Machine Tools World December 2017 by Divya Media Publications Pvt. Ltd.

Volume 03 No. 07 | December 2017 | ` 150

Pages 102 | RNI No. MAHENG/2015/64267

QUALITY CUTTING TOOLS

CEO CORNER Industry 4.0: The future ahead Industry 4.0 is all about doing things differently — introducing automation and data exchange in manufacturing technologies. It includes cyber-physical systems, the Internet of Things, and cloud computing. The goal is the “smart factory” with cyberphysical systems capable of autonomously exchanging information, triggering actions, and controlling each other independently. This facilitates fundamental improvements to the industrial processes involved in manufacturing, engineering, material usage, asset performance and management, and supply chain and lifecycle management. Adopting an Industry 4.0 approach also provides the means to navigate change. Manufacturers are reinventing their business models to focus on value-added services, and/or entering new geographic markets or adjacent market segments. Today’s Industry 4.0-outfitted factories are empowered to drive productivity and keeps costs down while ensuring quality and consistency across manufacturing processes globally. Technological advances have driven dramatic increases in industrial productivity since the dawn of the Industrial Revolution. The steam engine powered factories in the nineteenth century, electrification led to mass production in the early part of the twentieth century, and industry became automated in the 1970s. In the decades that followed, however, industrial technological advancements were only incremental, especially compared with the breakthroughs that transformed IT, mobile communications, and e-commerce. Now, though, we are in the midst of a fourth wave of technological advancement: the rise of new digital industrial technology known as Industry 4.0, a transformation that is powered by nine foundational technology advances. In this transformation, sensors, machines, workpieces, and IT systems will be connected along the value chain beyond a single enterprise. These connected systems (also referred to as cyberphysical systems) can interact with one another using standard Internet-based protocols and analyze data to predict failure, configure themselves, and adapt to changes. Industry 4.0 will make it possible to gather and analyze data across machines, enabling faster, more flexible, and more efficient processes to produce higher-quality goods at reduced costs. This in turn will increase manufacturing productivity, shift economics, foster industrial growth, and modify the profile of the workforce—ultimately changing the competitiveness of companies and regions.

CEO

MACHINE TOOLS WORLD DECEMBER 2017

ANCA Machine Tools Private Ltd 8/1 , Dr. M H Marigowda Road, Arekempanahalli , (Wilson Garden ), Bangalore - 560027, Karnataka, India T: +91 (80) 6759 2100, M: +91 96637 69911, E: indiainfo@anca.com, W: www.anca.com

www.mtwmag.com

Publisher & Printer

Contents

Shirish Dongre

CEO

Vol 3 Issue 07 | DECEMBER 2017

COVER STORY

Shekhar D.

Editor Shilpa Dongre

Assistant Editor Shweta Nanda

Marketing Team Ladoji Pendurkar, Amol Powle, Bhavin Shah, Bharat Shah, Vinod Surve, Kamlesh Balkrishna, Kavita Chaudhari

Designer & Layout Arun P. Shinde, Nandan S. Moghe, Dinesh S. Gawade

Online Division Ganesh Mahale

Circulation Executive

Cognitive heritage of technology excellence & precision

Satish Kadam, Amol Ranshur Branch Offices (Zonal)

NORTH (Delhi & NCR regions) Sandesh Jain : 09810837877 / 09871602777

SOUTH (Chennai & Coimbatore) Y. V. Raghu : 09566141224 Bangalore Vaman : 09686721340

EAST (Kolkata & Other regions) Kamlesh B. - 09819464242

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

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

MACHINE TOOLS WORLD DECEMBER 2017

MR. G. D. Rajkumar Director, Gedee Weiler Pvt. Ltd.

BUSINESS NEWS

DesignTech CAD Academy 3D Diwali Contest

ELGi’s partnership with ITF successful, demonstrates real energy savings

Making a success in the Tap market is all about attitude

Hoffmann Group inaugurates new office in Pune to expand its services in India

New Aerospace Facility for Maini Precision Products Inaugurated

Renishaw and Identify3D collaborate to enable secure digital manufacturing

Mastercam at Expo Manufactura 2018

IN FOCUS

DMG MORI and HEITEC strengthen automation expertize

FARO® announces Acquisition of Dustin Forensics

Schmersal India Wins Award for Best SME in Machine Safety

NTB : Coherent technology excellence with global standards

Precision Inspection & Tooling Aids-Solution for Engineering Industry, World Over

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

Machining Center for Impeller and Small-size Complex Shape Processing

Specifications

A-Axis

X-A

xis

Z-A

B-Axis

Ram Type Moving (X/Z-Axis)

Ã&#x2DC;200

mm Table Size

kg Workpiece Weight

40,000 (HSK-E40)

r/min Spindle Speed

EA No. of Tools

300/300/200

mm (X/Y/Z-Axis) Travel

50/50/50

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

200/200

rpm (A/B-Axis) Rotary Table Speed

2G/2G/2G

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

SIEMENS 840D sl

CNC Controller

Rotary Tilting Table(A/B-Axis)

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

Contents IN FOCUS

Shaping the next level of manufacturing

COMPANY PROFILE

Vol 3 Issue 07 | DECEMBER 2017

COMPANY PROFILE

CASE STUDY

Shavo Technologies offers high-tech tailor made solutions

Performance, Precision, Reliability and Affordability: The HAAS VF-I series delivers it all and more for SAHNEY KIRKWOOD !!!

TECH TRENDS upgradation: Metal processing plant 68 Safety benefits from flexible and modular safety solution from Pilz

First clinical study patient has novel drug delivery system implanted for Parkinson’s trial

PRODUCTS SHOWCASE

KING CUT PRO – The Large Gantry Type CNC Cutting Machine

96 56

Our Products Cluster - Metal Cutting Tools

LINEAR 74 CRASH-FREE MOTION

Steady Volt Servo Voltage Stabilizers

Nexgen Refrigerated Air Dryers

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

We give strategic advantages to our customers from diverse industries

MACHINE TOOLS WORLD DECEMBER 2017

Automation in sheet metal cutting and welding

Electrical Safety for Power Supplies!

YOUNG BUHMWOO INDIA CO. PVT. LTD. K-5, Phase II, SIPCOT Industrial Park, Mambakkam Village, Sriperumbudur 602 106, Tamil Nadu, India. +91 - 44 - 7140 0199 ybi@buhmwoo.com, marketingchennai@youngbuhmwoo.com AREAWISE SALES OFFICE • Chennai, Tamilnadu • Coimbatore, Tamilnadu • Bangalore, Karnataka • Noida, Uttar Pradesh/NCR • Pune, Maharashtra • Indore, Madhya Pradesh • Vadodara, Gujarat

Editorial Board

Editorial Index A Accusharp Ador Welding ANCA

J 56 78, 95 22, 34

B Bettinelli Mr. Arun Mahajan General Manager

AMT- The Association For Manufacturing Technology

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

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

D DesignTech DMG MORI DOLD Electric

Precision Tools

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.

G Gedee Weiler GEM Equipments H HAAS Heidenhain India Hoffmann Group

M Maini

Mastercam

N 18 24 97

NTB Hitech Ceramics 46 P Pilz

E Elgi Equipments EOS

Jash

20 52

68, 72

R Renishaw

38, 66

Rollon 42 96

S Schmersal Shavo

64 86 32

30 60, 97

U Unity Controls

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

Mr. Dinesh Khambhayta President MTMA-RAJKOT

Mr. Ayaz Qazi Director

Precihole Machine Tools Pvt. Ltd.

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

Mr. P.K. Balasubbramaniian President VBS Corporate Support

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

MACHINE TOOLS WORLD DECEMBER 2017

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

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

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

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

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

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

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

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

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

BUSINESS NEWS

DesignTech CAD Academy 3D Diwali Contest DesignTech CAD Academy, an authorized training partner of Siemens Industry software for their CAD and PLM solutions, Dassault Systèmes for CATIA, and Altair Engineering for their CAE HyperWorks suite of Solutions, celebrated Diwali with a unique DesignTech CAD Academy 3D Diwali Contest for Engineering students across various cities in India. DesignTech CAD Academy conducted 3D Diwali Contest wherein students had to develop designs of artifacts that best represent the spirit of Diwali for them at the respective CAD Academy’s authorised training centres. The contest was extended to the external students as well besides CAD Academy students. They had to develop fully rendered designs in not more than 4 hours using NX or CATIA software. The Contest was judged by the Technical Experts of DesignTech Systems Ltd. with more than 15 years of experience exclusively in Product Designing. Mr. Prashant Deshpande, Sr. Business ManagerEducation and Trainings, DesignTech CAD Academy stated “DesignTech CAD Academy 3D Diwali Contest gave students a chance to demonstrate their creativity, talent and expertise in using the latest CAD Technology thus increasing their confidence of being able to harness the full potential of the software tool to develop remarkable intricate designs. This year we received an overwhelming response of 300+ registrations for our contest.”

MACHINE TOOLS WORLD DECEMBER 2017

The Topmost Winner across all centers makes a direct entry to the HR interview stage, which if cleared he/she gets an opportunity to work at DesignTech Systems, Engineering Services Division. The Written and Technical interview of the said winner candidate is considered passed. Rest of the winners also received exciting prizes including a smart DesignTech CAD Academy Backpack, Sony Powerbank and a Winner Certificate. All India 1st Prize winner is Dasam Ravisatya from DesignTech CAD Academy, Pune - J.M Road Center. The list of other winners as per the centers :

Position

Student Name

CAD Software used by student

DesignTech CAD Academy Center

First prize winner

Prasad Shastri

NX Software

Pune-Kothrud

Second prize winner

Nikhil Pralhad More

NX Software

Pune-Kothrud

First prize winner

Rahul Ulhas Bacche

NX Software

Pune-Chinchwad

Second prize winner

Rakesh Kumar Rana

CATIA Software

Pune-Chinchwad

First prize winner

Neeraj Rittikar

CATIA Software

Pune-Satara Road

Second prize winner

Shraddha Saptarshi

CATIA Software

Pune-Satara Road

First prize winner

Dasam Ravisatya

CATIA Software

Pune-J. M. Road

Second prize winner

Sonali Kedar

CATIA Software

Pune-J. M. Road

First prize winner

Penmatsa Venkata Durga Raju

NX Software

Hyderabad

Second prize winner

K Praveen Kumar

NX Software

Hyderabad

First prize winner

K.Nagaraju

NX Software

Hyderabad-Kukatpally

Second prize winner

Pentela.Venkata.Dilip Sai

NX Software

Hyderabad-Kukatpally

First prize winner

Vivek Ganesh Kadam

CATIA Software

Satara

Second prize winner

Nikam Shubham Vilas

CATIA Software

Satara

First prize winner

Patil Sourabh Shantinath

CATIA Software

Kolhapur

Second prize winner

Pratikkumar Patil

CATIA Software

Kolhapur

First prize winner

Ankur Savita

NX Software

Gurgaon

Second prize winner

Diwansh Nagori

CATIA Software

Gurgaon

All the contestants of DesignTech CAD Academy 3D Diwali Contest received participation certificate.

BUSINESS NEWS

ELGi’s partnership with ITF successful, demonstrates real energy savings Elgi Equipments Limited (BSE: 522074 NSE: ELGIEQUIP), one of the world’s leading air compressor manufacturers, announced the outcome of its successful partnership with Indian Texpreneurs Federation (ITF), one of the largest textile groups in South India. ELGi’s air audit program helped ITF member companies to reduce average compressed air energy costs upto 43%. ITF is a 500 member strong organization covering all textile operations concentrated in Tamil Nadu. ITF’s mandate is to promote the textile sector. Its 500 members collaborate in an environment of confidentiality and mutual respect to share best practices to improve the industry’s operational standards. Externally, the group’s leadership partners with the government to raise awareness of challenges facing the industry. Given rising energy costs, textile units are exploring opportunities to reduce the cost of compressed air. To support the textile industry’s focus on energy reduction, ELGi partnered with the Indian Texpreneurs Federation (ITF) to design a comprehensive energy program. The program included information sessions for owners and general managers on the compressed air best practices, practical training sessions for textile maintenance engineers, and critically, free of cost air audit programs that helped recognize significant cost savings. On the partnership, Anvar Jay Varadaraj, Head of Marketing and Corporate Communications, ELGi said “Our relationship with ITF has been a resounding success owing to mutual respect and recognition of value. For ELGi, ITF members have

MACHINE TOOLS WORLD DECEMBER 2017

provided generous access to how textile customers are managing their compressed air systems, while mills have benefitted from our expertise. With ITF, we’ve had an opportunity to directly engage with textile CEOs to understand their manufacturing challenges” Speaking at the event, Mr. Prabhu Damodaran, Secretary of the Indian Texpreneurs Federation said, “In our efforts to compete in the global market, this relationship focused on intelligent energy monitoring and optimizing air consumption levels. ELGi enabled us to bring about improved manufacturing efficiency and cost leadership through energy conservation.”

Air Audit An Air Audit is a review of an operation’s use of compressed air. The audit evaluates both the generation and distribution of compressed air. A review of generation evaluates the compressor’s performance

compared to original specifications, energy consumption, current condition, and appropriateness for the application. A review of the distribution evaluates how compressed air is used in the plant, which includes leaks in the air lines and general consumption. Compressed air systems are dynamic and inefficiencies develop over time owing to air leaks and changes in air consumption. An air audit assesses a compressed air system and identifies areas of inefficiency with corresponding cost savings if rectified. An engineer presents a detailed report with recommendations on how to recognize the potential savings. The technical training sessions with textile maintenance engineers help instill compressed air best practices which enable engineers to sustain efficiency. The ELGi-ITF air audit program across 130 textile customers recognized annual savings of Rs. 14 Cr. with an average

compressed air energy cost reduction of 43%. ELGi will continue its engagement program.

About ELGi Elgi Equipments Limited is a leading air compressor manufacturer with a broad line of innovative and technologically superior compressed air systems. ELGi has earned worldwide distinction for designing sustainable solutions that help companies achieve their productivity goals and keep the cost of ownership low. ELGi offers a complete range of compressed air solutions from oil-lubricated and oilfree rotary screw compressors, oillubricated and oil-free reciprocating compressors and centrifugal compressors, to dryers, filters and downstream accessories. The company’s portfolio of over 400 products has found wide application across industries.

For more information Web: www.elgi.com

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For more information, visit mastercam.com/dynamic

BUSINESS NEWS

Making a success in the Tap market is all about attitude SK Precision is taking on the Tap market in Thailand and be the first domestic supplier to the region reducing their customers lead times and cost and improve service Taps are notoriously complex to manufacturer but that isn’t deterring Thai manufacture SK Precision who are building their capabilities to be the first domestic supplier of taps to the Thailand domestic market. The Thailand Government understands that manufacturing will be a key driver of growth long term and has been encouraging companies to establish facilities in their territories through tax and other incentives. As a result, there is a flourishing automotive and aerospace sector that require suppliers. SK Precision has around 50 people working two shifts servicing their traditional market of cutting carbide tools and PCD tools. Mr Tibordee Srikul president of SK Precision said: “We have been operating for over 20 years and know the local Thai market intimately. We saw an opportunity in the tap grinding segment as until now companies could only source taps from overseas suppliers and that means longer lead times of up to three months and higher cost.” “Our customers want just-in-time

MACHINE TOOLS WORLD DECEMBER 2017

products so they can reduce stock and inventory costs. Having a local supplier who can deliver taps in a short period of time helps them achieve a more efficient supply chain.” “Tap’s are a difficult tool to manufacture. A complex application, the geometry and tolerances requirements take a lot of skill and knowledge to produce. At SK Precision we like a challenge and saw the combination of a gap in the market and a new application as something we could make a success.”

“I didn’t want to be restricted to producing only one type of tap and after extensive market research we decided to invest in the Tap X because of its flexibility. Our investment in capabilities, both in technology and experience means we can now produce special and standard taps locally. But that is only the beginning, in the future I want to produce spiral tap, point taps and hand taps and forming taps.” “For me and my team it is all about attitude. We are always looking to the future to keep up to date on what technology and market trends are emerging. I like a challenge and I knew that there was great opportunity I could take advantage of. My philosophy is to take on a challenging market and develop it. Attitude is everything and that is how I make sure I am successful - I believe I can do it!” ANCA’s TapX Linear is leading the revolution in single setup tap manufacturing ANCA was the first machine manufacturer to deliver to market a

single setup machine for complete tap manufacture. Continuing this tradition of industry firsts, ANCA now offers the TapX Linear range of machines – the first single setup tap grinding machine with LinX linear motor technology on X, Y and Z axis. TapX Linear finds the perfect balance between proven designs combined with ANCA’s newest technologies. The rigid bisymmetrical column design on the solid polymer concrete base has been the foundation design of ANCA machines over the years. Now, in addition, ANCA’s new LinX cylindrical linear motors and linear glass scales are fitted as standard on X, Y and Z axis for proven and unsurpassed long term reliability and accuracy. The result is a superior machine that ensures customers will meet ever increasing market demands of precision tap grinding. TapX machines are purpose built, with tooling, coolant delivery and automation specifically for production grinding of all types of taps, from M3 up to M50, whether in high speed steel or carbide. Clever tooling design means change over from one tap type to another can be done in minutes, not hours. This delivers greater flexibility in your tap production and results in increased productivity and reduced costs.

For more information Web: www.anca.com

PARTNER FOR PRECISION

THE JUNKER GROUP The JUNKER Group is the ultimate partner worldwide for all needs related to grinding and air filtration technology. Maximum precision and absolute passion for what we do makes us a pioneering technology leader. It is our mission to set new standards and justify the trust placed in us by discerning customers from a vast array of industrial sectors.

ERWIN JUNKER MASCHINENFABRIK GMBH INDIA BRANCH OFFICE Office No. 104, City Square 29-2, K.M. Gandhi Path Bhamburda 411 005 Shivaji Nagar Pune, India +91 20 255 33 896 info@junker.in

www.junker.in

BUSINESS NEWS

DMG MORI and HEITEC strengthen automation expertize Bielefeld // Two strong partners are combining their know-how to speed up the development of innovative automation solutions: DMG MORI AKTIENGESELLSCHAFT and HEITEC AG are founding the joint venture “DMG MORI HEITEC“ – perfectly timed to coincide with the start of the SPS IPC Drives in Nuremberg, the leading trade fair in Europe for electric automation. Through DMG MORI HEITEC GmbH the two companies are continuing their successful collaboration over the past years and are mutually strengthening their market position in the fastgrowing field of automation. Of the more than 1,000 employees at the HEITEC group, around 600 work on automation solutions. One in four new machines from

DMG MORI is already provided with an automation solution. In future every machine shall be fitted with automation on the basis of a modular system. By modularbased compatible solutions DMG MORI HEITEC will supply small and medium-sized companies with an integrated automation concept. Software-based support for engineering processes using virtual models of machines, plants, robot applications and material flows is an essential measure to reduce costs, while simultaneously increasing productivity. DMG MORI HEITEC GmbH, based in Erlangen, has therefore set itself the goal of developing a virtual representation – in short “digital twin”. With the aid of digital engineering, project lead times can be cut by around

20%, and commissioning on site can be even more significantly reduced by up to 80%. Future additions or changes can be planned and tested with the digital twin running in parallel to the live operation. “We are strengthening our automation expertize as two equal partners in a joint venture. Thus, the development of the digital twin is of key importance: it speeds up and stabilizes all the customer processes – from development and setting up right through to service – and ensures flexible, steady procedures,“ says Christian Thönes, Chairman of the Executive Board of DMG MORI AKTIENGESELLSCHAFT. “Through automation and digitalization we are making a significant contribution towards

increasing productivity and efficiency. Supported by digital engineering we are achieving a considerably higher quality with shorter through-put times in development and commissioning,” says Richard Heindl, Chairman of the Executive Board of HEITEC AG. In the future, automation standards are also planned for a broad range of customer sectors and the realization of customized projects specifically for mediumsized companies, that is, the German “Mittelstand“.

For more information www.ag.dmgmori.com

FARO® announces Acquisition of Dustin Forensics FARO® (NASDAQ: FARO), the world’s most trusted source for 3D measurement and imaging solutions for public safety forensics, announces the acquisition of Dustin Forensics, a digital forensic animation firm based in Adairsville, Georgia. The acquisition of a worldrenowned forensics services firm represents the logical next step in actualizing the FARO® vertical business growth strategy. Dustin Forensics has been led by David Dustin, an innovator in 3D crime and accident scene reconstruction and a pioneer in the legitimatization and admissibility of 3D data as an

MACHINE TOOLS WORLD DECEMBER 2017

accepted courtroom tool. David will be taking on the newly created role of Director of Public Safety - Forensics Services. “We are excited to have Dustin Forensics join the FARO family,” stated Jeff Ruiz, Vice President of Public Safety Forensics. “Their real world expertise will not only strengthen the FARO service portfolio but also extend our reach into the broader markets of public and corporate security where there are significant opportunities to deliver comprehensive 3D scanning services for preincident planning, proactive threat assessments, and soft

target protection.” “I am thrilled to become a member of the FARO team,” commented David Dustin. “With the extensive resources of FARO, we will greatly accelerate our original mission – the advancement of laser scanning technology as it applies to public safety.” “This acquisition, in concert with the recent introduction of FARO Zone 3D and SCENE 7.1 solutions, powerful software platforms specifically developed for forensics, makes a clear statement on our commitment to extending our lead in the global forensics market,” added Joseph

Arezone, Chief Commercial Officer. “The combination of Dustin Forensics’ and FARO Technologies’ in-depth 3D expertise will enable a leadingedge portfolio of new forensics services.”

For more information Web: www.faro.com/India

BUSINESS NEWS

Schmersal India Wins Award for Best SME in Machine Safety Schmersal India wins Award for the Best SME in Machine Safety at the Navabharat SME Business Excellence Award 2017 held in Mumbai on October 28, 2017. The Navabharat SME Business Excellence Award 2017, intends to felicitate the achievements in the SME sector to encourage & support the SMEs that have the potential to be world-class enterprises and offer them the platform to promote themselves in partnering for sustainable growth. The awards were given in several categories and based on the size of the company, the amount and the type of work performed. It was an evening event, with a Panel Discussion on “GST & De- monetization – Its impact on SME Sector“, followed by awards night in the presence of 200+ delegates like SME Entrepreneurs, Officials from Industrial Association, Government Officials - Hon’ble Shri. Shiv Pratap Shukla ji – Minister of State- Finance, Govt. of India & Industry Minister of Maharashtra - Shri. Subhash

Desai ji, delegates from SME Chambers and Print & electronic media. Sagar Bhosale, Managing Director, Schmersal India Pvt Ltd., was a speaker at this event. He stated, “The Indian SME sector is growing at an exceptionally fast pace and has truly become the backbone of India’s GDP growth“. Educating the audience about the need of industrial safety, he made an earnest request to take initiatives in implementing safety at their workplaces. The jury’s citation expressed that the Schmersal India’s decade of efforts have been bearing positive results in spreading awareness on industrial safety. Starting from a small office to setting up a manufacturing plant, Schmersal India is excelling and firmly committed and dedicated to improving the safety aspects in

Mr. Sagar Bhosale, Managing Director, Schmersal India Pvt Ltd., speaking about the need and importance of Industrial Safety at the Navabharat SME Business Excellence Award 2017.

MACHINE TOOLS WORLD DECEMBER 2017

the industries across India. “Receiving an award in safety excellence is really rewarding and it makes me immensely happy that we are able to spread smiles along with safety at the workplace. Despite having won this industry accolade, we will endeavor to pursue our path of turning workplaces into safer places with exceptional determination,” expressed Sagar Bhosale.

Schmersal Team with the award

Hon’ble Shri. Shiv Pratap Shukla ji – Minister of State- Finance, Govt. of India and Industry Minister of Maharashtra - Shri. Subhash Desai ji handing over the award to the Schmersal India team.

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BUSINESS NEWS

Hoffmann Group inaugurates new office in Pune to expand its services in India German system partner for quality tools is expanding in India, plans to double its manpower and open offices in various parts of the country. going to introduce INR pricing in India from January 2018, probably the first overseas company to do so,” concludes Reichenecker.

The Hoffmann Group

Pune, November 22, 2017: Headquartered in Germany, Hoffmann Group, the European leader in quality tools, today announced the inauguration of a new office in Pune to tap the growing Indian market. Started its operation in 2016 in India, Hoffmann is witnessing rapid growth in the country. Hoffmann Group markets products through its own sales offices in Asia and is investigating in business models to further expand in the Indian market. Hoffmann Group is planning significant investments in the coming year, to increase its reach and enhance service. Speaking at the inauguration of the new facility, Mr. Martin Reichenecker, Member of Hoffmann’s Board of Executive Directors said, “India is one of the most important growth markets for us, and it is also important for sourcing. We offer a reliable supply of quality tools along with specific machining expertise. This way we

MACHINE TOOLS WORLD DECEMBER 2017

help Indian manufacturers raise their productivity. In future, our investment will see a steady growth and we see good opportunities to become an important player, especially in e-commerce in India.” Pinaki Banerjee, MD, Asia Pacific, Hoffmann Quality Tools, Asia Pacific Pte Ltd. said: “We started our operations in India on April 1, 2016 and I must say that we are fortunate that we have entered the market when the business sentiment looks positive, manufacturing is growing and FDIs are coming in. Also, I would like to point out that whenever a multinational enters the Indian market they first enter with a dealer network, then open a branch office before finally a subsidiary will be established. The way Hoffmann Group has started in the market by directly setting up a subsidiary, it is a clear commitment to the market and to our Indian customers.” Hoffmann Group is one of the leading system partners in Europe and directly competing with the best and biggest in the industry.

Hoffmann Group markets its own brand Garant and sources products from the leading manufacturers. With 75,000 products in the catalogue, the company works with roughly 500 suppliers and manufacturers, most of them are coming from Europe. “We are here for a long haul. We want to provide the best solution to the customers and help them enhance their productivity and efficiency,” Martin Reichenecker stated. “Apart from that, we are going to introduce ‘e-commerce’ in the Indian market where 75,000 products will be available. Our customers will be able to select the product, check the pricing, integrate it with their ERP system and the product will be delivered within two weeks. This will make the life of a purchase manager hassle-free. We are also known for our excellent logistics services. We deliver almost 60,000 products everyday throughout Europe and would like to replicate the same in the Indian market. Also, we are

As Europe’s leading system partner for quality tools, the Hoffmann Group combines commercial expertise with both manufacturing and service competence. To more than 135,000 customers this combination guarantees reliability in supply, quality and productivity, in the tooling sector and also in the workstations and storage sector. Optimum and reliable advice, from individual needs analysis through to efficient use of products, is assured at all times. Alongside tools for machining, clamping, measuring, grinding and cutting, the portfolio also comprises hand tools, protective work wear, workstations and storage and workshop accessories. Customers include major listed companies as well as medium-sized and small companies in more than 50 countries. In 2016, the Hoffmann Group generated a worldwide turnover of more than one billion euros. Including GARANT, its own premium brand, the Hoffmann Group offers 75,000 quality tools from the world’s leading manufacturers. With comprehensive customer service and delivery quality of over 99 percent as certified by the TÜV, the tools specialist, headquartered in Munich, is a reliable and efficient partner for its customers.

Creating Tool Performance

A member of the UNITED GRINDING Group

RS15 The universal machine for all tool types

The RS 15 is a manual universal grinding machine with integrated measuring device for rotationally symmetrical tools and indexable cutting inserts as individual pieces or low volume production. It machines tools up to 25 mm perimeter diameter for replaceable cutting inserts and up to 200 mm diameter for rotationally symmetrical tools. www.ewag.com

United Grinding GmbH – India Branch Office & Technology Center # 487, D1 & D2A, 4th Phase, KIADB Main Road, Peenya Industrial Area, Bangalore – 560058 Tel. +91 80 3025 7600 · Fax +91 80 3025 7603 · madabhavi@grinding.ch · www.grinding.ch

Creating Tool Performance

BUSINESS NEWS

Unleashing a new world of possibilities launching the FCP4 High Production Drill Grinder that can produce a completed drill in 20 seconds ANCA is again first to market with the FCP4 High Production Drill Grinder (FCP4). Producing drills from 0.8 to 4mm the new technology provides an exciting opportunity for drill makers, with important efficiencies and cost benefits by manufacturing a complete high speed steel drill on a single machine. From a blank piece of raw material, the FCP4 grinds the Flute, Relief and Point producing a finished drill. Grant Anderson, CEO at ANCA said: “Considering the yearly production of high speed steel drills is about 1.8 Billion drills, the opportunities are huge. The high-volume commodity drill market is a new market for us but is a great fit given our forty plus years’ expertise in tool and cutter grinding and our world leading technology.” The new machine will enable a complete drill to be manufactured every 20 to 25 seconds, a significant difference from what is currently available in the market. Up until now a drill has been manufactured on two or three separate

machines which is a large investment to make and a big task in changing drill sizes typically taking several hours and creating needless waste with scrap setup drills. The CNC capability of the FCP4 also has significant advantages in quicker changeover and less setup times required, making the option of smaller production runs viable. “We think we can bring a huge benefit to the industry as up until now there is little competition or product choice for volume manufacturers of HSS drills. Drill manufacturers are typically restricted to using machines that are old and CAM operated, and with older machines wearing out there are currently very few options for upgrading or improving their capabilities,” Grant continued. Simon Richardson, FCP4 Product Manager said: “We listened to our customers who, in this market, faced a lack of choice and responded to their needs to develop our own solution. With our extensive market knowledge and research

and development capabilities, I am confident this new machine will be well received and unleash a whole new world of possibilities for our customers.” The FCP4 will be fully CNC operated comprising of eight axes, using a principle similar to a Swiss Auto whereby it has a multi turret, capable of undertaking several operations simultaneously. It uses an ANCA Motion CNC system including AM5C drives, AMI5000 Touchpad, Commander, AMCore and Motion Bench. Watch a video here to see the FCP4 in action: https://www.youtube.com/ watch?v=Nk8Cdk344a8

• ANCA Motion CNC and drive technology • Intuitive and user friendly operator panel with touch screen • Flute shape adjusted by CNC and form dressed on the machine

FCP4 Benefits: • Superior surface finish and drill geometry • Quick changeover time facilitates small batch runs – as low as 20 minutes! • Minimised setup scrap • Adjust programs in cycle to optimise drills being ground

FCP4 Key Features: • Complete drill production from HSS blank • Full CNC grinding and dressing operations • Fully enclosed machine canopy with safety interlocks

MACHINE TOOLS WORLD DECEMBER 2017

For more information Web: www.anca.com

Performance

The numbers add up with XL-80

High performance calibration for machine tools, CMMs and motion systems ±0.5 ppm

certified linear measurement accuracy

1 nm

linear resolution (even at max. velocity)

4 m/s

maximum travel velocity

7 seconds

interval between updated environmental compensations

50 kHz

dynamic capture rate

80 m

linear range as standard

Portability - the small size of the XL-80 laser and XC-80 compensator means that a complete system (less tripod) can be packed into a truly portable ‘wheelie-case’, weighing around 12 kg

Ease of use - the XL-80 is quick and easy to setup and use, allowing users to maximise the available measurement time, whilst still retaining the benefits of a pure interferometry based system.

Renishaw plc, New Mills, Wotton-under-Edge, Gloucestershire GL12 8JR, United Kingdom T +44 (0) 1453 524111 F +44 (0) 1453 524102 E uk@renishaw.com

www.renishaw.info/xl-80

BUSINESS NEWS

New Aerospace Facility for Maini Precision Products Inaugurated Maini Precision Products (MPP) recently inaugurated its new dedicated aerospace manufacturing plant at Bommasandra Industrial Estate, Bengaluru. The 60,000 sqft large facility was inaugurated by Shri R V Deshpande, Minister for Medium and Heavy Industries, Government of Karnataka. MPP’s concentration is building up in three verticals of aerospace – Engines, Structures, and Systems. This demanded that the company have a much larger factory to accommodate their growth trajectory. For customer partners too, it was essential that they be able to visualise and have confidence that the company had assigned an exclusive aerospace unit to meet the long-term programmes and requirements of its partners. The facility that originally housed Maini Materials Movement (MMM) and subsequently Reva Electric Car Company has been completely renovated with additions at a cost of INR 7 crores comprising an area of office and factory of 60,000 sqft. Earthwork has started on Phase 2 and will be completed by June 2018 with an additional 40,000 sqft. This will create a base for the aerospace division to grow on an exponential basis to at least 400% from the current level it is at,” said Mr. Gautam Maini, Managing Director, Maini Precision Products. Dr Sudarshan K Maini, Founder, The Maini Group, said, “This for me is one more in the many stages of a momentous journey. It is a journey that has seen

MACHINE TOOLS WORLD DECEMBER 2017

many challenges and triumphs, one that I’ve shared with many extraordinary fellow travelers the journey continues, towards new destinations, with ever more opportunities waiting to be met.” “A new dedicated plant would permit us the flexibility to meet the supply chain requirements of aerospace leaders, Tier Ones and OEMs for rapidly building up a technology value chain that would position us as their strategic partner for their global requirements as well as Makein–India initiatives,” explained Mr. Naresh Palta, who represents the group’s corporate interests in Aerospace. After unveiling a granite plaque that was then signed by the Honourable Minister, Dr SK Maini, Dr KK Nohria and other members of the Maini Group and their key customers, Shri R V Deshpande spoke of his long association with Dr S K Maini and his wife Reva Maini. Commenting on MPP’s new aerospace facility, he said that aerospace was the fastest growing industry in the country and that he was extremely happy that Maini Precision Products is contributing in such a large way to further grow this industry in the state. Shri Deshpande said, “In the next eight years I foresee that India will be a super power as far as manufacturing is concerned. With programmes like Make in India, Start Up India and several others running so successfully, and with the support of industrialists like the Maini Group, we can only look towards a very bright future. Karnataka stands number one in investment

in the country as per figures recently released by the Chamber of Commerce and Industries. “With the current orders that have been placed and the current machines MPP has, the number of machines will reach close to 90 soon and will increase further with the current visibility in our awarded programs. The consistent performances in terms of quality and delivery, as well as competitiveness in the global market, have attracted the interest of more and more customers. It was then assessed that to keep up with the continuing flow of more and more work from current and new customers, we needed to enlarge the plant facility. Also from a long term growth perspective it was envisaged that the time has come to create a dedicated facility for aerospace.” said Sandeep Maini, Chairman- Maini Group MPP has been aggressively hiring the best engineering and manufacturing talent in the market who will cater to their new projects and is looking to hire further resources in pursuit of larger and more complex projects. This expansion of talent has also been a factor for the setup of a dedicated aerospace facility.

About Maini Precious Products: Maini Group is a model exemplar of the Make-In-India program, having made a humble beginning in 1973 with its flagship company Maini Precision Products Ltd. (MPP). The company started with manufacturing components, gradually expanding to sub-

systems and assemblies for global automotive companies. MPP started exporting its products to Europe in 1982 and by 2003 were exporting 90% of its products, all manufactured in India. As the Indian automotive market attained maturity in product development, MPP began to use its expertise to localise high technology, critical parts and sub-assemblies in India, enabling its customers to attain a higher level of localisation. Maini Group’s flagship company Maini Precision Products Ltd. (MPP) moved into aerospace manufacture in 2005 with Safran Aircraft Engines (then Snecma) as its first customer. The Aerospace Division was created by earmarking an exclusive space, of 4000 sqft. With around five CNC machines, within its existing automotive components manufacturing plant initially in Peenya and then at Bommasandra. The last decade has seen the Aero Division make progressive strides, adding several prestigious customers and in the process adding more machines and other equipment. The floor area requirement also grew and by 2016 the manufacturing plant had extended to a space of 20,000 sqft.

For more information www.mainiprecisionproducts.com

CAM? Decision made? Explore the benefits of hyperMILL and switch to the CAM solution for all of your 2.5D, 3D, 5-axis, mill-turn, HSC and HPC requirements.

www.openmind-tech.com OPEN MIND CADCAM Technologies India Pvt. Ltd. ■ 3C-201, 2nd Floor · 2nd Main Road · Kasturi Nagar Bangalore 560 043 · Karnataka · India ■ Phone: +91 80 3232 4647 ■ E-mail: Info.India@openmind-tech.com

BUSINESS NEWS

Renishaw and Identify3D collaborate to enable secure digital manufacturing

of intellectual property along the digital thread. Ultimately, Identify3D helps engineers make better decisions using in-depth analytics and reporting to enable innovation, optimization, and scalability across disparate digital production platforms. Renishaw, a world leader in metrology and additive manufacturing (AM) technologies, and Identify3D, a leader in software for the digital supply chain, are pleased to announce a collaboration to offer an end-to-end, secure digital manufacturing process. Identify3D will provide data protection coupled with contractual and manufacturing licensing from design to production on Renishaw AM systems. By choosing to secure all digital data in the engineering phase, the technology enables users of Renishaw systems to protect their digital intellectual property (IP), enforce production rules and provide traceability in the digital supply chain at the industry’s highest standard. “Renishaw understands how important it is to have an efficient and reliable control of data flow all the way to its machines,” said Stephan Thomas, Chief Strategy

MACHINE TOOLS WORLD DECEMBER 2017

Officer at Identify3D. “We are pleased that Renishaw, one of the world’s leading engineering and scientific technology companies, has selected Identify3D as a strategic partner to provide such a solution to the market place -- from design to distribution and production.” Marc Saunders, Director of Global Solutions Centres at Renishaw, commented, “Industrialising additive manufacturing requires that we manage and control a complex chain of processes to deliver consistent, traceable and qualified parts. Secure transmission and controlled use of digital IP is critical to enable agile Industry 4.0 supply chains. We believe that Identify3D brings a strong and necessary solution that will increase these controls, minimising variation to improve and protect AM production quality.” The two companies are currently working together on pilot

projects for several manufacturing customers. The collaboration will enable sectors such as aerospace, automotive, defence and medical devices to accelerate their adoption of AM, enabling secure, distributed manufacturing across their supply chains.

About Identify3D Identify3D is a leader in software for the digital supply chain. We enable companies to have the confidence that their intellectual property, processes, and products are both secure and aligned with established engineering standards. Identify3D provides manufacturing repeatability and traceability throughout the digital supply chain delivering quality assurance from design to finished product. We deliver greater control over the digital manufacturing process ensuring the security and integrity

About Renishaw Renishaw is one of the world’s leading engineering and scientific technology companies, with expertise in precision measurement and healthcare. The company supplies products and services used in applications as diverse as jet engine and wind turbine manufacture, through to dentistry and brain surgery. It is also a world leader in the field of additive manufacturing (also referred to as 3D printing), where it designs and makes industrial machines which ‘print’ parts from metal powder. The Renishaw Group currently has more than 70 offices in 35 countries, with around 4,500 employees. AM Solutions Centres are located in the UK, Germany, USA, Canada, India and China.

For further information www.renishaw.com/additive

BUSINESS NEWS

Mastercam at Expo Manufactura 2018

CNC Software will be highlighting Mastercam 2018, the most powerfulmachining version yet,at the Expo Manufactura 2018 show being held at Cintermex in Monterrey, Mexico, February 6-8, 2018. Supported by Mastercam Resellers Cad Avshmeip, S.A. and CIM Concept, S.A. de C.V.,attendees canstop by Booth #724to experience the latest in the industry-

MACHINE TOOLS WORLD DECEMBER 2017

leading Mastercam 2018which offersnew 2D/3D and multiaxis Milling features, powerful turning and Mill-Turn enhancements, Design and solid modelling improvements, and so much more. Mastercam 2018 now includes a fully translated version for Spanish-speaking users. Now native Spanish-speaking Mastercam users can unlock the power of Mastercam 2018 using an easier to understand interface. Stock awareness has been added to select 2D toolpaths whichacknowledges the stock and controls the tool motion to avoid any collision with remaining stock. This provides a safer and more optimized tool motion. Finish passesare optimize based on your remaining stock, giving you more efficient and safer tool motion.The workflow for all 3D High Speed toolpaths has been streamlined and

gives you fine control over exactly where to cut. High speed Hybrid toolpathsnow offer smoothing controls and deliver a finer finish, requiring less secondary finish work. If you work with stringy materials such as aluminum or stainless steel, Mastercam’s new Chip Break control prevents problems by allowing you to set length and time conditions, retract, and dwell options. Mill-Turn machine definitions now contain tailstock and quill components, tailored to your machine. Exclusive to Mastercam, a new set of turning strategies automate toolpath generation and support for Sandvik Coromant CoroTurn® Prime inserts and PrimeTurning™ method. PrimeTurning provides superior metal removal rate, productivity gains of over 50%, and increased tool life in a variety of

materials. Once again, we have increased the functionality and productivity of our CAD capabilities, keeping our philosophy of “CAD for CAM” and the needs of CNC Programmers in mind. While our customers create CAD models inside of Mastercam, we recognize they also import models from every CAD system on the market, so we maintain a robust set of up-to-date translators in every release.

For more information www.mastercam.com.

»smileCompact« The Mini-must-have for Professional Tool Presetting and Measuring

Robust, easy to operate, and built appropriately for shop floor use, »smileCompact« allows companies to get started quickly with professional tool presetting and measuring. It can be used directly on the shop floor beside the CNC machine or in a production island, and is a flexible and space-saving option. The new »smileCompact« is the perfect entry point into the world of ZOLLER.

Can be placed directly beside the CNC machine Best brand-name components New ZOLLER »pilotStarter« measuring machine control for comfortable, operator-independent application

More information on our website!

»pilotStarter« image processing software provides all standard measurements such as the length and cross dimension, radius, angle, concentricity, and axial runout at the push of a button

See »smileCompact« live at our regional offices in Pune, Bangalore, Chennai, Ahmedabad, Delhi and Kolhapur! Contact us: Phone 020-27496118, info@zoller-in.com or www.zoller-in.com

COVER STORY

Cognitive heritage of technology excellence & precision MR. G. D. Rajkumar Director, Gedee Weiler Pvt. Ltd.

Q. Please brief us about companyâ&#x20AC;&#x2122;s global reach & latest initiatives in Machine Tool Industry? We Gedee Weiler, are an Indo German joint venture company having a technical partnership with two German companies for more than 5 decades engaged in the manufacture of precision conventional and CNC Lathes for Global Markets. We have been exporting our Conventional and CNC machines to Germany and other parts of Europe thru Germany for more than 3 decades. Our Proturn series machines for tool

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room and batch production applications has a Patented Bed Design The CNC machines we export to Germany are equipped with servo automation by our partner and are supplied to the vendors of Auto giants in Germany such as VW and BMW for mass production of precision parts. The fact that exports contribute to more than 55% of our turn over (out of which nearly 95% to Europe) and that we recently started exporting to ASEAN countries stand testimony to our global reach.

Q. What are the applications of your products in various Industries? How do you plan to position these products? Our products find application in various industry like Auto Components, Aero Space, General Engineering and Tool Rooms. Especially our Lean Turn machines find extensive use in small, precision and mass production application while the Flex Turn models have the versatility to be provided with Linear Tooling/ Turret/ Live Tool Turret/ Dedicated Live tool spindles and Automation.

COVER STORY www.mtwmag.com

Our high precision conventional Lathes are ideally suited for Tool Rooms, Aero Space and other precision applications.

Q. What is the current scenario of Machine Tool Industry? The market scenario is quite promising and we expect the growth to be healthy. As the Indian economy is growing fast, huge investments being made in the infrastructure sector and with initiatives by the central government like Skill India, Make In India etc Indian Machine tool industry can expect to make quantum leap in growth

Q. What are the future opportunities for Machine Tool Industrial sector? Indian Industry is unique that it demands for latest technology and high productiv-

ity but at a very competitive price as India is a price sensitive market. Machines that can deliver process integration, multi tasking in combination with high output and affordable Automation will be the need of the hour. Export of machines to some of the emerging markets will be another area for Indian Machine tool industry to focus for growth.

Q. As per your opinion, what are the technology transformations in Machine Tool Industry over the years? Indian companies have responded well to the challenge posed by globalization and entry of Multi national Auto and Machine tool builders into India by launching several new products as well by improving their existing products in terms

speed, accuracy, flexibility and range. Indian machines are now well accepted by many of the leading European, Japanese and Korean Auto and Auto component makers having plants in India which meet stringent quality and productivity demands as well complying with TPM, 5S and 6 Sigma requirements. Indian machine tool builders are also upgrading to smart machines that can adopt to digital transformation.

Q. What are the distinguishing factors in comparison of Indian against the global Machine Tool Industry? The first and foremost value Indian machines can offer is the competitive price for a given application as against the global machine tool players. Offering total solutions by providing tooling/ fixturing and application support, quick service and spares support backed up by wide network, ingenious automation solutions , flexibility to offer customized solutions based on standard machines and quick deliveries are the other key benefits Indian machines offer to customers.

Q. Please comment on how can the Machine Tool Industry become globally competitive? Indian companies need to develop machines with higher spindle speeds and Rapid feed rates and multi tasking capabilities to compete in the global arena. Attention has to be focused as well on offering intelligent clamping and gripping and smart and cost effective automation so that these machines can get adopted in smart manufacturing factories.

Q. Could you brief us about your topline product range? What are value added services you provide to your customers? As a Company focussed on small parts calling for high precision and mass production we have six lines of our product range namely i) Basic line ii) Manual line iii) Proto line iv) Linear line v) Universal line vi) Vertical line.

DECEMBER 2017

MACHINE TOOLS WORLD

COVER STORY Our range of Capstan lathes namely MCL, MCT & MCS still are in good demand for mass production applications popularly known as 2nd operation machines. Our Lean Turn and Flex Turn machines are well suited for mass production of automobile and general engineering components. The recently upgraded Flexturn-Neo range of products are now available as ‘Automation Ready’ with auto doors in front and top, so that loader /robot can be integrated from front or top. Also, the machine can be used both with manual loading and auto loading. Triax 300 (MT) is a unique product from our linear line as a unique combination of linear tooling with multi tasking- one of its kind in India- facilitating turning, drilling, milling in one setting. Quattroturn 350 (TM) is a 4-Axis Vertical Lathe which can Turn, Mill and Drill at nearly half the time by simultaneous turning, drilling & tapping by two tools is again a one of its kind product offered only by us in India. Value added services: We have expanded our sales and service network by adding dealers as well direct service personnel across India which has greatly improved our response to our customer’s requests. We offer total solution to our customers to improve the produc-

MACHINE TOOLS WORLD DECEMBER 2017

tivity and quality for both new machines as well already supplied machines. We have recently set up a resource center in Faridabad where we have installed one of our machines which is available for our customers for demonstrations, trials and training.

Q. What are your future plans to maintain substantial market positioning in Machine Tool Industry? Over 5 decades we have established ourselves as a leader in precision small conventional and CNC Lathes in the global market. We will continue to remain focused on this segment by offering innovative solutions especially for mass production applications combined with multi-tasking and/ or automation by developing machines with modular units

which can be offered as stand alone units which can be expanded by adding additional modules and/ or Automation at a later date to increase production volume. We are establishing an in house tech center where all our latest products and state of the art work holding and tooling solutions will be available for any trials and demonstration. Our customers will have an opportunity to experience and feel the high productive, precision and automation solutions we can offer for their specific needs. We are making substantial growth in both domestic and export business. We have embarked on an aggressive expansion plan in our capacities as well our sales and service network which will help us achieve our goal of more than doubling our sales in both export and domestic markets in the next 2-3 years.

Q. What are your plans for your company to maintain trailblazer position in Machine Tool Industry? We are honoured to say that we are one among the very few manufactures of manual lathes in the world who build machines conforming to DIN 8605 Standards, one of the most stringent amongst machine tool static accuracy standards. Our passion for developing innovative solutions which deliver high productivity and quality at an affordable price has led us to our current positions of offering unique products in the Indian Machine Tool Industry. Our unique 3-Axis linear tooling multitasking machine and 4-Axis twin turret machines with live tool capabilities stand testimony to our above philosophy. We will continue to develop such innovative solutions combining multi –tasking and automation, modular machines which can be offered as stand alone machines that could be expanded by adding additional modules and/or automation in future which will help customers to keep their investments low in the beginning but at the same time would give flexibility to expand quickly to meet their changing needs.

MEASUREMENT ERROR

MEASUREMENT PRECISION

The Marposs WRP60 radio frequency system automatically detects axis position to enable part inspection on large, 5-axis milling machines and machining centers and applications producing deep parts. You get improved quality and reduced scrap. 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

IN FOCUS

NTB : Coherent technology excellence with global standards Mr.Kamal Kacholia, Managing Director NTB Hitech Ceramics

Q. Please brief us about company’s Indian & global reach ? NTB group is a highly diversified Hitech Engineering Company with a modern 7000 sqm Works at Chakan, near Pune. We are pioneers in Industrial Hitech Ceramics, Power Transmission/ Conveyor belts. Modular Industrial Conveyors/ Automation/SPM Systems and Carbons. NTB was established in the year 1976. NTB products are supplied to almost all well-known companies, having presence in Textiles, Food, Steel, Tobacco, Paper and Engineering industries. The company has not only gained good reputation in domestic market but, also has been exporting products to USA, Europe, UK, Africa and other countries. The company has been certified with ISO 9000:2008 quality system for the past 15 years. The production complies strictly with the standard and procedures of ISO 9001, which ensure good product quality and consistency. Our advanced facilities, rich experience, efficient management and excellent sales team have helped us to build a network of 6000 + satisfied customers.

Q. Please also highlight the latest initiatives in your industry domain? NTB has recently entered into manufacturing of Super Abrasive grinding

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wheels. We have developed State-Of-TheArt Vitrified Bond Diamond and CBN Wheels. These super abrasive wheels have great potential in industries who must grind very hard materials, like Carbide tools and wear parts, Ceramics, Glass, Wall and Floor Tiles, Hardened Die Steels, Tools Steels, Composites etc.

Q. What are the market opportunities for your company’s products in India? The domestic and the exports markets have a huge potential. The Vitriftried Bond Diamond and CBN wheels are required in Metal Cutting Tools Industry, Glass manufacturers, Tiles, Granite and Concrete industry, Automobile Die Makers, Crankshaft & Cam Shaft Grinding, PCD/PCBN insert grinding and many more grinding applications.

Q. What is future prospect for your industry? This is a sunrise industry and the future is great. We will be offering import substitution solutions to the industry, at highly cost effective prices.

Q.Is there any plans for expansion & new investment in terms of product development or new technology

adoption to cater the demand of the industry? In the coming years we have plans to set up a dedicated independent manufacturing facility for diamond and CBN wheels. We will be shortly approaching our bankers for the project financing

Q. What is the top line product range & Is there any plans to launch new products We will provide Vitrified Bond grinding solutions to our customers and give them benefit of grinding cost reductions, quality and productivity. As far as new products are concerned we will be launching hybrid bonds for special applications, as required by the customers.

Q. What is your vision for your company? A win-win strategy for “ Total Customer Satisfaction with Reasonable Price, Reliable Quality & Prompt Service”. Our vision is to offer high performance grinding solutions to the industry and get a respectable market share by tapping the huge potential for our products.

IN FOCUS

Precision Inspection & Tooling Aids-Solution for Engineering Industry, World Over

Rasesh Amin, Director Jash Precision Tools Ltd

Q. Being the key player in the industry, Please brief us company’s journey from inception & share some of the milestones achieved? Established in the year 1947 Jash made a humble beginning with manufacturing of machine tools like lathe, drilling and slotting machines. With the passage of time we diversified our portfolio into manufacturing of products like Machine Tools Accessories, Precision Surface and Inspection Equipments, T-Slotted Bed Plates etc. JASH Precision Tools Limited, a technology savvy company, is pioneer in India for manufacturing of Precision Surface Equipments, Holding Fixtures, Tooling Aids since last more than 7 decades and Precision 3-D Measuring Machines since last 18 years. All these years creating

MACHINE TOOLS WORLD DECEMBER 2017

precise straight, flat, parallel and square surfaces in microns has been the core strength of the Company. Company also offers Custom-Built products in allied line of manufacture. Today JASH is a well diversified Engineering Group manufacturing products for the World market.

Achievements: • First indigenous 3 Dimensional Axis CMM of India was designed and made by Jash. • Granite Vibration Isolation Work Table size 2.5mx 1m supplied to Raja Ramanna Center for Advanced Technology Indore (Dept. of Atomic Energy, Govt. of India). • Cast Iron Surface Tables of overall

IN FOCUS

•

size 7000 x 4000mm (4sets) supplied to ITP Limited, UK for their Layout and Marking Machine installed at car Styling and Designing Studio of Aston Martin, U.K.. Cast Iron T-slotted Bed Plate overall size 6m x 4m supplied to Cyclect Electrical Pte Ltd., Singapore for ICES, Singapore Project ‘A’ Star (2013) Magnaflux (Machine) for Magnetic Field Mapping supplied to Raja Ramanna Center for Advanced Technology (1997) Optics Table with 7 Linear Stages supplied to Raja Ramanna Center for Advanced Technology (2016) Surface table overall area (23m x 2.6m) supplied to General Motors, Shanghai Project (2012) T-Slotted Bed Plates (6mx6m, 1 set & 8mx6m, 2set) supplied to Airbus Defense and Space, Stevenage, U.K.. (2016) for satellite Assembly & Testing. And many more...

Q. Please brief us about company’s infrastructure & what are the technology alliances that has been made in order to out-front the competition? Our company has fully fledged design office with 3D parametric modeling software for design of products, simulation of castings and casting design, pattern shop, ferrous foundry, material testing laboratory, stress relieving facility, general purpose & precision machining, assembly & testing and inspection facilities, all in-house. That is why JASH products are reliable and dependable for quality and delivery schedule. We have strategic alliances with M/s. ITP Limited, UK (since 1990) for assembly, marketing and after sales support of their Horizontal Arm Machine machines/ systems for Inspection and Clay Milling/ Styling Studio applications in India. We are regularly supplying our Cast Iron surface Table to ITP for their Measuring Machines.

Q. What are the products manufactured by your company? 50

MACHINE TOOLS WORLD DECEMBER 2017

We are into manufacturing of High Precision Inspection & Work Holding Equipments and 3D CMM’s in India. Creating straight, flat, square, parallel and angular surfaces, whether small or large, having sub micron accuracy is forte of Jash from last 60 years which are being used by companies such as Airbus, Aston Martin, RRCAT and many other all over the world.

Q. What is your marketing strategy for India? Indian market holds lot of potential if one heads in right direction. Jash believes in providing the solution to its customers, we don’t run for sale and this mantra always made us stand out in this fluctuating Indian market. We simply reach directly to the end user although we have representative at strategic locations, as well.

Q. Product innovation through R&D is vital to be a leader in the competition, as per your opinion, how does R&D plays the role of catalyst in the success process? In Jash R&D is part of our daily work schedule as consistent improvement, adaptation and development in our products and fulfilling the customized requirement is only possible if we keep ourselves updated at regular intervals regarding technological developments and advancements. We strongly believe that quality is not an act, it is a habit. At Jash, QC, R&D and Engineering are three important elements around which our products are made. We have dedicated teams working on all three aspects at our workplace.

Q. Quality standards are benchmarked by the product performance; please brief us how do you maintain the quality norms from solution development to implementation? For Jash, Quality is the core factor. We always emphasize on providing quality products to the customers. Jash never compromised with its quality by reducing the price and today we can proudly say that there are no complaints for Jash

products in last 7 decades. Quality is embedded in blood of our team by virtue of working with quality conscious spirit.

Q. According to you, what are the factors affecting your business? From our experience we feel that Indian market was mostly price driven in the past and quality often took the back seat, with buyer often making final decisions motivated by the size of his/her pocket rather than going for a superlative product. Even now, the Indian buyer is more pricedriven in comparison to their European or American counterparts, not understanding the concept of a quality product and cost involved in its manufacturing. However, having said that, the market trends have been shifting consistently over last decade towards being quality centered with Jash having a satisfied quality-driven clientele pool.

Q. How do you perceive the future of the industry? The future is generally moving towards the bright side only. Our Product are manufactured with the point of precision and whenever you require precision solution, you will see us playing the lead role. Our engineered products serve as the base for all industries, be it Power, Energy, Pharma, Defense, Automobiles, etc. In totality wherever any kind of engineering is involved, our products will play an integral role.

Q. What is your vision for your company for near future? We at Jash strictly adhere to and follow our mission-cum-vision statement‘TO BE A WORLD LEADER IN PROVIDING BEST-IN-CLASS METROLOGY SOLUTIONS & PRODUCTS AND SERVICES TO THE ENGINEERING INDUSTRY.’ Therefore, we envision a 100% embodiment of above and become a world leader in the industry segment.

IN FOCUS

Shaping the next level of manufacturing With the future of manufacturing slated to go completely digital to gain flexibility and increase efficiency, EOS has been taking rapid strides in introducing the concept of Additive Manufacturing in various production sectors. In this interview with Huned Contractor, the company’s country manager for India, Anand Prakasam, elaborates about what EOS has to offer efficiency:

Q. What is the status of EOS’ presence in India?

Anand Prakasam, Country Manager-India, EOS

t the FormNext exhibition held from November 14-17 at Germany, one of the companies that made a splash was EOS, a leading technology supplier in the field of industrial 3D printing of metals and polymers. It showcased its latest and growing portfolio of additive manufacturing (AM) systems and software solutions. By providing 3D printing solutions for a highly flexible and efficient production on an industrial scale, EOS is shaping the future of manufacturing and launched the EOS P 500, its newest polymer system. “Customers benefit from maximum productivity, automation readiness and the ability to process polymer materials which require operating temperatures of up to 300 degrees Celsius. As such, the system is addressing the requirements of those customers wanting to introduce an industry scale mass production of high-quality polymer parts based on additive manufacturing,” a press note states. In this interview, Anand Prakasam, Country Manager, EOS India, elaborates about how the company will help Indian manufacturing companies to scale up their production and usher in production

MACHINE TOOLS WORLD DECEMBER 2017

EOS is the world’s leading technology supplier in the field of industrial 3D printing of metals and polymers. Formed in 1989, the independent company is a pioneer and innovator for comprehensive solutions in additive manufacturing. We enable our customers to produce high-quality products using our industrial 3D printing technologies. Established in Germany, EOS entered the Indian market in 1998 and is at the cusp of the manufacturing revolution in India. In India, we are headquartered in Chennai with representative offices in Bangalore and Delhi. EOS owns an 80% market share in India and has a presence in sectors such as aerospace, automotive, manufacturing, tooling, healthcare including dental, amongst others. One of our key differentiators is that we offer customised solutions and not just systems and master the three key factors that impact the quality of a part: systems, materials and the build process, including customized process parameters. What we believe differentiates us in the Indian market is our consulting program called Additive Minds, which we started a year ago. What we have learnt from over 300 consulting projects in the last few years is that companies deciding to implement industrial 3D printing in their organisation normally go through four typical stages and very often still need assistance in this process – which EOS can offer at all stages besides machine trainings. These stages are – finding the application, developing the application, ramping up the application and certifying and scaling the production. Implementing the technology will induce a disruptive transformation not only in the markets

these companies are serving but in their own organisation as well. EOS provides consultancy to these companies on their way to a successful implementation of the AM process. Through this initiative, we not only provide the technology, but also assist in the integration of the technology into a customer’s shop floor so that they can deliver better experience to their end customers.

Q. To what extent have Indian manufacturers adopted Additive Manufacturing systems? Additive Manufacturing is still at a nascent stage in India as far as manufacturing is concerned. However, now more and more industries are opening up to the technology. In most cases, the general assumption is that AM is a very expensive process. This lack of awareness makes OEMs hesitant about incorporating AM solutions to make their entire production process more cost-efficient and thereby gain a price advantage. Also, many large-sized manufacturers do not have control over the original designs and are mostly focused on making and assembling components for the final products. Therefore, it is difficult for them to incorporate AM right from the design stage to take the benefit as AM enables a design-driven manufacturing. So true change and consequent added value already needs to start during the design process. However, that being said, we are seeing an increased awareness about the technology and more companies are open to shifting to serial manufacturing. For instance, in industries such as aerospace and automotive the adoption is quite high. In fact we have recently worked for the first ever 3D manufactured component for ISRO, as part of our partnership with Wipro 3D. Additionally, we are seeing

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IN FOCUS sectors such as healthcare and lifestyle that are warming up to AM solutions. In my opinion, the sentiment is favourable and there are numerous opportunities that will unfold gradually.

Q. Can you provide a case study of how AM has been of benefit to a manufacturing company? Recently, EOS and Wipro collaborated to engineer a component for ISRO known as the North-West Feed Cluster 2x2 – also India’s first ever additively manufactured component to go into space. This component was a part of GSAT19 communications satellite and was launched in June 2017. The satellite carried with itself technologies related to feed realisation, 3D printed components along with hybrid CFRP technology on ISRO safelights. Using Additive Manufacturing technology ensured that the product was redesigned to become lightweight and more customised for the purpose of this journey out of space. The material used for manufacturing this component was aluminum. The component cleared various tests and validations, including assembly vibration test, climatic test and RF tests before it took flight. This is a significant feat in EOS’s journey and has helped establish us as an industry leader whose path-breaking technology was utilised for this satellite.

Q. What is your prediction about the market size for AM in India? We feel that the way forward is to develop the ‘smart factories’ using AM where we visualize the future of manufacturing to go completely digital to gain flexibility and increase efficiency. Since there are not many published data on market size we can refer to the 6W research report, where India’s 3D printer market is projected to cross USD 79 million by 2021, representing a large potential market for this technology, making larger companies also realise the potential in such a market. Once

MACHINE TOOLS WORLD DECEMBER 2017

implemented, this technology will not only aid in the production of spare parts but also in the production of newer models and we look forward to see how the industry advances. Talking for EOS, India is an aggressive market and we expect it to grow exponentially. Manufacturers are slowly realising the benefits of using cutting-edge technology like Additive Manufacturing and we are witnessing an increase of acceptance for the same. It is because of this reason that we are looking at a 30% year-on-year growth as a company. The three biggest sectors for us are automotive, aerospace and dental and we are very much in the growth trajectory of the Indian 3D printing market. We see the adoption growing predominately in tooling, automotive, medical and dental. We have the technology and we offer the skills and infrastructure to support Indian companies while they upgrade.

Q. What are the challenges that companies face in India to adopt AM systems? As I have mentioned before, even though companies are aware of the advantages of Additive Manufacturing, it is the lack of knowledge, and to a certain extent, skill, that is missing. It’s not about mass awareness, but targeted awareness creation and we can do this for every industry by organising seminars and other events to familiarize companies about our consulting services. Apart from that, if the government can support new initiatives such as ‘Design in India’, this will then give us an opportunity to create an optimized product from scratch and reduce the costing as such will help the AM market to grow fast. Any production technology that enters the market is majorly introduced to supplement and also overlap with conventional or existing methods. This new production method will provide value to the companies on the overall life cycle of the product. EOS has a vision that for the factory of the future through its end-toend additive manufacturing solutions and services, including the Additive Minds consultancy group. Industries such as medical, aerospace, dental and tooling will

require solutions to enable faster, cheaper, high quality and large-scale part production in the future. We understand the challenges of our customers with regards to Industry 4.0 and the need for increased productivity.

Q. What new technologies is the company exploring for implementation in the near future? EOS recently launched the EOS P500, its newest polymer system during FormNext 2017. This particular system addresses the requirements of those customers wanting to introduce an industry scale mass production of high quality polymer parts based on additive manufacturing. Customers benefit from maximum productivity, automation readiness and the ability to process polymer materials which require operating temperatures of up to 300 degrees Celsius.

Q. What has been the success story of EOS worldwide? EOS remains on course for continued growth. Today, EOS has customers in 65 countries. It increased its turnover by 10% over the previous fiscal year 2015-16 to an expected 345 million Euros. Over this period, EOS delivered around 450 systems worldwide. As such the worldwide installed base of EOS systems rose to around 3,000, representing approximately 51% polymer and 49% metal technology. As such, EOS also sees continuous increase of metal applications, particularly for serial applications, which is also reflected in the 94 EOS M 4-series metal systems installed to date. The business success is also reflected in continued growth facilities worldwide. In summer 2017, EOS moved production, training and parts of warehouse, quality, training and laboratories into an additional 9,000 sqm facility in Maisach near Krailling, Germany to ensure a continuous expansion of its production and training capacities. On a global level, the offices in both France and Singapore also grew.

COMPANY PROFILE

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COMPANY PROFILE

We give strategic advantages to our customers from diverse industries

ettinelli S.p.A, established in 1953, specializes in the development and manufacturing of precision motion control components and systems. In 1996 a separate division named CDS Cam Driven Systems was created for engineering solutions in automation and motion technology. CDS produces the widest range of mechanical Cam Driven Units, commonly known as rotary / indexing tables for precision motion control applications, requiring rotary or linear transfer, positioning and handling. The products range includes, cam indexing and servodriven tables, ring positioning drives, intermittent and oscillating drives with parallel or right angle configuration, rotary & linear part handlers, precision link transfer systems, and epicycloidal servo reducers.

Wide ranging products

The broa4d product spectrum covers IP parallel shaft indexers, IT roller dial indexing tables, TR roller dial indexing tables, HP roller dial indexing tables, IG/ IGA roller gear indexer, TL precision link conveyors, MHP/LHP part handlers, FT-HT open center ring tables and packages of rotary indexing tables. Bettinelli has a wide range of standard products. These are delivered in 3 weeks. When it comes to customized products, these are designed, manufactured and shipped in 6-8 weeks. The manufacturing takes place centrally in Italy. The regimen starts with design & engineering, CNC induction hardening, CNC milling, grinding, quality check and then assembly, painting and

Parallel Shaft Indexer 58

MACHINE TOOLS WORLD DECEMBER 2017

Rotary Indexing Tables, TR Series Rupesh Paparaju, Director, Bettinelli Automation Components, India

shipment. In order to ensure quality, all components are machined internally, including the cam hardening by a proprietary CNC controlled induction hardening equipment. For better finish, the products are also subjected to chemical nickel plating, blasting and painting. The manufacturing process is constantly controlled to conform to international standards. The company’s quality systems are ISO-90012008 certified. Strategic advantages

Over the years, Bettinelli Group and CDS Indexers have become synonymous with high quality automation products and technologies. “Our design and manufacturing systems have furnished competitive and strategic advantages to numerous industries in pharmaceutical, automobile, manufacturing, packaging and a plethora of other sectors. And for automation functions, our solutions are invariably preferred by companies,” says Rupesh Paparaju, Director, Bettinelli Automation Components, India. The Indian subsidiary, headquartered in Pune, serves its customers in India by providing installation, commissioning, and after-sales support. It also offers technical consultation. In the pharmaceutical industry cam driven systems are used in filling, blister pack, tablet making and packaging machines. In automobile industry, they are used in pallet transfer tables, assembly

machines, painting applications and test rigs, just to mention a few. In machining industry, they are used with advantage in deburring, lapping and pressing machines and in transfer lines. In SPM & robotics, they find applications in transfer lines, station loading, sequential operations and so on. Inwelding, these indexers are inevitable in positioners, synchronous welding, robotic welding and component transfer. Packaging too is a major application area. Cam systems are used in box filling machines, wrapping machines, cartoning and capping machines. Indexers are also used in casting, printing and cosmetics industries. Closer to the customer

The Indian arm of Bettinelli, based in Pune, Bettinelli Automation Components Pvt. Ltd., is highly customer-centric. “Our presence in India means quite something in fostering a symbiotic relationship with our customers. It helps us to match our world-class products with our eminent customer support,” underlines Paparaju, Director, who has built up a team to improve Bettinelli’s response time. “CDS are high-tech products which lend themselves to enhance the operational efficiency and productivity at the customer’s end. We stay close to the customer to understand his needs and offer customized solutions within the shortest possible time to ensure peak uptime of his equipment and operations”, he adds. - P.K. Balasubbramaniian

COMPANY PROFILE

Shavo Technologies offers high-tech tailor made solutions

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

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

High pressure regulators

MACHINE TOOLS WORLD DECEMBER 2017

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

COMPANY PROFILE

High quality instrumentation valves

Applied gas delivery systems

generators and regenerative blowers. “As a matter of fact, our journey of working with high technology industries started with Gast which today remains one of the world leaders in air motors

and fractional horse pumps,” reveals Mr. Shah. Meech’s forte is industrial electrostatics. With a standing of over 40 years, Meech has developed a wide range of products like ionizing bars,

Electrostatics for effective static neutralization

MACHINE TOOLS WORLD DECEMBER 2017

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

CASE STUDY

Performance, Precision, Reliability and Affordability: The HAAS VF-I series delivers it all and more for SAHNEY KIRKWOOD !!!

Mr Amit Patil, G.M. Operations, Sahney Kirkwood Pvt. Ltd

Sahney Kirkwood, manufacturer of electrical insulation products, located in Nasik, are the proud owners of Haas VF2-I and VF-4-I vertical machining centres with India Value Package. Many optional advanced features available in VF-2 and VF-4 come standard with VF-2-I and VF4-I. It was a natural choice. About the Company Sahney Kirkwood an export oriented unit started in Nasik, in 1984. They manufacture mica-based Electrical insulators, for the traction industry. Their main customers are locomotive manufacturers and repair shops, spread across the US and Europe. Sahney Kirkwood, Sahney Commutators, and Isovolta (India) are part of the Sahney group’s engineering business. Headquartered in Bangalore, India, the company’s customers are spread in 5 continents and in over 25 countries. Isovolta (India) is a JV with Isovolta AG of Austria, a leading manufacturer of electrical insulation materials, technical laminates, and composites, having manufacturing facilities in 9 countries. Sahney Kirkwood started as a Mica electrical insulation producer. It has

MACHINE TOOLS WORLD DECEMBER 2017

machines like mica laying machines, pressing facilities, wide web grinders, shearing machines, cutting machines, forming, and moulding machines. Later, they ventured into pre-preging and started manufacturing industrial laminates for electrical Insulation. They machine composite materials and have a full-fledged CNC machine shop, along with some conventional machines. Currently, they are machining glass reinforced epoxy laminates, polyester based laminates, and silicon-based laminates. Initiating the Journey with Haas Mr Amit Patil, G.M. Operations, Sahney Kirkwood Pvt. Ltd., said “ Several years ago, we were in the market to buy a CNC machine and did a comparative analysis of Indian, Taiwanese, Chinese, American, and European machines. When buying a CNC machine, our only constraint was size, as the raw material we use is in the shape of flat boards, which is loaded on to the machine. It was essential for us to have bigger table sizes. The ease of operating the machine was the next crucial factor for us while buying a CNC machine as we did not have expertise in CNC Machining technology”. They received very good feedback from their vendors about the quality of Haas machinery and their after-sales service. Also with Haas, they find it easy,

as Haas has its own control & they have to coordinate with the same team for any queries. In 2012, they bought a Haas VF-3 Vertical Machining Center machine for manufacturing bigger parts & a Haas VF2 to manufacture smaller components. The company now has 7 CNC machines and 1 CNC Router. All their CNC machines are from HAAS, which includes models like VF-2, VF-3, VF-4, and VF-5. Selecting VF-2-I and VF-4-I In 2017, Sahney was in the market for 2 new Vertical Machining Centers. Before buying any machine, the company always compares machines from different manufacturers. After thorough analysis, they narrowed down on the newly introduced Haas VF-2-I and VF-4-I models, as they were already familiar with the machine and the company. The VF-2-I and VF-4-I are essentially the standard VF-2 and VF-4 configured with an India Value Option Package: an inline high torque 10,000 rpm 30 HP spindle, 24+1 Side mount tool changer, High Speed Machining Package and Ethernet option. The powerful HAAS spindle and high-speed machining options helped Sahney reduce the existing cycle times and improve accuracies. Mr Patil further informed, “I have visited many manufacturing facilities in India and found that the 1.5 million sq. feet manufacturing facility of Haas Automation, USA, is a class apart. I spoke with the technical experts at HAAS and

CASE STUDY also walked through the VF-2 and VF-4 production line (on which all models VF2, VF-4, VF-2-I, VF-4-I are manufactured and assembled). Since the production line at Haas is automated and adopts Flexible Manufacturing Systems (FMS), the stringent quality standards for every machine is maintained throughout the manufacturing process,”. The purchase of VF-2-I and VF-4-I as with their earlier CNC machines were informed selections with the focus on quality, reliability and performance. After-Sales Service by Haas The company found the hands-on training provided by Haas to be excellent

and the employees of Sahney Kirkwood were able to operate the machines with ease. “Not only were the machines delivered on time, as promised by Haas, but they also provided comprehensive training to our staff, at our factory and at their training centre. This helped to make the machines operational the very next

day after they were purchased”, said, Mr. Patil. The support backup and service from Phillips Machine Tools India who have a local office in Nasik, was found to be excellent. The service team was cooperative and reliable. Haas has also trained maintenance engineers at Sahney Kirkwood for troubleshooting, and they are able to rectify the errors at the initial stage, without any assistance. For additional information on how Phillips can help improve your productivity, contact: Mr. Nikhil Modi – support.india@phillipscorp.com

First clinical study patient has novel drug delivery system implanted for Parkinson’s trial The first patient in a new clinical study was implanted with a novel drug delivery system, developed by Renishaw, The procedure took place at Karolinska University Hospital in Stockholm, Sweden. The implantation marks the beginning of a joint clinical study between Renishaw and Herantis Pharma. This phase I - II clinical study will investigate the treatment of Parkinson’s disease using Cerebral Dopamine Neurotrophic Factor (CDNF) delivered with Renishaw’s system. Parkinson’s disease is a common debilitating neurodegenerative disease affecting seven million people worldwide. It causes tremors, muscle stiffness and slowness of movement and current therapies treat these symptoms alone. One challenge in developing treatments for this disease is the blood brain barrier, which prevents large molecules from accessing the brain tissue. “Renishaw’s drug delivery system could be revolutionary in improving treatment options for Parkinson’s disease,” explained Paul Skinner, General Manager for Renishaw’s Neurological Products Division. “The system enables the delivery of large drug molecules,

MACHINE TOOLS WORLD DECEMBER 2017

such as CDNF, directly into the brain circumventing the blood brain barrier.” “The drug delivery system consists of four catheters which, during the procedure, are accurately implanted into the patient’s putamen, one of the key regions of the brain affected by Parkinson’s disease,” continued Skinner. “The catheters converge in a port mounted to the skull behind the ear, through which drugs will be administered on a monthly basis as part of the study. The system can also be used with other new drug candidates that need to be delivered to precise areas of

the brain, which could be crucial in the development of treatments for this and other debilitating diseases.” The study will involve 18 volunteers across three sites two in Sweden and one in Finland. It will evaluate the safety and tolerability of the drug delivery system and CDNF, a large molecule that could slow the progression of Parkinson’s disease, improving the quality of life for patients and prolong their lives. For six months, each volunteer will receive monthly infusions of CDNF, or artificial CerebroSpinal Fluid (aCSF) for those receiving the placebo, via the drug delivery system. The clinical study has received funding from Horizon 2020, the European Union’s research and innovation programme. Following this study, it is hoped that the drug delivery system will be used in clinical trials for the treatment of other neurological conditions, including brain tumours and Huntington’s disease.

For more information Web: www.renishaw.com/neuro

The new control system PNOZmulti 2 with up to 80% less energy consumption …

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TECH TRENDS

Safety upgradation: Metal processing plant benefits from flexible and modular safety solution from Pilz are transported to the transverse shearing machine via a transverse conveyor. Once an operator has placed the parts in position, motor-driven blades cut the plates lengthwise to the customer’s specifications. The transverse shearing machine also cuts strips for ongoing processing as welding ends for pipe production, as well as test samples, which arrive at the test centre for quality assurance purposes. Finally, via the subsequent roller conveyors, the plates arrive for cold geometric measurement, during which the surface is inspected along with the lengths cut by the transverse shearing machine.

When retrofitting its heavy plate processing plant, Salzgitter Mannesmann Grobblech GmbH opted for an automation solution from Pilz, the complete supplier for safe automation.

large-scale plant for processing heavy plates at Salzgitter Mannesmann Grobblech GmbH was due a retrofit, which was also to include modernisation of the safety architecture. The configurable control system PNOZmulti was to be used in combination with PDP67 modules. The solution from Pilz, the complete suppler for safe automation, proved to be both simple and efficient. Now the plant also meets the requirements of EN ISO 13849 up to Performance Level (PL) d. Steel girders and gantry cranes are spread throughout the production hall and there’s a smell of metal in the air. The hall is the size of several football pitches and when the giant forming and metal cutting machines are set in motion, it’s noisy. Salzgitter Mannesmann Grobblech GmbH in Mühlheim an der Ruhr is part of Salzgitter AG and manufactures

MACHINE TOOLS WORLD DECEMBER 2017

intermediary products, from which large pipes can be produced, to be used later as pipelines for example. How plates become pipes The “Pipes” Division comprises the following areas: plate rolling mill, pipe bending plant, test centre and energy supply. In the pipe bending plant, seamless, welded steel pipes are bent with precision and accuracy using inductive heating. This places the most stringent demands on material, manufacturing and range of sizes. The requirement is for precision prefabricated heavy plates, which may be up to 26 metres long, around 5 metres wide and between 8 and 50 millimetres thick. Coming from the rolling mill and the subsequent cooling beds, the heavy plates reach the double side-trimming shears via a roller table. The shears trim the edges of the plates to the required size, then they

Retrofit requires a new safety concept The heavy plate cutting machine covers an area of ten by six metres and is around five metres in height. When the time came for the plant to undergo fundamental modernisation, the agenda also included the integration of a modern safety concept. A re-assessment and evaluation of the risks was required in order to satisfy the normative requirements of the new Machinery Directive. Manual intervention in the plant for inspection, setup and maintenance purposes is essential; that includes access to the safety zone, so reliable safety solutions were required at several points in order to protect man and machine. However, these were not to restrict the plant’s productivity. Until then, safety had essentially been based on single-channel emergency stop circuits and traditional contactor technology. The customer’s future requirement was for safety to act completely independently of the control system. The range of tasks incorporated the following points: On the fully enclosed transverse conveyor plant, a total of

TECH TRENDS seven gates were to be protected against unauthorised or accidental opening; the distributed emergency stop pushbuttons were also to be monitored. The plant must be brought to a safe stop if any gate is opened without authorisation. The plate lifting equipment and the wagons for crosswise transportation of the plates were to be manoeuvrable at safely reduced speed by an enabling switch, via a mobile panel with multiple control points distributed within the safety zone for setup and maintenance mode. What’s more, the requirement manual specified that reliable management of the safety-related signal exchange with upstream and downstream plant sections was to be guaranteed. The requirements for the area with the transverse shearing machine were fairly similar: In addition to safe monitoring of 12 safety gates in the periphery and implementation of a safe plant stop, it was also to be possible to carry out setup and maintenance work in enable mode. And the situation was similar for the plant section involving cold geometric measurement, where the precision of the cutting dimensions is examined. PNOZmulti as an efficient, easily adaptable safety solution The configurable control system PNOZmulti is made by Pilz, the complete

Due to the long distances within the hall, PDP67 modules record the safe signals from the sensors directly, thereby reducing the cabling work.

MACHINE TOOLS WORLD DECEMBER 2017

Fig. 3: F_A_Salzgitter_D41_7613_control_cabinet_PNOZ_cold1_2014_02_297mm; Control cabinet with configurable control system PNOZmulti (Pilz GmbH & Co. KG)

As a central safety component, the configurable control system PNOZmulti from Pilz monitors all the safety-related signals from the emergency stop buttons, safety gates systems and enabling switches.The configurable control system PNOZmulti from Pilz merges safety and automation tasks and, thanks to expansion modules, can be adapted flexibly to changed requirements.

supplier for safe automation. Here are some of the tasks that it reliably resolves: As a centralised safety manager, PNOZmulti works in conjunction with the PDP67 modules in the periphery to monitor all safety-related signals from the emergency stop pushbuttons, safety gate systems and enabling switches. In an emergency, the configurable control system initiates safetyrelated actions. As there are long distances to the various gates and emergency stop pushbuttons, the PDP67 modules record the safe signals from the sensors directly on the spot, thus reducing the amount of cabling involved. The failsafe PNOZmulti base unit has 20 digital inputs, 4 digital semiconductor outputs and 2 relay outputs. It is flexible and simple to expand with up to 8 I/O modules. PNOZmulti records all the necessary sensors and switches the safe outputs directly. There’s no need for hardware that’s susceptible to wear. Free configurability using the software tool PNOZmulti Configurator and intuitive parameter setting make the intelligent safety manager simple to use. PNOZmulti stands for “Configuration rather than wiring”, because the configurable control system replaces a large number of relays and wiring connections.

Plant made safer without limiting productivity A total of seven PNOZmulti base units and 13 PDP67 modules in the periphery guarantee safety on the heavy plate processing plant. “The plant now meets Performance Level (PL) d. Thanks to the Profibus interface on PNOZmulti, we can now also download data to the visualisation device for display. What’s more, the data can be read into a PDA system, which makes troubleshooting and fault tracking a great deal easier”, says Heiko Nickel, electrical project engineer at Salzgitter Mannesmann Grobblech GmbH, describing the benefits in a nutshell. While cooperating on the project Pilz was also able to prove itself not only as a component and system supplier but also as a competent advisor and service provider in matters relating to risk estimation and technical feasibility – from the project phase right through to technical support. “I can say with some certainty that we will work with Pilz on other retrofit projects in future”, says Heiko Nickel, summarising.

For more information http://www.pilz.in/

TECH TRENDS

â&#x20AC;Śand the door remains closed: Pilz introduces a new safety gate system PSENmlock

ilz is adding PSENmlock to its range of safety gate systems. PSENmlock offers safety gate monitoring and safe guard locking upto the highest category PL e in one device. The slimline yet robust design makes PSENmlock both flexible to use and easy to install. PSENmlock comes with the flexibly mounted actuator which ensures high tolerance compensation and unrestricted functionality even with sagging gates and vibrating machines. With LEDs on three sides, diagnostic data is easily identifiable in many installation positions. PSENmlock comes with a holding force of 7500 N and the integrated latching force of 30 N, the safety gate system prevents the guard from opening inadvertently.

MACHINE TOOLS WORLD DECEMBER 2017

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TECH TRENDS

CRASH-FREE LINEAR MOTION One of the greatest threats to the long life of a linear motion system usually occurs on its very first stroke. Rollon’s Compact Rail features a robust design that withstands all but the most severe crashes.

ow do you know when a linear bearing has reached its end of travel? When the carriage hits the wall. At least, that is how the old engineering joke goes. But in reality, crashes are no laughing matter. Also known euphemistically as “hard stops,” crashes occur when an out-of-control pillow block slams into the bearing’s end stop or some other intermediate target. They most often occur when a linear axis is started up for the first time. Even a single crash on that very first stroke can ruin a bearing, triggering expensive repair or replacement costs. The reason why bearings crash on start up mostly comes down to human factors. A control engineer can do a great job calculating the perfect motion profile for a given application, only to overlook

MACHINE TOOLS WORLD DECEMBER 2017

some installation details during start up. Small errors like entering an incorrect motion parameter or failing to connect a limit switch are common and can be catastrophic for the linear bearing. Fortunately, it is not that difficult to minimize crashes and give your bearings a longer lease on life without spending a lot of money. Here’s how: GET ON THE SAME PAGE All too often there is little communication between the engineer who designs a mechanical system and the engineer who ultimately runs it. This lack of communication can make crashes more likely because it increases the likelihood that the linear axis may be run with motion profile it was not designed to

handle. For example, a linear axis may have adequate space for over-travel based on the design inputs—loads, speeds, accelerations and inertia mismatch. Yet if it runs under different conditions, that over-travel space can shrink or disappear. To avoid this kind of problem, it is important for both design and control engineers to have a sense of whether the design values leave enough flexibility to accommodate changes in real-world operating parameters. If not, a less aggressive motion profile may be the only way to avoid crashes. AVOID OVER-ENGINEERING Other than busted bearings, one of the negative consequences of crashes is over-engineering. Instead of trying to avoid crashes, the engineer will accept

TECH TRENDS them as inevitable and try to design systems that will survive them. To do so, engineers may end up specifying bumpers or gas shocks. As popular as they are, bumpers and other shock absorbers are a bit like training wheels on a bike. Once someone knows how to ride, off they go. Likewise, linear motion systems that are properly designed and controlled can run safely without the expense of additional protection. Another crash protection strategy involves beefing up linear motion components. Engineers will sometimes size the bearings to survive crashes rather than to meet the application’s load, speed and acceleration requirements. This strategy may not add much cost on a single axis, but upsizing the linear motion components on an entire machine can get expensive. All the more so if all those upsized bearings trigger a shift to larger motors, gearboxes and framing elements. When upsized bearings lead to this kind of pervasive over-engineering, it would not be unusual to see 30 percent increase

Crashes most commonly occur on start-up due to an incorrect motion profile.

MACHINE TOOLS WORLD DECEMBER 2017

The end caps on Rollon’s Compact Rail (top) are cosmetic and, even if broken in a crash, will not interfere with the operation of the slider. End caps on recirculating ball linear bearings (bottom) house the crucial rolling elements and are a potential point of failure if shattered in a crash.

in total machine cost. FAVOR CRASH-WORTHY BEARING DESIGNS While most crashes do occur on start up, it is true that they occasionally occur well after a machine has been commissioned. Sometimes a loss of power can trigger a crash, or someone might inadvertently change a control parameter. And truth be told, some machines are not run all that carefully. For these reasons, it can make sense for engineers to design with some crash-worthiness in mind. But what is the best way to do that? Engineers can choose to go with shock absorbers and over-engineered components, accepting those costs as the price of crash protection. Or they can favor linear bearings that inherently have crash-worthy construction. Not all bearings are created equal when it comes to surviving a crash. Recirculating ball systems whose pillow blocks have plastic end caps are notoriously susceptible to crash damage—because the plastic tends to shatter. Even a single crash with this type of pillow block, and you may find its ball bearings all over the floor. Bearings based on larger roller elements lack this particular Achilles heel. Their

ball bearings and their raceway are contained within the roller element, not within a plastic cap. Rollon’s Compact Rail is a prime example of this type of bearing, and it will run just fine with a shattered end cap. And if it ever does experience any crash damage, its interchangeable rollers and pillow blocks allow it to be easily repaired without changing the rails. Given the choice between crash avoidance and crash protection, engineers can save the most money by avoiding crashes in the first place. And it is true that carefully designed motion systems with room for unexpected overtravel are unlikely to crash. Yet in the real world, it pays to be prepared for the occasional hard stop. With the availability of crash resistant roller bearings, crash protection does not necessarily require the expense of adding shock absorbers and over-sized components.

For more information, Rollon India Pvt. Ltd. Web: www.rollonindia.in

TECH TRENDS

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

MACHINE TOOLS WORLD DECEMBER 2017

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

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

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

Fig. 1: TANDEM MIG

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

MACHINE TOOLS WORLD DECEMBER 2017

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

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

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

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

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

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TECH TRENDS

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

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

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

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

MACHINE TOOLS WORLD DECEMBER 2017

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

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

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

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TECH TRENDS

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

MACHINE TOOLS WORLD DECEMBER 2017

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

TECH TRENDS

Higher Precision for Machining Centers in Automated Large-Batch Production

utomobile customers demand a variety of vehicle types and engines in accordance with highly diverse framework conditions, asking about differing vehicle sizes, motor types or engine power within the individual markets, depending on fuel costs, emission standards and tax measures. For automobile manufacturers this hampers any estimation of quantity progressions or capacity planning and the design of production lines. To meet customer needs, automobile manufacturers offer engines with the same number of cylinders but in differing performance classes, which also leads to an increase in variant diversity. Ever shorter vehicle product life cycles in combination with volatile markets therefore lead to changed production challenges for automobile manufacturers [1]. To meet such challenges, the aspect of flexibility is added to the classic production parameters such as quality, time and costs. For production lines for the machining of vehicle powertrain components (engine, transmission and axle components), this means departing from classic transfer lines with fixed timing and high productivity, and adopting lines with linked machining centers and higher levels of flexibility. In addition to the challenge of responding to fluctuations in demand in automotive sales markets, the future will also bring increasing legislative and end-user requirements regarding the emission of pollutants and fuel consumption of vehicles. One approach to dealing with such a situation consists of reducing friction in the powertrain, which in most cases would lead to increased quality requirements for

MACHINE TOOLS WORLD DECEMBER 2017

Figure 1: Cylinder head machining in large-batch production (photo: MAG IAS GmbH)

the components to be produced. The interlinked machining centers used in production lines also have the task of implementing the demands of manufacturers in process-safe ways with large vehicle quantities (see Figure 1). The use of linear encoders in Closed Loop control in the feed axes of the machining centers contributes to meeting such diverse requirements. From transfer lines to linked machining centers Greater flexibility for variants, machines and capacity Transfer lines lack adaptability Because individual stations within a transfer line are designed for machining specific workpieces, these fixed, chained lines cannot be simply expanded by adding additional stations. To make available the maximum planned capacity requirement, it is therefore necessary to implement the main part of production line investment at the start of production (SOP). Because quantities slowly increase (line ramp-up) at the beginning of production or fall away (line ramp-down) at the end of the product lifespan, excess

production capacity is the result (Figure 2) , and as a result the installed capacity is not fully exploited. Additional challenges come about if capaci-ty requirements during regular operation in the transfer line are larger than originally planned, and workpieces required by the market can no longer be produced with the installed line capacity. Duplicating a transfer line to absorb such quantity peaks, however, would lead to significant over-capacity. Flexibility through linked machining centers Production lines with smaller capacity ranges can be installed by using linked machining centers, enabling a wider spectrum of production tasks and therefore higher production flexibility. Adaptation to actual quantity needs during line ramp-up can then be achieved by integrating additional machining centers into the existing production line at free stations or by duplicating the complete line. This method of approximating available capacity to capacity needs

TECH TRENDS have an advantageous chip fall, whereby less cooling lubricant or even minimum quantities of lubricant (MQL) are used to wash chips. Such machines can also be variably automated via easy front or top loading for workpiece supply, enabling use of the same machine model for various production lines even with different loading systems. Double-spindle machines, with only slightly larger support base areas, are sometimes used due to their higher productivity (see Figure 1).

Figure 2: Quantity flexibility—capacity availability vs. capacity needs [4]

is aimed at expanding the production system with as much cost-efficiency as possible [2]. As a consequence, the largebatch production of vehicle powertrain components is now distancing itself from transfer lines and is increasingly adopting machining centers or transfer centers [3]. The increased flexibility of linked machining centers is directly related to the require-ment for highly rapid and economic re-sponses to fluctuations in demand. As an example, one demand is that differing vari-ants of a workpiece should be machined on the same production line without need-ing to adapt the setup (variant flexibility). Another approach is using additional machines to simply expand production lines. This could be called reuse flexibility, as the use of standard machines and their standardized linking enables simplified integration and reuse of such machines in other production lines. If line capacity is seen with respect to the complete lifespan of a manufactured workpiece, the fluctuations in demand outlined above also lead to differences between capacity needs and capacity availability in the production line. While with transfer lines only comparatively large jumps in production capacity can be achieved, production lines with linked machining centers enable capacity to be increased in smaller steps at production ramp-up. Such production lines can also

MACHINE TOOLS WORLD DECEMBER 2017

be decommissioned again thanks to their high flexibility at production rampdown [4]. Figure 2 shows a step-by-step investment during the ramp-up phase of a workpiece to be produced, and the reduction in the ramp-down phase (quantity flexibility). Figure 3 shows an example of a production line layout for the mechanical machining of a powertrain component. The machining centers are illustrated linked by gantry load-ers and grouped into individual machining operations. A machining operation there-fore consists of several machining centers operated in parallel with the same process-ing content. Advantages of horizontal machining centers Horizontal machining centers are usually used for production purposes, and they

Features of large-batch automotive production In summary, the following characteristics for machining cubic workpieces in largebatch automotive production can be identified as follows: • Automated production with linked horizontal machining centers • One machine operator supervises eight to fifteen machines • A machining operation usually consists of several identically built machining centers operating in parallel with identical processing content • A workpiece is machined sequentially across several machining operations • A single workpiece is produced with several machining centers, meaning that several centers are responsible for tolerance conformity of the workpiece The last point in particular makes clear that the produced tolerances of a workpiece depend on the individual machines or sub-processes of the entire production sys-tem. In contrast to die and

Figure 3: Example of a production line for large-batch manufacturing (photo: MAG IAS GmbH)

TECH TRENDS for a cylinder head. Milling is relatively low compared to drilling or similar machining, and this is understandable because the primary geometry of the workpiece has already been cast, apart from a few areas. Specified holes in Cubic powertrain components Figure 5: HEIDENHAIN linear encoder in a castings, however, are Machining process and tolerances horizontal machining center manufacturable only at The powertrain of a vehicle can be sepaby the majority of drilling operations high cost or are not possible at all for rated into engine, transmission and axle required. In addition to diameter complex geometries. They have to be modules [1], and these modules in turn tolerances mainly influenced by the integrated into the me-chanical produc consist of further component groups such dimensions of the tool, such as reamers, tion line using drilling opera-tions, so as the valve train and its components. workpiece drawings also contain that their share of the machining process The cylinder head, crankcase and tolerance specifications for position, clearly predominates. transmission housing are examples of distance and hole depth. The various machining operations also classic cubic components in powertrain enable conclusions about the axis moveproduction. Linear axes determine dimensional ments required for machining. Because of Because of high quantities and related accuracy the drilling operations, most of the movecost-efficiency, workpieces are normally Complying with specified tolerances is ments consist of positioning the tool to manufactured to near net shape before determined among other factors by the the workpiece and a single-axis feed mechanical machining. This means that capability of the linear axes of a machine and re-traction motion. And because the the primary geometry of workpieces is tool to achieve precise positioning (Figure work-pieces usually have no free-formed already predetermined by the casting 5). Depending on the workpiece or set sur-faces, during milling operations or forging process, e.g. when forging of drawings, differing tolerance values the motion in the working plane (via connecting rods or crankshafts, and this is and tolerance divisions for production traverse in two linear axes) is sufficient in reflected in the machining operations for features may exist. addition to a positioning motion. cubic workpieces [5, 6]. Figure 6 shows the distribution of The predominant number of tolerance (position, distance and depth geometrical tolerances on the workpiece Focus on drilling tolerances) for a crankcase. The example to be pro-duced is therefore determined Figure 4 shows the machining operations shows that somewhat more than 30 % of the toler-ances analyzed are ≤ ±0.1 mm, and production features also exist on cylinder heads and transmission housings with tolerances of ≤ ±0.1 mm required by the designers. Examples are the position and depth tolerances of drill holes in the area of a cylinder head valve train as well as the bore axis distances of the main and neck bearing axes on a differential housing. Reliably complying with tight tolerance values To achieve the above-specified need for improved flexibility, producers make it their goal among other things to use standard machine tools in manufacturing, making it unnecessary to use additional specialized machines for individual Figure 4: Machining operations & their share of the manufacture of a cylinder head [5] production dimensions. This in turn mold production where workpieces are produced on one machine and supervised by a single ma-chine operator, with largebatch production dependencies exist between the individual machining steps in the process chain. This fact must be taken into account when de-signing the process as well as the produc-tion line.

MACHINE TOOLS WORLD DECEMBER 2017

TECH TRENDS Equation 1 specifies the variables Cm & Cp: Cm,Cp = T / (6 ∙ s) (equation 1) T = tolerance range in accordance with drawing dimensions s = standard deviation

Figure 6: Distribution of position, distance and depth tolerances for a crankcase

means that, even if tolerance values are ≤ ±0.1 mm, they must still be complied with in a safe and reliable way with the machining centers installed in the production lines. Cubic powertrain components Capability analyses supply specifications for machine capability and process capability The tolerance values specified previously seem large compared to requirements in the die and mold production sector. It must be considered, however, that values for automotive workpieces initially correspond to the designer’s drawing specifications. Automotive manufacturers carry out statistical capability analyses on the machining centers to make sure that the machine tools and implemented production processes are capable of meeting requisite drawing tolerances over a long period with a defined safety margin to the tolerance limits [7]. Capability tests for machine & process For acceptance testing of the machine tools, 50 workpieces, for example, are pro-duced on the system or single machines and the distribution of produced tolerances is then evaluated using statistical methods. Capability specifications or capability indi-ces are defined for the capability tests. To determine the machine capability the indices Cm or Cmk are defined, and for recording process capability

MACHINE TOOLS WORLD DECEMBER 2017

the indices Cp or Cpk. The indices Cmk and Cpk take into account a non-central distribution of measured tolerance values captured on several workpieces. Determining the machine capability pro-vides knowledge about the temporary scat-tering behavior with tolerances produced by a machine tool subjected to constraints that are as constant as possible (≡ short-term testing). The process capability aims to determine the long-term scattering be-havior of a machine under process con-straints (≡ long-term testing). See [7] for equations for calculating the indices based on the measured tolerance values of pro-duced workpieces, as well as for further information.

Manufacturers specify capability indices for the quality-relevant tolerances, and production machines supplied by the machine tool builder must at least achieve these during acceptance testing. With regard to the acceptance test, determining the indices leads to a further limitation of tolerance values specified in the workpiece drawing. Figure 7 demonstrates this with the example of a tolerance of T = ±0.1 mm under consideration of the machine capability specification Cm. Automotive manufacturers also specify feature classes for tolerance that are critical (Cm = 2.00), important (Cm = 1.67) or less important (Cm = 1.33) in relation to component functionality. Target: Minimum scattering For uniformly high workpiece quality and minimum scrap rates, the target is to achieve lowest levels of scattering with tolerances produced, and therefore low deviations from the standard. Equation 1 can therefore be construed as follows: Cm,measured = T / (6 ∙ s) ≤ Cm (equation 2)

Figure 7: Correlation between the drawing tolerance specification & capability index Cm

TECH TRENDS www.mtwmag.com

or 6 ∙ s ≤ T / Cm (equation 3) Cm,measured corresponds to the index derived from measuring a tolerated dimension on e.g. 50 workpieces produced during machine acceptance and the standard deviation calculated from them. Capability tests check compliance with maximum acceptable scattering Equation 2 demonstrates that the capability index resulting from the measurements becomes greater the lower the standard deviation is. The value (Cm,measured) from measurements on the workpieces must be greater or equal to the value of Cm specified by the manufacturer. If this is taken into account, specifying a capability index corresponds to specifying the maximum acceptable standard deviation by the man-ufacturer for a tolerated dimension (equa-tion 3 and Figure 7). For the example in Figure 7, with Cm = 1.67 this means that for the original tolerance of ±0.1 mm, 99.73 % of all tolerance dimen-sion values measured on various workpiec-es must be in the range of ±0.06 mm. As a consequence,

the acceptable standard de-viation must have a maximum value of only ±10 µm. Achieving such values is a signifi-cant challenge for the linked machining centers in large-batch production. Error limits for machining Flaw sizes in the process and their effects The previous pages outlined the order of magnitude of tolerances on workpieces for vehicle powertrains. The question arises as to the percentage of available tolerance of a production feature that flaw size arising in the process depletes. If the total flaws are greater than the available tolerance, the machine tool or process cannot fulfill the specified machining task. In the following, the error limits that can occur on a machine tool e.g. due to workpiece clamping or thermal drift behavior on axes are therefore estimated, and the aim is to estimate the residual tolerance reserve by comparing the available tolerance with the existing error limits. This reserve enables the machine tool or process to compensate for unpredictable or difficultto-control production influences. Index tolerance of workpiece clamping The loading of machine tools is usually automatic, using special loading modules such as gantry loaders. Before a workpiece is machined, it needs to be positioned and fixed in the clamping fixture of the machine, and because this must be carried out without manual intervention, positioning is usually done by index pins in the clamping fixture. This means that the mechanical fitting tolerance between the index holes of a workpiece and the index pins of the clamping fixtures in the production line must be considered. According to the drawing specifications, identical tolerance for the index holes is available for each workpiece produced on the production line, but the actually produced dimension varies from workpiece to workpiece. This also applies to the individual index pins of the clamping fixtures. As a result,

constantly identical indexing deviation cannot be expected. The specified maximum tolerance ranges for the index holes and index pins should, however, be complied with in each case as rejects will otherwise be produced. This makes it possible to estimate an error limit. With the above-specified cubic automotive powertrain components (cylinder head, crankcase, transmission housing), index holes with a diameter of 12 mm are often drilled. Clamping of the workpiece within the indexing pins is not desired because this can lead to excessive loads on the loading systems or workpiece clamping errors, and therefore to possible idle times in the production line. To avoid this, a transition fit of Ø 12 H7/js6 is assumed in the following. These specifications achieve the following maximum error limit for workpiece indexing in the clamping fixtures: To manufacture features with tight tolerances, the workpieces are sometimes moved in a defined direction using thrust cylinders in the clamping fixture prior to clamping. This means the workpieces are radially pressed onto the index pins, so that from the central drilling axes only a maximum of half the error limit occurs (≡ ±5.88 µm). Because sliding units often make clamping fixtures more complex and therefore more expensive, they are not integrated in all machining stations. Tool change tolerances On the tool side, inaccuracies also occur during tool changes and depending on the tool interface used. In the machining centers of the above-specified production lines, main spindles and tools with hollow taper shank interfaces are normally used. In [8], the predominant repeatability of the hollow taper shank connection is specified as < 1 µm (axial) & < 3 µm (radial) (≡ ±0.5 µm axial; ±1.5 µm radial).

[ To be Continued in Next Issue. ]

Courtesy: Heidenhain India Website: www.heidenhain.de

DECEMBER 2017

MACHINE TOOLS WORLD

PRODUCTS SHOWCASE www.mtwmag.com

PRODUCT SHOWCASE KING CUT PRO – The Large Gantry Type CNC Cutting Machine Ador’s KING CUT PRO is a CNC portal cutting machine which is very precise and reliable. The machine has one head for plasma sheet metal cutting and one head for flame cutting of sheet metal with a dual side longitudinal drive with AC motors. The standard equipment comes with a basic machine package with CNC controller, one torch, central gas diffusion with manometers and a remote flame ignition.

The following equipment are supplied as required by the customer: Additional Equipment: • Plasma power source KJELBERG with machine torch • Programming software MOST 2D • Support table for sheet metal with segment extraction system • Extraction-filter system • Laser position indicator for determining the cutting point Optional : • Extension of the longitudinal rail • Additional cutting head

The CNC Controller – Phantom:

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

The Phantom brings you the performance of a cutting edge CNC that is built on more than 40 years of experience in the motion control and cutting industries. This controller is designed for multiple axis cutting machines and features the latest advances in CNC technology on a proven platform engineered to increase productivity, reduce costs and enhance profitability. The software provides flexibility, ease of operation and technologies that put Ador’s experience and expertise in your operator’s hands, resulting in extremely good cut quality and high productivity. The Phantom can operate any cutting machine and interface with virtually all plasma systems. Following are its standard features: Bright touch screen interface, Touch screen interactive display, Expandable shape library, True multi-tasking environment, Fast Dxt file conversion, Go to(Job interrupt), Quick plate alignment, and Monitor & track consumables. Advanced Plasma Process Control (Plasma Process Wizard) is available as optional extra. Ador offers cost-saving height control unit for simple plasma cutting applications. The KHC1 system provides all the essential functions that are needed for good cuts and optimum utilization of work-piece.

DECEMBER 2017

MACHINE TOOLS WORLD

PRODUCTS SHOWCASE

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

Following are some of its unique features:

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

• • • • • • •

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

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

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

MACHINE TOOLS WORLD DECEMBER 2017

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-theart ISO 9001-23008 certified facility is equipped with dedicated men and machines to chisel out products of impeccable quality and reliability.

PRODUCTS SHOWCASE www.mtwmag.com

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

Designed to performs

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

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

Electrical Safety for Power Supplies! Reliable Insulation Surveillance in IT Networks

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

The demand for the availability of machines and plants in the region of factory machinery and process technology is constantly increasing. The requirement for this is a functioning and reliable power supply. Unexpected insulation faults in the plants can lead to unwanted supply disruptions culminating in damages to persons and property. Therefore, insulation surveillance equipment in IT systems is required. The insulation monitor RN 5897 from the VARIMETER IMD series from DOLD was specifically developed for use in modern power supplies. These are often comprised of converters, thyristor regulators, and direct current components. Through EMV interference suppression measures, high leakage capacitance onto the ground is present. The RN 5897 is suitable for system leakage capacitance up to 1000 µF as well as for voltages up to DC/AC 300 V. Using an additional ballast unit, it is possible to use the system with voltages reaching up to AC 760 V and DC 1000 V. As well as an adjustable alarm threshold, the insulation monitors also enable a configurable warning signal. A multicoloured LCD screen constantly updates stating the current insulation value. The insulation monitors guarantee additional surveillance over current-free networks. A selective earth fault detection of L+ and L- enables quick fault localisation. The insulation monitors will also be used in USV facilities, photovoltaic facilities, mobile generators and so forth.

DECEMBER 2017

MACHINE TOOLS WORLD

PRODUCT INDEX A

Engraver Cutter

AC I DC Geared Motor

AC Linear Servo Motor

Actuator Line

Air Compressors

Air Filtration

FALSE COVER

Exchangeable Head End Mills

IFC

F Flexible Couplings

Alloy Wheel Machining Solutions

Aluminium Profiles

Gas Flow Products

Angle Encoders

Gas Management

Automation Products

Gear Boxes

Gears, Racks & Pinions

Grinding Machines

Ball Transfer Units

Brake Motors

23, 33

Ground Threads

H C

Harmonic Filters

Cable Glands

HHS & TCT Saw Blades

Cables

High Pressure Filtration

CAD CAM SOFTWARES

Hydraulic Press

Cam Driven Systems

Centre Drills

FALSE COVER

Chamfers

FALSE COVER

I Inserts

FRONT GATEFOLD

Clamps for Linear Guides

Inspection Equipment

CNC Grinding Machines

Instrumentation Fittings & Valves

CNC Horizontal Boring Machine

CNC Lathe

CNC Machining Centers

BACK PAGE

L Laser Tube Cutting Machine

CNC Smart Mills

Lathe Machines

CNC Solutions

Length Gauges

Light Energy Management Systems

CNC Tool Grinding Machine

Commercial Finance

Linear Actuators

Conduits

Linear Encoders

Connectors

Linear Line

Consumables

Linear Motion Guides

Contact Scanning System

Contouring Controls

Curvic Coupling

Cycloidal Gear Boxes

D Double Column Machining Centers

Drill Tap Center

Drills

FALSE COVER, FRONT GATEFOLD

M Machining Centers

Position Displays

Power Conditioners

Precision Air Moving Products

Precision Ball Screws

Pressure Control Solutions

Project Engineering Solutions

R Radio Frequency System

Real Time Power Factor System Reamers

FALSE COVER

Reffnlng Furnace

Rotary Encoders

S Safety Relays

Screwiacks

Slewing Ring

Spotting Drills

FALSE COVER

Stabilizers

Static Elimination Solutions

Stepper & BLDC Motor

Surface Cleaning

T Taps

FRONT GATEFOLD, 39

Telescopic Line

Thermal Imaging Cameras

Tool Holders

FRONT GATEFOLD

Tool Presetting & Measuring Machines

Tooling Equipment

T-Slotted Floor Plates

Tube Bending Machine

Tube Cutting Machine

Tube End Finishing

Metal Cutting Tools

Metal Working Fluids

Motion Toolpaths

Ultra Isolation Transformers

Value-Selling Training Solutions

Vertical Machining Centers

U 83

FRONT GATEFOLD

End Mills Cutters

FALSE COVER

Energy Absorption & Vibration Isolation Products

Oxy-Fuel CNC Cutting Machines

End Mills

IBC

Plunge Shaving Machine

Mass Flow Controllers

Oil/ Coolant Mist Cleaner E

9, 29

PLC

MACHINE TOOLS WORLD DECEMBER 2017

P Planetary Gear Heads

Welding Equipments

Plasma CNC Cutting Machines

Welding Tables

ADVERTISERS INDEX COMPANY NAME

PG. NO.

A ACCUSHARP CUTTING TOOLS PVT. LTD. ACE MANUFACTURING SYSTEMS LTD.

BACK PAGE

ADOR WELDING LIMITED

ANCA MACHINE TOOLS PRIVATE LTD APEX PRECISION MECHATRONIX PVT. LTD.

BIRLA PRECISION TECHNOLOGIES LIMITED

CNC SOFTWARE, INC.

FLIR SYSTEMS INDIA PVT. LTD.

53 21

GEDEE WEILER PRIVATE LIMITED

GLEASON WORKS (INDIA) PRIVATE LIMITED

ERWIN JUNKER MASCHINENFABRIK GMBH

PILZ INDIA PVT. LTD.

RENISHAW INDIA (PUNE)

HOSABETTU HEAVY MACHINERY LLP

ROLLON INDIA PVT. LTD. - INDIA

HYUNDAI WIA INDIA PVT. LTD.

INDUSTRIAL ENGINEERING EXPO - 2018

JASH PRECISION TOOLS LIMITED

S SHAVO TECHNOLOGIES PVT. LTD.

T TRUCUT PRECISION TOOLS PVT. LTD.

FALSE COVER

U UNITED GRINDING GMBH

UNITY CONTROLS PVT. LTD.

PARAGON MACHINERY CO. LTD.

HEIDENHAIN OPTICS & ELECTRONICS INDIA PRAIVATE LIMITED

EPPINGER TOOLING ASIA PVT. LTD.

53, 87

PARADIGM TRAINERS PRIVATE LIMITED

ELGI EQUIPMENTS LTD.

RAVIK ENGINEERS PVT. LTD.

LAPP INDIA PVT. LTD.

ELECTROTHERM (INDIA) LTD.

OPEN MIND CADCAM TECHNOLOGIES INDIA PVT. LTD.

L DOWEL ENGINEERING WORKS

INSIDE FRONT COVER

INSIDE BACK COVER

MMC HARDMETAL INDIA PVT. LTD.

D DELTA ELECTRONICS INDIA PVT. LTD.

PG. NO.

COMPANY NAME

FIBRO INDIA PRECISION PRODUCTS PVT. LTD.

GODSON BENDING SYSTEMS PVT. LTD.

C CAPITAL FIRST

FATTY TUNA INDIA PVT. LTD.

B BETTINELLI AUTOMATION COMPONENTS PVT. LTD.

PG. NO.

ACMEE - 2018

AMTEX - 2018

COMPANY NAME

MACHAUTO EXPO - 2018

MARPOSS INDIA PVT. LTD.

MGM-VARVEL POWER TRANSMISSION PVT LTD

MITSUBISHI ELECTRIC INDIA PVT. LTD.

YG CUTTING TOOLS CORPORATION PVT. LTD.

FRONT GATEFOLD

YOUNG BUHMWOO INDIA CO. PVT. LTD.

Z ZOLLER INDIA PVT. LTD. DECEMBER 2017

41 MACHINE TOOLS WORLD

Inside Story

G. D.

Mr.

Rajkumar

Director, Gedee Weiler Pvt. Ltd.

My Lifeâ&#x20AC;&#x2122;s Goals Aim & Ambition: My aim is to expand our manufacturing activity into producing waste water recycling plants. Vision: To be a leader in providing High end technology at affordable cost from Gedee weiler. Social Goal: My Ambition is to promote Skill development the way it is being imparted in Germany in India. Business Goal: To make Gedee weiler a company with a Global footprint with High end technolgy machines.

My Leisure Choices Favourite Tourist Spot: Valparai & Blackforest Music I Like: Tamil, Italian. Sports I Love: Motorsport & Remote Control Car Racing.

Ask my Taste Buds Favorite food: Southindian, German & Italian. Favourite Drink: Wine & Beer.

100

MACHINE TOOLS WORLD DECEMBER 2017

Automation for a Changing World

Delta Compact Non-backplane Mid-range PLC AS Series Delta self-developed SoC 32-bit CPU to enhance execution speed Positioning control function for up to 8-axis motion control via CANopen / 6-axis 200 kHz pulse control Friendly software and robust non-backplane design

taâ&#x20AC;&#x2122;s Del ent pat

Robust slot & clip interlocking design

www.deltaelectronicsindia.com automation@deltaww.com

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

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