x 10 -3 mbar. This reduced pressure option does away with the need for large vacuum chambers and worries about leaks and seals. Simple mechanical pumps and local seals are sufficient to achieve ~1 mbar. These systems are also more tolerant to fluctuations in working vacuum pressure, gun to work distance and work-piece cleanliness. 9. WIND TOWER MANUFACTURING – SPECIALIZED CUTTING AND WELDING PROCESS APPLICATIONS Wind Tower fabrication employs extremely precision applications of metal cutting and welding processes like gas cutting triple torch, with Single pass three torch cutting Automatic setup which provides High accuracy, Capacitive height adjustment, Infinite rotation of cutting head, Automatic angle adjustment 20 - 50° (Option for 30 - 60°). In addition, plasma cutting system is used with Automatic Setup, Highest Accuracy, and Bevel angle adjustment: +/- 52°, Initial height setting with tactile sensor, Cutting height adjustment via automatic arc voltage sensing process.
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Precision High end CNC Plasma cutting process is utilized with high degree of automation needed to guarantee consistent quality. Programming software, Numerical control and Automatic rotating bevel tools are used to dispense with manual tasks. Automated SAW systems with Twin Wire, Tandem, Tandem – Twin and Multi – wire systems are used along with customized welding heads, wire feed systems, joint tracking systems, Column and Booms, TELBO systems, Rotators and Positioners. In addition, Tractors and Fit – up units are all used for this application and also for many other welding applications. 10. CONCLUDING REMARKS Where will engineering construction be in five years time? Productivity improvements can come from many different areas in the total fabrication process, e.g. general design, detailed
design, contract drawings, CNC instructions, cutting and profiling, welding, inspection, finishing etc. It needs to be realised that optimising the welding process and procedure in isolation may have only a small effect on overall productivity. As an example, fabricators in the bridge and building sector continue to make big improvements in reducing the cost per tonne of steel fabricated by focussing on efficiency improvements in non-welding operations. These non-welding areas will continue to receive much attention in the next few years. For example, 3D solid modelling is expected to be at the heart of the improvement process enabling virtual assembly, direct instruction of cutting and welding machines, computer modelling of metal processing and welding operations and optimising of welding sequences. In addition automated inspection and data gathering will increase in usage to give more comprehensive Quality Assurance. Productivity improvements could also come from greater standardisation in steel specifications and in joint details and from modularisation of large structures to reduce the time spent on site fabrication and erection. Use of new welding processes and an increased use of automation and robots will take place slowly and gradually, only being justified where the introduction creates significant gains in productivity or cost reduction. As such, these changes can be expected particularly in situations where skilled labour is short, where welding cells can be kept fully occupied or where customised, made to order components are needed. (Contributed by Ador Welding Ltd.)
For more information Web: www.adorwelding.com
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PRODUCT SHOWCASE KING CUT PRO – The Large Gantry Type CNC Cutting Machine Ador’s KING CUT PRO is a CNC portal cutting machine which is very precise and reliable. The machine has one head for plasma sheet metal cutting & one head for flame cutting of sheet metal with a dual side longitudinal drive with AC motors. The standard equipment comes with a basic machine package with CNC controller, one torch, central gas diffusion with manometers and a remote flame ignition. The following equipment are supplied as required by the customer: Additional Equipment: • Plasma power source KJELBERG with machine torch • Programming software MOST 2D • Support table for sheet metal with segment extraction system • Extraction-filter system • Laser position indicator for determining the cutting point Optional : • Extension of the longitudinal rail • Additional cutting head
For Product Enquiry Contact Ador Welding Limited Akurdi Chowk, Chinchwad, Pune 411 019 Tel.: 020- 4070 6000 Email: cmo@adorians.com Web: www.adorwelding.com
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The CNC Controller – Phantom: The Phantom brings you the performance of a cutting edge CNC that is built on more than 40 years of experience in the motion control and cutting industries. This controller is designed for multiple axis cutting machines and features the latest advances in CNC technology on a proven platform engineered to increase productivity, reduce costs and enhance profitability. The software provides flexibility, ease of operation and technologies that put Ador’s experience and expertise in your operator’s hands, resulting in extremely good cut quality and high productivity. The Phantom can operate any cutting machine and interface with virtually all plasma systems. Following are its standard features: Bright touch screen interface, Touch screen interactive display, Expandable shape library, True multi-tasking environment, Fast Dxt file conversion, Go to(Job interrupt), Quick plate alignment, and Monitor & track consumables. Advanced Plasma Process Control (Plasma Process Wizard) is available as optional extra. Ador offers costsaving height control unit for simple plasma cutting applications. The KHC1 system provides all the essential functions that are needed for good cuts and optimum utilization of work-piece.
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PRODUCTS SHOWCASE
“ENGINEERING FILES” Indian Tool Manufacturers “ITM”, A division of Birla Precision Technologies Ltd. is one of the leading “Engineering Files” suppliers in India, “Dagger Brand” Files are made out of finest steel material, with state -of – the Art manufacturing facility to produce best quality of Files in its category. A Engineering File is a tool used to remove fine amounts of material from a metal work piece. It is commonly used for removing burrs, sharp edges in engineering process. Most are hand tools, made out of High Carbon Steel bars of rectangular, square, triangular, or round cross-section, with one or more surfaces. A narrow, pointed tang is common at one end, to which a handle will be fitted. Files teeth are cut with unique, automised, hydro-pneumatically-controlled cutting machines forming equally spaced teeth and uniform dept of cut to ensure consistent cutting quality and desire surface finish. Uniform, well- spherodized steel structure and required carbon rich surface produces uniform hard tooth for longer life. The shape and size of work piece, the material it is made of and the desired surface finish will have to be considered for selecting the right File. Our product range consists of Machinist Files, Saw Files, Wood and Rasp Files, Needle and Diamond Files etc. 1.Machinist Files: All Machinist Files are available in 3 cuts i.e., Bastard, 2nd Cut and Smooth. Size Range: 100 mm – 350 mm (4” -14”) 2.Saw Files: All Saw files are available in single Cut i.e, 2nd Cut. Size Range: 100 mm – 200 mm (4” -8”) 3.Wood and Rasp Files: All Wood & Rasp Files are available in 3 cuts i.e, Bastard, 2nd Cut and Smooth. Size Range: 150 mm – 350 mm (6” -14”) 4.Needle Files: Needle Files are generally used in Jewelery Industries and small component manufacturers, These Files are available in shapes of Flat, Three Square, Square, Half Round, Round, Knife Edge etc. Size Range: 160 mm 5. Diamond Files: Diamond Files are generally used in Tough and difficult to cut materials etc. These Files are available in shapes of Flat, Three Square, Square, Half Round, Round, etc. Size Range: 160 mm Advantages of ITM File are: • Extra Life • Corrosion Resistance • Better Productivity • Superior Finish • Finest Quality Steel.
For Product Enquiry Contact Birla Precision Technologies Limited Email: itmth@indiantool.com
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Tips for Better Performance: • A new File should be used with light pressure in the beginning, preferably on a surface which has been filed earlier. • In case of clogging of File teeth, clean the teeth with a soft metal wire brush. • Use the Files for cutting in the forward stroke only. • Filing jobs should be hold rigidly.
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Cross Roller Bearing Features To solve the problem of reducing the mechanism which use one bearing to replace two bearing solution. PMI’s designs and manufactures a variety of cross roller bearings that can handle radial, thrust and moment loads at the same time. These compact bearing feature rollers crossed at right angles between inner and outer rings. This structure can reduce the combined height required for bearings, achieving high rigidity and excellent load capacity. There are currently Standard type CRB, Mounting Holed type CRBF, Robots Installation type CRBR and Customization type CRBX for choose. Product Application It suitable used in the rotating parts of machine tools, industrial robots, measuring instrument and IC manufacturing.
For Product Enquiry Contact Superslides & Ballscrews Co. India Pvt Ltd SUPERSLIDES HOUSE, A-774 T.T.C Industrial Estate, MIDC, Firebrigade Road, Off Thane- Belapur Road, Koparkhairne, Navimumbai-400 701 (INDIA) Tel.: 022-4935 5555 (40 Lines), Fax: 022-4935 5556 E-mail: sales@superslides.in / info@superslides.in Website: www.superslides.in
Product Characteristics High Accuracy: PMI offers precision cross roller bearing in the P2, P4, P5, P6 and P0 grades that to satisfy the needs of customers for precision equipment. The bearings produced by the test are classified that according to the accuracy of the ISO standard. High Rigidity、High Load Capacity: Rollers crossed at right angles between inner and outer rings, the roller and groove contact area compare with ball bearings is bigger and contributing to miniaturization and increase load capacity and rigidity. Save Space: Traditional Ball bearing combination space larger than Cross roller bearing about 1.5~2 times, reduce the design space and miniaturization. Specification Diversification: Bore diameter 20mm to 110mm available for selection. Crowning Rollers: The rollers designed crowning curve that to avoid stress concentrate at both ends of the roller for the reason that it is maximum stress value of the roller can be reduced and the loading is relatively average, so improve the life of cross roller bearing.
FLIR Ex-Series™ INFRARED CAMERA WITH MSX®
For Product Enquiry Contact FLIR Systems India Pvt. Ltd 1111, D Mall, Netaji Subhash Place, Pitampura, New Delhi – 110034, INDIA Tel: +91-11-4560 3555 | Fax: +91-11-4721 2006 Email: flirindia@flir.com.hk Webiste: www.flir.in
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FLIR E4, E5-XT, E6-XT, and E8-XT are powerful, cost-effective, easy-to-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 (E6-XT and E8-XT), the Ex-Series has models to fit your target size, working distance, visual detail needs, and budget. All models include MSX® technology for extraordinary thermal imaging detail. With Ex-Series cameras, you can gain the competitive advantage by providing clients with thermal images that clearly reveal the source of electrical, mechanical, and building-related problems. • Fully automatic and focus-free • Download images, create reports, and share what you’ve found instantly • Lightweight and well-balanced at just 0.575 kg • Withstands a 2-meter drop test • IP54 Enclosure provides a high level of protection against dust and water • 2-10-year warranty.
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PRODUCTS SHOWCASE
Cotton Knitted Seamless Cotton is a natural fiber & it is soft, supple, with no irritation despite longer wear & absorbs the moisture, making comfortable. These gloves are available in different weight & thickness for various requirements & different cuff length depending on application. The Dotted Gloves can be offered in 7,10 & 13 Gauge Knitting. Features & Benefits The gloves made from 100% Cotton-natural fibers that provide excellent comfort, economically priced, with increase in thickness/ weight, it can provide abrasion & heat protection. Seamless Knit Construction & Close Flexible Fit increases the comfort, dexterity, durability & eliminates irritation despite long period of wear & allows the circulation of air reducing perspiration, Ambidextrous- fits either hand for double glove life. M & L Sizes can be done. The long cuff can also be offered for more protection on wrist area & fitting. 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 • General Purpose • Automobile Industries • Mining • Fishing • Packaging • Also used as Liner or inner Gloves.
Steady Volt Servo Voltage Stabilizers Frequent voltage variations are a menace that can damage electronic components like power supplies, drives, PLCs, controllers, etc. Their effects are widely felt in CNC, printing and textile machines as well as laboratory, data processing, medical & telecommunication equipment. Frequent breakdowns of such machines are costly to repair. This apart, the downtime and frequent interruptions in operation brings substantial loss of revenue. Steady Volt from Unity Controls is a state-of-the-art Voltage Stabilizer designed to protect such equipment from voltage variations and its ill-effects. Following are some of its unique features:
For Product Enquiry Contact Unity Controls Pvt. Ltd 405, Sapphire Arcade, 42 M.G. Road, Ghatkopar (E), Mumbai 400 077 Phone: 022- 2501 3832 / 33 E-mail: sales@unitycontrols.in Web: www.unitycontrols.in
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• • • • • • •
Intelligent microprocessor-based system(available in new digital models) Digital interface with large LCD display and keypad Auto re-start, adjustable output voltage, trip bypass, fault list No hunting, oscillation and noise generation Innovative transformer design to minimize power loss Constant output voltage across a wide input voltage range Single phasing prevention, surge suppressor and EMI / RFI filter
With the best-in-class response time and correction rates, Steady Volt offers improved power quality and greater energy efficiency, thereby saving the cost of breakdowns and energy utilization. Apart from protecting your equipment from damage, Steady Volt also saves energy during continuous operations.
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2 out of 8 selectable safety functions One device for many applications
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
We extended again the safety functions of our multifunctional safety module UG6970 from the SAFEMASTER- family. It monitors two independent safety functions. They can be selected as desired from the basic functions emergency stop and safety door, choosable with cross circuit monitoring as well as from further basic functions like two- hand circuits, safety mat/edge, light curtain and alternative switch. At this, the device offers maximum safety up to performance level (PL) e/ Kat 4 or SIL 3. The SAFEMASTER settings are performed without programming, simply and quickly via 3 rotary switches. With a narrow device only 22.5 m wide, two different safety circuits of machines and systems can be monitored simultaneously in a simple manner. In addition, the safety module features flexible starting conditions. For example, the device can be optionally activated via manual or automatic start. The connection methods are just as flexible. Apart from conventional screwtype terminals, cage clamp terminals are also available for simple and quick installation without tool. The plug-in connection blocks allows for quick device replacement in the event of service thereby offering additional saving potential. The SAFEMASTER is designed for 2-channel operation with adjustable cross fault monitoring. In addition, it features line fault detection on the ON-button. LED indicators and semiconductor signal outputs ensure quick diagnosis. The UG 6980 is available if only one safety circuit shall be monitored.
Nexgen Refrigerated Air Dryers
For Product Enquiry Contact GEM Equipments (P) Ltd. SF No.103, Avinashi Road, Arasur, Coimbatore 641 407 Phone: 0422-2363800 / Email: sales@gemindia.com
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The Nexgen Refrigerated Air Dryers from Gem Equipment are known for engineering excellence, innovation and reliability.The heat exchangers are designed to provide worry-free, highly efficient heat transfer whether you are processing simple fluids, viscous solu8tions, or particulates. They feature honey comb construction of aluminium fins, true cross-flow for greater effective temperature differences, non-clogging larger cross-sectional area for air flow, integral air-air and air-refrigerant exchanges, with stainless steel demister moisture separator, robust non-corrosive grade aluminium, and larger heat transfer area for higher efficiency. The rugged electronic panels display both inlet and dew point temperatures. They incorporate a Tripper module with alarm for compressed high discharge pressure, compressed low suction pressure, expansion valve malfunction, auto drain valve function and fan motor cycling. Introduction of speed control is one of the major developments towards the optimization of refrigeration systems based on average load. For periods of high cooling demand, the compressor speed can be increased which results in a higher refrigerant flow and thus higher cooling capacity and vice versa during periods of low cooling demand. Compressed air purification equipment must deliver uncompromising performance and reliability while providing the right balance of air quality with the lowest cost of operation. As a quality-centric group, Gem ensures that its dryers are test at each stage of assembly as per ISO 7183 or relevant standards. It maintains stringent engineering practices throughout the production process to achieve higher reliability. Gem’s state-of-the-art ISO 9001-23008 certified facility is equipped with dedicated men and machines to chisel out products of impeccable quality and reliability.
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A ACE MICROMATIC GROUP
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ADOR WELDING LIMITED
85
ANCA MACHINE TOOLS PVT LTD
7
APEX PRECISION MECHATRONIX PVT. LTD.
105
AUTOMOTIVE ENGINEERING SHOW - 2019
112
B BIRLA PRECISION TECHNOLOGIES LIMITED
61
C CNC SOFTWARE, INC.
INSIDE BACK COVER
D
COMPANY NAME
PG. NO.
COMPANY NAME
HURCO INDIA
69
P
I
107
DOWEL ENGINEERING WORKS
111
DUTCH TECH TOOLS PVT. LTD
33
DVS TECHNOLOGY GROUP
20 - 21
25
81
PRECIHOLE MACHINE TOOLS PVT. LTD.
89
IMTOS - 2019
17
PRECISION MOTION INDUSTRIES, INC. ( PMI )
23
INDIA MANUFACTURING EXCELLENCE AWARDS - 2019
114
Q
INTEC - 2019
29
QUAKER CHEMICAL INDIA PRIVATE LIMITED
53
IPTEX + GRINDEX- 2020
115
QVI INDIA PVT. LTD.
75
R
J JERGENS INDIA PVT. LTD.
70
RENISHAW INDIA
59
JYOTI CNC AUTOMATION LTD.
57
ROCKLINIZER
76
ROLLON INDIA PVT. LTD. - INDIA
93
RR KABEL LIMITED
41
KYOCERA
73
S
L LUBECO
47
M
E
PARAGON MACHINERY CO. LTD.
IMTEX FORMING - 2020
K
DELHI MACHINE TOOL EXPO 2019
PG. NO.
SHAVO TECHNOLOGIES PVT. LTD.
87
SOLITAIRE MACHINE TOOLS LTD.
63
ELECTROTHERM (INDIA) LTD.
15
MARPOSS INDIA PVT. LTD.
77
SPRAYMET SURFACE TECHNOLOGIES PVT. LTD.
97
ELGI EQUIPMENTS LTD.
27
MARVEL GLOVES INDUSTRIES
109
SUGINO MACHINE INDIA PVT. LTD.
39
EPPINGER TOOLING ASIA PVT. LTD.
102 - 103
MEERA CASTING
113
T
EXXONMOBIL LUBRICANTS PRIVATE LIMITED
9
MGM-VARVEL POWER TRANSMISSION PVT LTD
99
THE ASSOCIATION FOR MANUFACTURING TECHNOLOGY
65
MICRO-EPSILON INDIA PRIVATE LIMITED
91
TRUCUT PRECISION TOOLS PVT. LTD.
FALSE COVER
F FACCIN S. P. A.
19
MIDAS SAFETY PRIVATE LIMITED
101
U
FATTY TUNA INDIA PVT. LTD.
79
MILLENIA TECHNOLOGIES
55
UNITY CONTROLS PVT. LTD.
FLIR SYSTEMS INDIA PVT. LTD.
31
MITSUBISHI ELECTRIC INDIA PVT. LTD.
13
V
MMC HARDMETAL INDIA PVT. LTD.
INSIDE FRONT COVER
V M TRADERS
G GEDEE WEILER PRIVATE LIMITED
11
N
GP PETROLEUMS LTD.
35
NYNAS NAPHTHENICS PVT. LTD.
HANGSTERFER'S
68
OERLIKON BALZERS COATING INDIA PVT. LTD.
83
W 51
WOHLHAUPTER / ALLIED MACHINE & ENGINEERING COMPANY
67
Y
O
H
95
INNER INSIDE FRONT COVER
YG-1 INDUSTRIES INDIA PVT. LTD. APRIL 2019
FRONT GATEFOLD
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Inside Story
Mr.
Hari
Prakash M Chief Executive Officer GP Petroleums Ltd. My Life’s Goals
Aim & Ambition: The words of Swami Vivekananda ,“You are the creator of your own destiny”, has been a constant motivating factor. I am passionate about leading a business enterprise to deliver shareholder value through sustainable growth. Am driven by the opportunities to coach and build high performance teams for business turnaround, leveraging my experience of managing diverse teams across Asia Pacific countries. I believe in good work life balance for self and for teams around me which ensures peak performance. Vision: To be seen as a leader who walks the talk and leads the team towards the organisation’s goals. To work towards equality of people by upholding ‘Diversity & Inclusion’ in every walk of life, be it in corporate environment or social networks. Social Goal: To give back to the local communities I have been fortunate to be associated with the ‘Rotary International’ over the last decade to support projects that uplift the living conditions of the deprived communities around us. Business Goal: To give my best to GP Petroleums Ltd., which has been charting a successful growth agenda since the association with GP Global group. Our vision for GP Petroleums Is, “To be the preferred partners, for providing world class Lubricants & Services, by applying technology and creating innovative Business Solutions”. Our business goal is for IPOL Industrial lubricants to be recognised as partner in progress in the B2B manufacturing segment by optimising ‘Total cost of Operations’. In the B2C segment, we will exponentially grow the the IPOL brand by delivering value for money across the growing Automotive consumer segment.
My Leisure Choices
Favourite Tourist Spot: Have lived in Shanghai and Singapore for many years, exploring the mysterious Orient and the mystic South east. However I feel best in Backwaters of Kerala and the hills of Coorg with family. Music I Like: Love to listen to the melody of Hindi, Malayalam and Tamil songs. Many a times took time off with the English jazz and the rap to keep my adrenalin going. Sports I Love: I love badminton and play even now when I get a chance. Always passionate about cricket though I have not played for long, but watch the T20 & IPL.
Ask my Taste Buds
Favorite food: I love Indian food from South and North. Occasional indulgence in Thai and Italian cuisine is welcome. Favourite Drink: Happy with the wide choice across geographies.!
In Awe of
I Admire: Rekindled my inspiration visiting the Sabarmati Ashram recently. Cannot but admire the stature, leadership, uniqueness & the will power demonstrated by the Father of our Nation, Mahatma Gandhi.
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MACHINE TOOLS WORLD
APRIL 2019
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