Volume 03 No. 09 | February 2018 | ` 150
Pages 110 | RNI No. MAHENG/2015/64267
QUALITY CUTTING TOOLS
CEO CORNER Budget 2018 & it’s impact on machine tool industry India’s growth story can only be further enhanced by aligning objectives and policies that function together to place the country as a manufacturing base. It is also crucial to encourage the use of high-end manufacturing processes and technologies in digital factories that can encourage Additive Manufacturing and other forward-looking initiatives for the sector. Reduction in corporate tax in budget 2018 for entities with a turnover of up to Rs 2.5 billion to 25% is expected to benefit MSMEs as well as the Indian machine tool industry. Government of India, with this budget, has tried to establish harmony between demands rising from various sectors and bringing some kind of a fiscal discipline to meet the country’s economic goals in the long-term. The increase in budget outlay for infrastructure development especially for railways electrification and capacity enhancement including development of tracks is expected to step up demand for coach manufacturing. This will also create a demand for a broad range of machine tools such as special-purpose wheel lathes, light-rail transit systems, and heavy duty single and double column vertical turning and lathes, large bridge type milling machines, horizontal lathes and special machines. Over 80% of the companies engaged in the auto component manufacturing are SMEs. Customs duty on select items such as engine & transmission parts, brakes and parts thereof, suspension and parts thereof, gearboxes and parts thereof, airbags etc have been enhanced from 7.5/10% to 15%. These items account for more than 50% of $ 43.5 billion domestic component industry’s turnover and over 30% of it’s $ 11 billion exports. Hike in customs duty will not only encourage investments but also encourage technology development in these areas. Development of the defence corridor between Chennai and Bengaluru will result in new opportunities for the Indian forging industry. The increased budget allocation for road and public infrastructure, rural infrastructure development and public healthcare will also give a fillip to these sectors and meet the aspirations of ‘Make in India’.
CEO
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MACHINE TOOLS WORLD FEBRUARY 2018
ANCA Machine Tools Private Ltd 8/1 , Dr. M H Marigowda Road, Arekempanahalli , (Wilson Garden ), Bangalore - 560027, Karnataka, India T: +91 (80) 6759 2100, M: +91 96637 69911, E: indiainfo@anca.com, W: www.anca.com
www.mtwmag.com
Publisher & Printer Shirish Dongre
CEO
Contents
Vol 3 Issue 09 | FEBRUARY 2018
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
ZOLLER: Smart Factory Solutions with Quality & Precision
Online Division Ganesh Mahale
Circulation Executive Satish Kadam, Amol Ranshur Branch Offices (Zonal)
36
Christoph Zoller, CEO, E. Zoller GmbH & Co. KG
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
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MACHINE TOOLS WORLD FEBRUARY 2018
BUSINESS NEWS
COMPANY PROFILE
18
Schmersal group founds subsidiary in Japan
20
Additive manufacturing finds a place in the sun
22
DMG MORI strengthens digitized production
22
WALTER presents FINE PULSE technology
40
42
46
50
We give strategic advantages to our customers from diverse industries
Shavo Technologies offers high-tech tailor made solutions
24
EWAG presents new laser processing machine
30
Kistler Group posts strong growth in 2017
30
Hatebur minimizes changeover time
WIL – A formidable name also in Gearboxes
A surge to the top: Superslides & Ballscrews Co India
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
xis
Z-A
B-Axis
Ram Type Moving (X/Z-Axis)
Ø200
mm Table Size
15
kg Workpiece Weight
40,000 (HSK-E40)
r/min Spindle Speed
20
EA No. of Tools
300/300/200
mm (X/Y/Z-Axis) Travel
50/50/50
m/min (X/Y/Z-Axis) Rapid Traverse
200/200
rpm (A/B-Axis) Rotary Table Speed
2G/2G/2G
G (X/Y/Z-Axis) Acc./Dec. Speed
SIEMENS 840D sl
CNC Controller
Rotary Tilting Table(A/B-Axis)
HYUNDAI WIA INDIA PVT. LTD. Address : #4/169 1st flr, LOTTE Bldg, Rajiv Gandhi Salai, (OMR), Kandanchavadi, Chennai - 600 096, Tamilnadu, India Office Tel. No. : (0)76049 03348, E-mail : sales@hyundai-wia.com
Contents
Vol 3 Issue 09 | FEBRUARY 2018
TECH TRENDS
CASE STUDY
Accusharp Gun-Drills
76
52
Precision of a new generation
54
Safe monitoring of wind turbines
100
Stop at a dizzying height
PRODUCTS SHOWCASE
88
Studer - the experts in internal and radius grinding
74
Manufacturing gets “Smarter”
102
The new Gast 86/87R Series of oil-less rocking piston compressors and vacuum pumps
103
4 Rolls Double Pinch Linear Guides – 4HEL
86
Modern Gear Manufacturing Equipment, Made in India
58
Inter-stage Membrane Dryer: Lower Life Cycle Costs, Zero Maintenance
104
2 out of 8 selectable safety functions
105
FARO® Offers the world’s best measurement ARM
106
FLIR DM285 – Industrial Imaging Multimeter with IGM. 10
MACHINE TOOLS WORLD FEBRUARY 2018
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
M
52 70, 105 20, 96
B
Bettinelli Automation 40 D Mr. Arun Mahajan General Manager
AMT- The Association For Manufacturing Technology
Mr. A.P. Jayanthram Ex-Managing Director Heidenhain Optics & Electronics India Pvt. Ltd
Mr. GK Pillai Managing Director & CEO Walchandnagar Industries Ltd.
DMG MORI DOLD Electric
18, 22 104
E
Elesa+Gante ELGI EQUIPMENTS ERWIN JUNKER EWAG
94 58 80 24
F
Faccin FARO FLIR Systems India 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.
103 105 106
G
Gleason
86
H
Hatebur Heidenhain India Hexagon
30 60 84
MAC Machine Tools and Automation
74
Marposs India
82
Micro-Epsilon
76
P
PILZ India ReeR Safety
98
Renishaw
20
Rollon
90
S
Schmersal
18
Seco Tools
22
Shavo Technologies
42, 102
Superslides
Kistler Group
United Grinding
88
Unity Controls
104
W
Walchandnagar
46
WALTER
22
30
Zoller
For editorial contribution contact E-mail: shweta@divyamediaonline.com
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
12
Mr. B.P. Poddar Vice President - Sales & Marketing FEMCO Fatty Tuna India Pvt. Ltd.
MACHINE TOOLS WORLD FEBRUARY 2018
Mr. Jayant Vaidyanathan VP - Sales & Application Tsugami Precision Engineering India Pvt. Ltd.
50
U
Z
K
Mr. Dinesh Khambhayta President MTMA-RAJKOT
54
R
MTW Overseas Associates USA Nancy TARTAGLIONE, Mepax USA n.tartaglione@mepax.com / usa@mepax.com
GERMANY Sebastian OLLIER Mepax Deutschland, Tel: +49 711 222 54 456, deutschland@mepax.com
FRANCE MEPAX SA, Romain CLASS Tel.: +33 1 39 02 77 78, FRANCE
SPAIN Sofiane JEDIDI Mepax España Tel : +34 963 255 886, spain@mepax.com
ITALY Valeria VILLANI Tel.: +39 339 8610117, Via Firenze, Milano, Italia
UK Liz Jones Tel: +44 (0)1227 276016 , l.jones@mepax.com
RUSSIA Garri ZALTS Mepax Russia Tel: +7 495 576-7666 / gizalec@yandex.ru
CHINA/South Korea/Taiwan Mepax - Konaxis Shanghai Julien PENARD Tel : (+86) 21 6252 2731/ china@mepax.com
36
VERSATILE IN EVERY REGARD
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BUSINESS NEWS
Schmersal group founds subsidiary in Japan Tetsuya Horimoto named new managing director To improve its coverage of the Japanese market, the Schmersal Group has founded an independent subsidiary in Japan. Tetsuya Horimoto has been named managing director of the new Schmersal Japan KK. He takes over from Dr Tekashi Kabe, who entered his well-earned retirement at the end of 2017 after many successful years as the manager of the previous Schmersal sales office in Japan. Tetsuya Horimoto is an electronic engineer with many years of management experience at leading international companies in the automation sector. He is also a TUV-
certified Functional Safety Engineer. “By founding a subsidiary in Tokyo, Schmersal will extend its range of safety technical components and systems for the Japanese market. At the same time, we will increasingly be able to offer our customers our comprehensive services from our tec.nicum division on a local basis,” explains Tetsuya Horimoto. The aim is to expand the Schmersal site in Japan in terms of both space and personnel. In future, a separate warehouse should allow faster deliveries to the customers. Additional qualified engineers will soon ensure better customer
support. “The majority of our customers in Japan come from the mechanical engineering sector, the steel industry, the automotive industry and lift construction. Japanese
mechanical engineering companies in particular export the majority of their products. It is these customers in particular that we can support with the sound knowledge of our tec.nicum experts about the different international and European legal directives and standards on machine and occupational safety, and the relevant safety solutions.” The newly founded Schmersal Japan KK is based at the same location in Tokyo as the previous Schmersal Japan Branch Office.
For more information Web: www.schmersal.jp
DMG MORI showcased innovations at DECKEL MAHO Pfronten Digital factory, integral automation solutions and technology excellence– DMG MORI showcased its complete range of manufacturing competence at the traditional DECKEL MAHO Pfronten Open House from 30. January to 3. February 2018. On over 8.500 m² of exhibition space the leader of technology presented 70 high-tech machines including the new NTX 3000 as a world premiere as well as innovative manufacturing processes such as ADDITIVE MANUFACTURING with a total of three complete process chains. With the DMG MORI Qualified Products (DMQP) the machine tool manufacturer offers perfectly matched peripherals and accessories for production and with VCS basic a new technology cycle is launches for volumetric compensation and automatic calibration. The digital transformation in
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MACHINE TOOLS WORLD FEBRUARY 2018
machine tool manufacturing will also be one of the key issues at the DMG MORI Open House in Pfronten. The presentation on the exhibition will consistently pursue the Path of Digitization in Pfronten. The digital transformation follows a bottom-up strategy from the CELOS machine on to CELOS manufacturing and right through to the digital factory. At DECKEL MAHO Pfronten DMG MORI bundles its entire manufacturing competence in
both the aerospace sector and the field of die & mold. In its respective DMG MORI Technology Excellence Centers the machine tool manufacturer offers its customers far more than just hightech machines and performance. Experienced experts from DMG MORI are being involved in the future projects of customers at a very earlier stage. “As a full-service provider we supply the entire spectrum of required components with our machines – from the
smallest electrodes in tool and mold construction right through to the XXL components needed in the aerospace industry”, emphasizes Markus Piber, Managing Director of DECKEL MAHO Pfronten GmbH. Automation solutions are gaining in importance in efficient manufacturing. DMG MORI supports this development by ensuring all machines from its diverse portfolio can be delivered from a single source ex works as either a standard automation or as a customised automation solution. “Our overall performance spectrum ranges from the planning and simulation and on right through to final hand over of the complete turnkey system”, explains Markus Rehm, Managing Director of DECKEL MAHO Seebach GmbH and DMG MORI HEITEC GmbH, a DMG MORI AKTIENGESELLSCHAFT and HEITEC AG joint venture.
The Trusted Partner in Metal Forming Machines
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Faccin's plate rolls, angle rolls, dished-head lines and special machines are used all over the world by the most exigent manufacturers that require top precision, high productivity and long-term reliability.
BUSINESS NEWS
Additive manufacturing finds a place in the sun Global engineering technologies company, Renishaw, has worked with the Friends of Berkeley Castle to create an additively manufactured sun dial for historic Berkeley Castle in Gloucestershire, UK. Because sun dials are specific to onelatitude and longitude, a bespoke product was essential for the project to be successful. Renishaw used its own additive manufacturing technology to produce a precise final product. The finished sun dial was unveiled at the Friends’ Summer Party in August 2017 and will be displayed in the Castle’s garden on a pedestal. The Friends of Berkeley Castle approached Renishaw about
creating a unique sun dial design for the 12th century castle. Retired mechanical engineer and Friends of Berkeley Castle Member, Bob Hunt,designed the sun dial according to the castle’s latitude and longitude.The design incorporated specific features to link the sun dial to Berkeley Castle, including the Berkeley Arch and Door in the design of the gnomon (vertical piece) and a moat and cobbled courtyard
on the dial face (horizontal piece). By careful design, the sun dial provides additional information, for example by projecting a beam of light onto the dial face at midday. This beam of light can be used to indicate the Vernal and Autumnal equinox. Another feature achieved by precision engineering and careful design, is that the shadow cast by the extended arch will align with the light beam only at midday on
the equinox. Construction of the sun dial required high precision, which was achieved using metal additive manufacturing. The design was manufactured on a Renishaw AM250 metal additive manufacturing system from stainless steel. Once completed, the sun dial was mounted on to the empty pedestal using a specially designed mounting unit, ensuring correct alignment with the sun. “The basic design of a sundial might be simple; a stick in the ground and some markers to indicate the hours,” explained Friends of Berkeley Castle Member, Bob Hunt.
ANCA invests in renewable energy to power its headquarters ANCA is one of the first businesses to team up with Australia’s fastest growing business power retailer, Flow Power, to buy power generated by renewable energy sources. An innovative and progressive business model, Flow Power tackles the issue of price and environment with this unique offering. This renewable power, sourced from Ararat Wind Farm, can be used in real time to offset grid electricity consumption, potentially saving thousands of dollars in energy costs. ANCA Group CEO, Grant Anderson said:“At ANCA we are always looking for opportunities to reduce our impact on the environment and, as a manufacturing plant, the partnership with Flow to access renewable power will bring us tremendous benefits.This is a winwin helping both our business and
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MACHINE TOOLS WORLD FEBRUARY 2018
the environment.” “ANCA has succeeded on a global scale by taking an innovative approach to manufacturing. We see Flow Power’s unique model of giving companies back the control over their energy costs as an approach that shares our core value of innovation.” “Furthermore, being part of a wholesale strategy helps future proof us in a market where fluctuating power costs are
increasingly become a concern for businesses. The wholesale strategy generally outperforms fixed retail contract prices and provides greater transparency on spend and increased flexibility,” Grant concluded. Matthew van der Linden, Managing Director of Flow Power, comments, “We’re very pleased to welcome ANCA as a customer and one of the very first companies to benefitfrom Flow Power’s
Renewable Corporate PPA. This agreement is one of the first of its kind in Australia and will allow Australia to catch up with other international markets that have proven this model to be a success.” “Flow Power wants to empower businesses to take control of their energy consumption. Our Renewable Corporate PPAs help businesses to lower their carbon footprint and reduce overall emissions, while benefitting from lower power costs.” ANCA will now buy its power from Ararat Wind Farmthrough a Power Purchasing Agreement to access fixed rates for long-term savings. While very common around the world, this deal is one of the first in Australia.
BUSINESS NEWS
DMG MORI strengthens digitized production Digital factory, holistic automation solutions and technology excellence: at the traditional open house exhibition at DECKEL MAHO Pfronten, DMG MORI is showed the entire scope of its technology competence. The 9,000 international trade visitors saw 70 high-tech machines across 8,500 m² of exhibition space, including the new NTX 3000 as a world premiere, as well as innovative manufacturing processes, such as ADDITIVE MANUFACTURING. The open house exhibition’s central theme is the “Path of Digitization”, by which DMG MORI is promoting the digital transformation in machine building worldwide. More than 10,000 DMG MORI machines fitted with CELOS have been supplied so far. Moreover, DMG MORI is offering its customers and suppliers an integrated and open digital solution with the open, digital platform ADAMOS. Short-term over
100 customers will be connected to the new IIoT platform and all DMG MORI machines will operate with total connectivity. At the end of 2017, DMG MORI acquired WERKBLiQ GmbH from Bielefeld with its 20-strong team as a further milestone of its digitization strategy. WERKBLiQ offers a nonproprietary platform where all those involved in the maintenance process can be linked to one another. The WERKBLiQ user interface allows
machine operators to access all the important data and key figures in individual dashboards at the click of a button. “This digitizes the entire maintenance and repair process and speeds it up considerably,” says Christian Thönes, Chairman of the Executive Board of DMG MORI AKTIENGESELLSCHAFT. From the start of the open house, the warranty period for all motor spindles of the “MASTER” series will be 36 months, without restriction on hours. “Now more than ever, “First Quality” means quality without compromise at DMG MORI,” adds Thönes. The MASTER spindles excel through extremely good reliability and a considerably longer service life compared to conventional spindles. This is in part due to the use of Vacrodur – an innovative type of steel that provides outstanding resilience, wear resistance and temperature stability.
New Seco Solid-Carbide WALTER presents FINE Cutting Tools boost PULSE technology machining speeds
Seco Tools has introduced the industry’s first product line specifically dedicated to knee implant machining. The new Jabro® medical range of solid-carbide cutting tools combines different machining strategies such as highspeed machining to shorten part cycle times when machining knee implants by as much as 50 percent. The tools’ continuous grades and optimized coatings result in exceptional part surfaces that reduce, and often eliminate, the need for polishing or fine finishing operations. These features also promote excellent process stability
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MACHINE TOOLS WORLD FEBRUARY 2018
and long tool life. The Jabro medical range includes 9 advanced geometries and 39 tools, most of which are positioned in Jabro Tornado high-speed cutting family. Each geometry is designed for particular applications in the machining of tibial tray and femoral knee implant parts. And because the new dedicated tools excel in the machining of CoCr (Cobalt Chrome) and Ti6Al4V ISO-S12 parts (3D printed), they maximize machine performance for other medical components such as those for hip replacements and bone plates as well.
With “FINE PULSE TECHNOLOGY” WALTER introduces a new eroding concept that sets new standards in terms of surface and cutting edge quality and consequently the process reliability of PCD tools. Launched in October 2016, this new eroding concept will be installed as standard in all WALTER erosion machines. For some time now we at WALTER have been constantly developing the existing eroding concept to meet the increasing demands made on PCD tools in terms of quality & service life, as well as price & production time. In particular, the generator has been recognised as a central element with potential and has therefore been completely redesigned. Improvements in eroding software and a variety of other factors based on the machine design were also optimised as part of the “FINE PULSE TECHNOLOGY” concept. With super-fine finishing, an even more perfect surface quality and cut-
ting edge can now be generated on a PCD tool – and with the same processing time as before. The difference to the other tools on the market can even be seen with the naked eye on the most common PCD types with 10 µm grain size. A tool produced with “FINE PULSE TECHNOLOGY” on a WALTER eroding machine shines on its free surface, similar to a polished (ground) tool. Even coarse-grained PCD types can now be fine finished with the new “FINE PULSE TECHNOLOGY” and a perfect surface quality can be produced. In some cases even entire steps in the production chain can now be omitted because the eroded tools no longer have to be re-sharpened or polished.
BUSINESS NEWS
EWAG presents new laser processing machine EWAG has launched a new laser processing machine, the LASER LINE PRECISION the perfect machine for the modern tool manufacturer wanting to get started in laser technology.The latest short-pulse fibre-laser technology used in the green-wavelength range (532 nm) offers highly efficient machining results for the commercially available diamond cutting materials such as CBN, PKD and CVC-D. Rotationally symmetrical tools of up to 200 mm diameter and up to 250 mm length as well as indexable inserts from 3 mm inscribed diameter and up to 50 mm circumscribed diameter can be machined without force with the LASER LINE PRECISION.
The unique and patented Laser Touch Machining® machining process offers excellent
surface quality, even on tools with complex or delicate geometries. Any cutting contours, clearances and 3D machining of chip breaker geometries can be performed in one clamping operation. The resulting flue gas and the vaporised material are suctioned away and carried to a corresponding suction/filter system. With a footprint of only 5sqm, and in comparison with the globally tried-and-tested LASER LINE ULTRA, the LASER LINE PRECISION is the most compact high-end laser production centre for super hard tools. An optional 6-axis robot offers the highest flexibility during minimally manned multi-shift operation.
IMTEX FORMING 2018 attracts huge attention Indian Machine Tool Manufacturers’ (IMTMA) flagship event and South East Asia’s largest exhibition on metal forming technologies ‘IMTEX FORMING 2018 & Tooltech 2018’ was inaugurated recently at Bangalore International Exhibition Centre (BIEC),Bangalore by Shri R. V. Deshpande, Hon’ble Minister for Large & Medium Scale Industries and Infrastructure Development, Government of Karnataka. Other dignitaries includedMr. A. S. Kiran Kumar, Former Chairman of ISRO and Mr. Nirmal K. Minda, President Automotive Component Manufacturers Association of India (ACMA). Mr. Jamshyd N. Godrej, Chairman Exhibitions, IMTMA, Mr. P. Ramadas, President, IMTMA and Mr. V. Anbu, Director General& CEO, IMTMA also presided over the inauguration. Nearly 40,000 visitors from around 60 countries are expected to visit the show in the next 6 days. Around 100 business delegations from public and private sector representing various manufacturing industries such as automotive, aerospace, defence, railways, power,
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MACHINE TOOLS WORLD FEBRUARY 2018
capital goods, general engineering, medical engineering, and so on are expected to visit the exhibition. Inaugurating the exhibition, Shri R.V. Deshpande called upon the industry to invest in Karnataka. He said that Karnataka is the most preferred state for investment. Karnataka was the first state to bring a start-up policy and is the only state in India to have an electrical vehicle policy. The state has been in the forefront of supporting the manufacturing sector and it has
successfully created 12,61,000 jobs and over 5,00,000 jobs are in pipeline. Mr. Deshpande also spoke about the machine tool park in Tumakuru being jointly developed by the Government of India and the Government of Karnataka. Voicing about IMTEX’s formidable stature in Indian machine tools sector, Jamshyd N. Godrej, Chairman, Exhibitions - IMTMA said the popularity of the show can be gauged from the tremendous response and
enthusiasm shown by exhibitors and visitors and we are optimistic that the show will grow in stature in years to come. IMTMA President P Ramadas stated, “Indian machine tool industry registered an impressive growth rate of 23 per cent during 2016-17. Indian machine tool industry is expected to grow by around 20 per cent during 2017-18 and Indian metal forming industry is expected to grow at a CAGR of around 15 per cent in the next 3 years.”
BUSINESS NEWS
Kistler Group posts strong growth in 2017
The Kistler Group reported full order books in 2017:“I am very pleased with business performance,” says Rolf Sonderegger, CEO of the Kistler Group. “Thanks to our acquisitions of the past year, Kistler has gained new technologies which we will continue to develop with focus on the needs of our customers.” The Kistler Group posted strong growth in 2017: with a growth rate of 18%, an increase of 17% after adjusting for currency effects,
sales revenue in the past year grew to approximately 422 million Swiss francs including acquisitions. Worldwide, 123 positions were created. The year 2018 at Kistler will be marked by digital transformation. Digital transformation has top priority for Kistler in 2018. All of Kistler’s business areas are touched by this transformative process, and it extends far beyond the simple implementation of digital technologies. “At the moment, we are exploring avenues that are being opened through digitalization for new business models, organization and for our product and system portfolio. With regard to our portfolio, this means, for example, expanding the actual product offerings (hardware) to include both data-based and complementary services as well as
software,” says Sonderegger. Internal areas such as production and HR are also directly affected by digital transformation. Particularly when it comes to recruiting of new specialists, the Kistler Group’s enormous growth and high level of specialization pose considerable challenges. CEO Rolf Sonderegger anticipates strong growth rates once again
in 2018 and expects to achieve sales of approximately 463 million Swiss francs; he sees promising potential for industrial applications from Kistler on the Chinese market. Under the motto “Absolute Attention – One Step ahead through Innovation,” the development and market launch of numerous new products have Kistler on track for a successful 2018.
Hatebur minimizes changeover time At the trade show WIRE in Düsseldorf from April 16-20, Hatebur, a global leader in high-quality forming machines and tools, will present the groundbreaking cold former COLDmatic CM 725 (Hall 15, Booth C44). The 7 stations former is designed for the forming of highest precision parts with a length of 8 to 125mm and a wire diameter of up to 22mm. With these specifications, the COLDmatic CM 725 is ideal for suppliers of the automotive industry. “Our engineering team implemented several innovations to make our clients more efficient and productive: With a production capacity of up to 180 parts per minute, the CM 725 is much faster than previous machine generations”, reports Reinhard
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MACHINE TOOLS WORLD FEBRUARY 2018
Speed, flexibility, precision and minimized changeover times: The new Hatebur COLDmatic CM 725 makes manufacturers more efficient. (Picture source: Hatebur) Buehrer, Head of Marketing and Sales at Hatebur. In addition, Hatebur minimized the changeover times considerably: At the wire infeed, a linear servo motor ensures that the grippers push the wire forward with highest precision. “The volume variation of the cut-off parts is below 0.35%.
Together with the high quality of the sheared surface, which is typical for the COLDmatic, this results in a cut-off quality that allows forming from the first station”, says Mr. Buehrer. The centerpiece of the COLDmatic is the newly designed transfer-system on which the grippers for the part
transfer are mounted: All grippers are individually driven by servo motors, can be individually opened and closed as well as programmed. “This programmability brings enormous advantages when it comes to changeover times. Instead of changing all the parameters manually, all previously saved settings can be applied in just a few seconds”, explains Mr. Buehrer. Because of the servo motors, the COLDmatic CM 725 uses much less mechanical parts than previous machines, reducing the overall costs by almost 20%. The innovative fast changing system allows operators to lift out all seven punches and dies at once and exchange them with prepared units. All tools can be exchanged in only ten to fifteen minutes.
More Precision High precision sensor systems Inductive sensors (eddy current) for displacement, distance & position Non-contact measurement of displacement, distance and position on electrically conductive materials For demanding, industrial environments: dirt, pressure, temperature High resolution and temperature stability High bandwidth for fast measurements Customer-specific sensors and controllers Robust and industrial-grade sensor designs Versatile application possibilities due to comprehensive product range
Spindle Growth System Cost-effective design Miniature sensor design Miniature, compact controller Sensor technology can be integrated completely into the sensor Suitable for ferro- and nonferromagnetic materials Temperature measurement integrated in the sensor
+91 20 2674 1009 | info@micro-epsilon.in | www.micro-epsilon.in
BUSINESS NEWS
Union Budget 2018 an Enabler for Manufacturing Growth: IMTMA Union Budget 2018 presented by Finance Minister Arun Jaitley will drive the much-needed growth for MSMEs across sectors. The reduction in corporate tax for entities with turnover of up to Rs.250 Cr to 25 per cent is expected to benefit MSMEs as well as the Indian machine tool industry which has a significant number of MSMEs. This is also expected to help the ease of doing business besides generating jobs. Commenting on the overall significance of the budget, IMTMA President P. Ramadas said, “Government of India with this budget has tried to establish harmony between demands rising from various sectors and bringing some kind of a fiscal discipline to meet the country’s economic goals in the long-term. The aim to bring down the fiscal deficit to 3.2 per cent of the country’s GDP
in 2017-18 will help the country’s manufacturing growth in the long run.” Penning down his thoughts on the budget, Director General and CEO of IMTMA, V. Anbu said, “The reduction in corporate tax rate for MSMEs is a positive development since many of these units operate within prescribed limits. The incentives spelt out in the budget will bolster these units to enhance their production capacities.” The increase in budget outlay for infrastructure development especially for railways electrification and capacity enhancement including development of tracks is expected to step up demand for coach manufacturing. This will also create a demand for a broad range of machine tools such as special-purpose wheel lathes, light-rail transit systems, and heavy duty single and double
column vertical turning and lathes, large bridge type milling machines, horizontal lathes and special machines. Further, the increased budget allocation for road and public infrastructure, rural infrastructure development and public healthcare will also give a fillip to these sectors and meet the aspirations of ‘Make in India’. To sum up, IMTMA welcomes the announcements made in the budget. We believe that it will take some time for the buds to flower and create a demand for goods and services in sunrise sectors. The budget serves as a morale boost for the industry to charter its path through innovations and research which are vital for establishing long-term success for manufacturing in India.
IMTEX FORMING 2018 & Tooltech 2018 Paves Way for Technological Advancements IMTEX FORMING 2018 & Tooltech 2018 organized by Indian Machine Tool Manufacturers’ Association (IMTMA) held at Bangalore International Exhibition Centre, Bengaluru from 25th to 30th January 2018, which was largest in the series, concluded on a positive note. The exhibition size grew by 18 per cent and showcased future technologies which could be vital for enhancing productivity for Indian manufacturing industry. Exhibitors displayed wide range of high-end presses, laser cutting machines, and technologies related to bending and tube drawing. Advanced technologies such as Industry 4.0 and Internet of Things were also displayed by many exhibitors. Automation, robotics, sensors, CAD/CAM and tools that were more related to support the metal forming user industries were also displayed. International associations from Germany, Italy, Japan, Taiwan, UK and USA also participated in the exhibition. Parallel events also recorded good visitor turnouts. Over 350 participants from 130 companies participated in the International Seminar on Forming Technology held on 24th January 2018 at BIEC, Bengaluru. Researchers from 44 institutions presented their R&D projects. The best research projects
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were awarded. Marathwada Institute of Technology won the first prize. PDPM IIIT DM won the second prize and Indian Institute of Technology Bombay won the third prize. Companies entered into tie-ups with some of these institutions to use their research for commercial purposes. Twenty-one delegates from 7 countries took part in the International Buyer-Seller Meet held from 27th to 28th January 2018. More than 2000 students from over 50 institutions took part in ‘i Connect’ to enrich themselves with opportunities in store for them in the manufacturing sector. Delegations from public and private sectors representing user industries such as auto components, aerospace, defence, railways, electrical and electronics, plastic machinery, white and brown goods, medical engineering, and others took part in the show. Speaking about the significance of IMTEX FORMING 2018 on the small and medium enterprises (SMEs), IMTMA President P. Ramadas said, “Indian manufacturing landscape has a significant number of SMEs. The exhibition was important for fulfilling their aspirations and goals. The SMEs were able to leverage opportunities which would enable them rise a notch higher.
The presence of decision making authorities from original equipment manufacturers (OEM) resulted in securing well qualified leads and accelerated the sales process at the show. The show generated overwhelming response from SMEs engaged in manufacturing of vices, presses, manufacture of parts such as wheels & castors, measuring, welding and material handling solutions, & so on.” Reflecting on the potential of the show, IMTMA Director General & CEO, V. Anbu added, “IMTEX FORMING 2018 was the largest in the series in terms of exhibition area as well as exhibitors. There has been a significant increase in the number of business visitors which affirmed the immense potential of business opportunities that the exhibition had in store for the manufacturing industry. The show will further strengthen the bonds between machine tool manufacturers and customers and we hope the leads generated during the show will result in good business outcome.” IMTEX FORMING 2018 served to open up the way for development of Indian metal forming sector by acting as an enabler to forging longterm business relationships which could lead to the growth of the country’s economy.
Connect your devices and enter into the world of Smart Manufacturing
MAC Machine Tools and Automation Add : #64, Parimala Towers, 1st & 2nd Floor, MES Road, Yeshwanthpur, Bangalore – 560022 Tel : 080 65691520, Email : marketing@macindia.in, marcomm@macindia.in , Web : www.macindia.in
COVER STORY
ZOLLER: Smart Factory Solutions with Quality & Precision Q. Being the key player in the industry, Please brief us company’s journey from inception & share some of the milestones achieved? Alfred Zoller founded the company as mechanical workshop in 1945. His vision was cost-efficient manufacturing in metal-cutting production. Eberhard Zoller developed the company further to become a leader in innovation and quality in the measuring sector – and to become a global player. Today, the 3rd generation continues the ZOLLER success story – worldwide. The ZOLLER company has successfully established subsidiaries in the growth markets USA, China, India and Japan. With enthusiasm for inspection and measuring technology, ZOLLER near Stuttgart in the South of Germany, have been developing innovative solutions for greater efficiency in manufacturing processes for almost 75 years. More than 38,000 presetting and measuring machines with worldwide unrivalled software solutions have been installed to date.
Q. Please brief us about company’s infrastructure & what are the technology alliances that has been made in order to out-front the competition? If we talk about infrastructure, we have manufacturing plant in Pleidelsheim, Germany which is centralized one to maintain the quality aspect. All over the world we have around 50 corporate offices which are always ready to provide the exclusive solutions
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to our customers. In technical area we have strong alliances and most of all machining service providers with whom we are continuously developing for full proof shop floor solutions.
Q. What are the products manufactured by your company? ZOLLER develops all solutions inhouse, software as well as hardware. Tool presetters, measuring machines and smart cabinets are assembled at the German headquarters. Using high-quality components from German suppliers makes all products 100% made in Germany. Our specialists in IT, engineering, and application technology work together every day to create innovative and flexible solutions that take you further. More than 40 software developers and engineers enhance our »pilot« measuring software and the TMS Tool Management Solutions and guarantee an easy operation in today’s complex production process.
Q. What is your marketing strategy for India? We started from Europe but in the last few decades we have increasingly concentrated on Asia. Since the 90’s we have roots here in Asia and we see that the Indian market is one of the most vibrant markets in Asia. As the trends are changing recently regarding the new government policies and the positive environment in the country, which leads the Indian industry towards next level of manufacturing good quality products.
As a key player in tooling with quality products, we would like to use this big aspiration of the Indian market to bring ZOLLER be the first choice to the world as a “Best Product Manufacturer”.
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? Of course, R&D plays an important role in having success in the market. All measuring machines, software solu-
COVER STORY www.mtwmag.com
Christoph Zoller, CEO, E. Zoller GmbH & Co. KG tions, smart tool cabinets, and automation solutions are developed in-house. Furthermore, we create innovations in cooperation with our customers. Open innovation is a key principle of ZOLLER’s business approach: no matter how global our business is, we always remain close to our customers. This is the only way to adapt highly modern measuring solutions to actual market requirements. Our new developments always come about with our customers’ participations. We consider their needs; this is the only way to become more successful together!
Q. Quality standards are benchmarked by the product performance; please brief us how do you maintain the quality norms since from solution development to implementation? ZOLLER aims to provide premium products and excellent service. Apart from innovation and service, Quality is the basis of our corporate identity. Our awareness for quality and the associated quality and environmental policy is underlined by certifications in accordance with ISO 9001, ISO 14001 and VDA 6.4.
The observance of all legal and official requirements is binding for E. Zoller GmbH & Co. KG. These certificates prove the consciousness in realizing the quality concept and our commitment to a continued improvement process with regard to quality and environmental management. All employees in the single functional areas contribute to the implementation of the quality and environmental policy and work on developing and realizing the best possible solution in each project. The quality standard for our products is extremely high – starting from the
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COVER STORY development up to the assembly of premium brand name products – and also plays a major role for our service and the processes within our company.
Q. According you what are the factors affecting to your business? Of course, the industrial development to industry 4.0, smart manufacturing, smart factories has a big effect on the further developments of our solutions. A smart factory takes advantage of the technical possibilities of digitalization for a networked production workflow, which is consistent, transparent and efficient as a result. At ZOLLER, we consider this from the perspective of the variable of the “tool” and create the prerequisites for smart tool management — in relation to actual tools and in relation to the associated tool data. We do this with z.One, which is ZOLLER’s central tool database, TMS Tool Management Solutions software, TMS hardware, ZOLLER automation solutions and, of course, ZOLLER presetting and measuring machines.
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The important thing for me is that Industry 4.0 is not just a concern for large companies, but is also an important issue precisely for small and medium-sized companies who want to remain competitive. With ZOLLER, the user has a consistent tool database and can initiate automation processes, which are investments that quickly pay for themselves, including at small companies. At ZOLLER, we took on the subject of networking very early, and the data consistency of ZOLLER products with third-party systems has a long tradition. This consistent, future-oriented openness to all systems involved in the production process — whether they are machines, inventory or CAM systems — has always characterized ZOLLER solutions.
Q. How do you perceive the future of the industry? The future production of course will be an all networked one. The smart factory operates with the data that is available. With respect to tool management, the
goal is to have the right tool with the right data, at the right place at the, right time. The aim is to link real and virtual tool data over the entire production process and to allocate it to the physical tool, and to provide this information regardless of location. The challenges placed on the tool itself are in the direction of intelligent, self-organized tools; “The Smart Tool”. In the recent successfully concluded research project of the Federal Ministry for Research and Development, ZOLLER has collaborated with partner companies in smart tool development. This tool system of the future not only always knows the location and condition of its tools, but also communicates with the machines and systems that are relevant to the production workflow, exchanging information with those machines and systems about the condition of tools. Smart tools consist of a uniquely identified tool holder with integrated sensor, logic and transmission unit, as well as the tool itself, with a unique, integrated identification. The
COVER STORY www.mtwmag.com
saved data can be accessed at any time via a database and as a result it allows tool changes to be optimized, setup times shortened and costs saved during the production process.
Q. What is your vision for your company for near future? We already have products in our portfolio, that support smart factory requirements of the future. All of our presetting, measuring and inspection machines are aligned with the requirements of Industry 4.0 and can be integrated in existing production processes and networked with existing systems. At the EMO in Hanover, Germany last year, we presented our Smart Cabinets product line for the first time, which are entirely new intelligent tool storage systems with software connections. By connecting the Smart Cabinets to TMS Tool Management Solutions software, storage locations can be graphically displayed in 3D and inventory can be
tracked, all at the click of a button. We not only offer the software, but also the compatible hardware for efficient and reliable tool handling over the entire life span of the tool, from a single source. For customers, this means no more manual data input, no duplicate data maintenance, no more searching for tools — instead, the tool inventory is always at a glance, and the right tools are always on hand at the right location. Another aspect is automation. Automation over the entire tool handling process is taking on ever greater importance. ZOLLER will continue to lead the way in the future here as well. Today, all ZOLLER products are already network-capable and can be integrated in existing production environments. All devices and systems can also be expanded and upgraded. What certainly sets us apart even further is that no one else in the world has anywhere close to as many networking options with thirdparty systems, from CAM to nearly every machine control.
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COMPANY PROFILE
We give strategic advantages to our customers from diverse industries
Rupesh Paparaju, Director, Bettinelli Automation Components, India
B
ettinelli S.p.A, established in 1953, specializes in the development and manufacturing of precision motion control components and systems. In 1996 a separate division named CDS Cam Driven Systems was created for engineering solutions in automation and motion technology. CDS produces the widest range of mechanical Cam Driven Units, commonly known as rotary / indexing tables for precision motion control applications, requiring rotary or linear transfer, positioning and handling. The products range includes, cam indexing and servodriven tables, ring positioning drives, intermittent and oscillating drives with parallel or right angle configuration, rotary & linear part handlers, precision link transfer systems, and epicycloidal servo reducers.
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
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6-8 weeks. The manufacturing takes place centrally in Italy. The regimen starts with design & engineering, CNC induction hardening, CNC milling, grinding, quality check and then assembly, painting and shipment. In order to ensure quality, all components are machined internally, including the cam hardening by a proprietary CNC controlled induction hardening equipment. For better finish, the products are also subjected to chemical nickel plating, blasting and painting. The manufacturing process is constantly controlled to conform to international standards. The company’s quality systems are ISO-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
Rotary Indexing Tables, TR Series
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.
Parallel Shaft Indexer Closer to the customer
The Indian arm of Bettinelli, based in Pune, Bettinelli Automation Components Pvt. Ltd., is highly customer-centric. “Our presence in India means quite something in fostering a symbiotic relationship with our customers. It helps us to match our world-class products with our eminent customer support,” underlines Paparaju, Director, who has built up a team to improve Bettinelli’s response time. “CDS are high-tech products which lend themselves to enhance the operational efficiency and productivity at the customer’s end. We stay close to the customer to understand his needs and offer customized solutions within the shortest possible time to ensure peak uptime of his equipment and operations”, he adds. - P.K. Balasubbramaniian
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COMPANY PROFILE
Shavo Technologies offers high-tech tailor made solutions
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Rushil Shah, Managing Director, Shavo Technologies Pvt. Ltd.
havo Technologies Pvt. Ltd., a part of the Shavo Group founded by Mr. H.K Shah, a pioneer in the pneumatics field in 1960, is in the frontiers of niche high technologies cutting across diverse disciplines. The company headquartered in Pune and headed by Mr. Rushil Shah, Managing Director, represents some of the world leaders in their respective fields for technology solutions like static elimination, precision air movement, high quality instrumentation, high purity gas delivery, corrosive gas handling, energy absorption and so on. With a vast portfolio, the company serves over a thousand customers from diverse key sectors including semiconductor, aerospace, defense, chemical, oil & gas, automobile and so on. “Over the years, we have gone from selling components to systems and
Applied gas delivery systems
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solutions and turnkey capability in an effort to keep offering better value by leveraging the technologies we provide,” says Mr. Rushil Shah. All its principals have specific technologies that would be classified ‘cutting edge’ considering the fact that all of them are world leaders in their fields. Following are brief details of their principals and business areas: TESCOM is a recognized leader in the manufacture of high-pressure regulators up to 20,000 psig designed to work with all types of fluids, both corrosive. Tescom range covers over 70 standard models of high-pressure regulators to meet almost any requirement. HAM-LET specializes in the design, development and production of high quality instrumentation valves and fittings in a wide variety of materials for high, pressure, temperature and vacuum applications. These products are used in diverse industries like petrochemical, semiconductor, energy, food, biotechnology, pharmaceutical, defense, pulp & paper and mining. CLASSIC FILTERS brings you filter elements to filter housings to complete filter systems for almost any function. It delivers some of the most robust high quality, coalescing filters and particulate filters in the world. In order to manufacture high tech devices such as semiconductor devices, flat panel displays and even photo voltaic or solar cells, precise fluid control is a must. HORIBA is the established world leader in offering a full line-up of gas, liquid, and vapor delivery products. Applied Energy System Inc. is one of the world leaders in the field of ultra high purity gas delivery systems like gas cabinets and panel for solar, semiconductor, nano technology and other high purity industries. Gas specializes in design and
COMPANY PROFILE
High quality instrumentation valves High pressure regulators
manufacture of air moving products including vacuum pumps, compressors, air motors, gear motors, vacuum generators and regenerative blowers. “As a matter of fact, our journey of working with high technology industries started with Gast which today remains
one of the world leaders in air motors and fractional horse pumps,” reveals Mr. Shah. Meech’s forte is industrial electrostatics. With a standing of over 40 years, Meech has developed a wide range of products like ionizing bars, hand-held ionizing air curtains, etc.
Electrostatics for effective static neutralization
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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
TNC 640 – The new High-End Control for Milling and Turning Operations The new TNC 640: for the first time, milling and turning are combined in one TNC. Now users can switch as desired between milling and turning—within the same NC program. Switchover is independent of the machine kinematics. It automatically takes the respective operating mode into account and without any additional action.This new simplicity is complemented by dialog-guided plain language programming, the optimized user interface, powerful programming aids as well as comprehensive cycle packets taken from amply field-proven HEIDENHAIN controls into the new TNC 640.
HEIDENHAIN OPTICS & ELECTRONICS INDIA PRIVATE LIMITED
Angle Encoders
Linear Encoders
Chennai 600031, India
Contouring Controls
phone +91 44 3023 4000
Position Displays
Length Gauges
www.heidenhain.in
Rotary Encoders
COMPANY PROFILE
A surge to the top: Superslides & Ballscrews Co India Established in the year 1999, the company has built a prestigious reputation and is a sought after name for its products
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oday, Superslides & Ballscrews Co. India Pvt. Ltd is counted among the recognized firms engaged in trading and supplying a wide range of Linear Motion Products and Ball Screws. The range offered by the company includes External Ball Circulation, High Lead, D-Type, Heavy Load, Internal Ball Circulation and External Ball Circulation. In addition to this, the company offers Internal Ball Circulation, High Lead, FA Series, MSA Series, MSB Series and MSR Series, to name a few. These products are sourced from PMI, Taiwan, who immense knowledge in this domain. The company’s products are manufactured using superior quality raw material and sophisticated technology as per the international standards and norms. Moreover, owing to their features such as strong construction, easy fitting, durability, compact design and corrosion resistance, these products are widely demanded by the clients. Due to these features, its products are widely used in welding machine, laser cutting machine, automatic tool changer, beam welding machine, PCB drilling machine, measuring & testing machine, amusement equipment, material handling equipment, tyre forming
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Mr. Rajiv Desai, Managing Director, Superslides & Ballscrews Co. India Pvt. Ltd.
machine and CNC lathes, to name a few. To handle the activities of its business in a streamlined manner, the company has appointed a highly skilled team of professionals. These professionals posses rich knowledge in this domain and procure the entire as per the set industry standards and norms. They also ensure to offer superior quality products to the clients as per their requirements. Apart from this, professionals take the responsibility to offer the products within the committed period of time to the patrons. The company has developed a large and capacious warehousing unit, which is also well-connected with major transportation modes. This helps it in making timely delivery of consignments
and gaining the complete satisfaction of patrons. Due to these factors, the firm has been able to customers such as Hindustan Unilever Ltd., Aditya Birla Group, B.H.E.L, Hero Honda, Swaraj Mazda, Eicher Motors, GUDEL India, Hyundai Motors, Indian Railways, Larson & Toubro Ltd., Premier Automobiles Ltd., TAL Manufacturing Solutions., H.M.T, L.M.W, Galaxy, SUZLON, T.V.S Group, MAC Powers and more. Under the able guidance of its directors, ‘Mr. Rajiv Desai / Kunal Desai’, the company has been able to gain an immense appreciation in the industry. The firm’s rich knowledge, leadership skills, constant motivation have enabled it to serve its clients in the best possible manner.
TECH TRENDS
Accusharp Gun-Drills Make Deep-Hole drilling more efficient and easy for you.
D
eep-Hole Drill, as initially invented for ‘Gun-Drilling’ application in Europe during the Second World War; and since then is popular as ‘GunDrill’. However, over last 75 years, its applications are extended in Auto and other engineering metal cutting industries for Deep Hole Drilling. Still these Deep-Hole Drills are yet popularly called as ‘Gun-Drills’, even if used for other applications. Accusharp Cutting Tools have entered into this new segment of Round Tools for Deep-Hole Drilling applications. The applications are for deep holes drilling on Crankshaft, Engine blocks, Turbo Blades, Paper Rollers, Machine Tools, Fixturing, etc. Standard geometry for Gun-Drill has been shown herewith. However, it may change according to its applications for different work materials, and machining parameters. Moreover, any change in the cutting edge geometry will have effect on bore surface finish, geometrical accuracy, drill centring, chip shape, chip removal, process reliability, and useful life of the drill, etc.
Our standard grinding geometry can take care virtually of all drilling operations successfully. However, for any special working conditions, like deep drilling long chipping material work piece or material that is difficult to machine, we design and manufacture Gun-Drills with special geometries, accordingly. Our present range of Gun-Drills is
of Diameters between 4 and 30 mm., having length up to 1000 mm.
For more information, Website: www.accusharp.co.in
Trouble shooting guide: Problem:
Probable Cause:
Probable Solutions:
Premature drill point wear
Machine vibrations, Loose clamping of the work piece.
1) Check the guide bushes. 2) Improve rigidity of the clamping fixture.
Crater wear
Improper guidance for the drill into the work piece
1) Check the guide hole diameter 2) Improve rigidity of the clamping fixture. 3) Work with reduced feed rate at the start.
Groove marks on the hole
Rubbing of the drill in the hole
1) Increase feed 2) Check filtration quality coolant quality 3) Stop spindle rotations before drill retraction
Hole entry dia. enlarged
Tool set up error
1) Check bushing, guide ways. 2) Improve work clamping more rigid.
Moreover, guidance from our technical experts would always be available for any critical problems other than the above common issues to resolve.
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TECH TRENDS
Safe monitoring of wind turbines
Pilz supplies a safe speed monitor PNOZ s30 to safely monitor the rotor and generator speed, as well as the transmission ratio.
More automation and greater dynamism – the demands on the mechanics and control technology are increasing on wind turbines just as they are in traditional engineering. At the same time it is absolutely essential for plant builders and operators to meet the specifications of the Machinery Directive. Guidelines published by Germanischer Lloyd WindEnergie GmbH (GL Wind) also categorise protection against excess rotor speed as a safety-related function. Safe speed monitors meet these specifications and combine fulfilment of safety requirements with economical operation.
T
he technical development of wind turbines has progressed rapidly over the last few years. Apart from the basic principle of converting the wind’s kinetic energy into electrical energy, the first wind turbines from the 80s have very little in common with today’s megawatt systems. According to the German Federal Wind Energy Association, rated powers have increased tenfold on average in the last decade, while the rotor diameter and hub height have doubled. As plants increase in size, the demands on safety and control technology also increase. A failure of the control technology can lead to a total failure of the wind turbine. This can be hugely damaging for the plant manufacturer or
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operator, not only in a material sense but also in terms of image. Complying with the specifications of the Machinery Directive When designing and building wind turbines within Europe, manufacturers and operators must adhere to the specifications in the Machinery Directive 2006/42/EC: The Machinery Directive has been incorporated into domestic law in Germany via the Product Safety Act (ProdSG) and is therefore binding for wind turbine manufacturers. This Act calls for a comprehensive risk assessment for all of the plant’s lifecycle phases and operating modes and obliges the manufacturer to issue a declaration of conformity in accordance with Annex IIA
of the Machinery Directive. The 2010 edition of the “Guidelines for the certification of wind turbines” from the leading certifier for wind turbines, Germanischer Lloyd WindEnergie GmbH (GL), provides wind turbine manufacturers with a further set of rules that consider the functional safety aspects of control functions. GL names EN ISO 13849-1, Safety of machinery – Safety-related parts of control systems, Part 1: General principles for design, as an appropriate standard for comprehensive fault consideration. EN ISO 13849-1 describes a procedure for classifying safety-related control functions into a relevant Performance Level (PL) with regard to their functional safety. This can be taken as a measure of the safety function’s reliability.
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TECH TRENDS Standard components are not enough On wind turbines, the wind’s kinetic energy is transferred to the rapidly rotating generator shaft via the slowly rotating rotor shaft and gear box. According to GL, protection against excess rotor speed represents a safetyrelated function and is classified as PLd. If an error occurs, standard components cannot guarantee these safety functions with the PLd calculated in the risk assessment. In the event of a failure, the user may receive no feedback about the actual plant status; in this case, the possibility of a hazardous situation for man and machine cannot be excluded. Personal injuries may result and material damage may also occur, leading in the worst case to a total plant failure. The implementation of speed monitoring requires components which maintain a defined failure mode even in the event of an error and which also have the necessary approvals; this applies throughout, from the encoder system to monitoring, through to evaluation and shutdown. Safe reaction to errors Scalable solutions are used for all wind turbine safety functions in order to meet their specific safety requirements. The automation company Pilz from Ostfildern supplies the safe speed monitor PNOZ s30 to safely monitor the rotor and generator speed, as well as the transmission ratio. The speed monitor can be used as a standalone module for safe monitoring of standstill, speed, position, speed range and direction of rotation in accordance with EN ISO 13849-1 up to PL e and EN IEC 62061 up to SIL CL 3. As the speed monitor is able to safely monitor speed ranges and direction of rotation, the unit is suitable for a wind turbine’s speed-related safety functions. PNOZ s30 also has UL/ cUL approval, which is important for international use, and is certified by TÜV. In order to meet the high technical requirements of safety functions, the
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speed monitor PNOZ s30 has a dualchannel control architecture throughout. A standard encoder detects the rotor speed as the first channel. The second channel is represented by a standard proximity switch, which measures the generator speed. With this initiator signal as an additional encoder signal, the standard encoder represents a dualchannel redundant and diverse system. The transmission ratio between the rotor and generator is defined through the gear box and represents the third parameter that is to be monitored. In this way the PNOZ s30 monitors
Pilz provides scalable solutions for a wind turbine‘s safety functions in order to meet their specific safety requirements.
the maximum speeds of the rotor and generator shaft as well as their relationship to each other. Overspeeds and infeasibilities in the encoder signals are reliably detected and the appropriate safe reaction is triggered if necessary. In this way, faults or errors can be detected before they result in damage to the plant, or more precisely the gear box. Save time during commissioning and maintenance The speed monitor provides a userfriendly basic menu and advanced functions. All the information necessary for operation is entered in the menu. The speed monitor is operated via a rotary knob. Used in conjunction with the monochrome display, time can be saved during commissioning and unit exchange, as no separate software is required. The display shows the set limit values and parameters as well as the current speed. It gives the user constant information about the current speed. The parameters for an application are stored on the corresponding chip card and so can easily be transferred from one unit to another. This reduces costs and saves time. What’s more, the parameter data is password-protected and so is safe from manipulation or unintended changes. Application of the new functional safety standards and their implementation presents a challenge to wind turbine designers and operators. The focus is on gear boxes and the associated monitoring of rotor and gear box speeds. Use of the safe speed monitor PNOZ s30 satisfies the GL recommendation for overspeed detection with PLd. Not only does the unit fulfil the safety-related requirements, it can also react quickly to any deviations. In this way, fault or error sources can be identified early, costly downtimes can be minimised and the service life of the plant can be extended. For more information, Website: www.pilz.in
TECH TRENDS
Inter-stage Membrane Dryer: Lower Life Cycle Costs, Zero Maintenance
H
ow a submarine dives into the deep sea and re-surfaces is a question of simple physics. And aiding in this function is air compression technology. The vessel floats on the surface when the weight of water it displaces equals its own weight. This displacement of water creates an upward force called buoyancy that opposes the downward acting gravity. Since a submarine can control its buoyancy, it can submerge and re-surface. A submarine controls its buoyancy with the help of its ballast tanks; these tanks are filled with water to increase the overall weight of the submarine, thus allowing it to submerge. And when that water is pumped out by displacing it with compressed air, its weight is reduced and the submarine re-surfaces. So by either flooding the ballast tanks or venting it, the submarine can dive or rise. But compressed air is required not just for charging ballast tanks to change buoyancy but also for life support. A constant supply of compressed air is therefore maintained on board in large steel pressure vessels called air flasks. Clearly, the air compressor is a critical piece of equipment on board a submarine. However, storing a large amount of compressed air alone is not enough; that air also needs to be dry in order to ensure safe operation. Compressed air at a high
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pressure enters ballast tanks through a blowing valve. And since the air gets throttled in the process, its temperature drops substantially. If there is moisture in the air, there are chances of that moisture freezing in air passages or in the blowing valve itself. Hence in the humid marine environment, maintaining air quality is crucial not just for diving and rising but also for engine controls, weaponry and various other control systems. Compressed air is therefore maintained at a minimum of -20o C at atmospheric dew point. Failure to do this resulted in the sinking of the USS Thresher, a US navy nuclear submarine in 1963. The vessel sank as the presence of moisture in the compressed air led to icing in the blowing valve. Following this disaster, the usage of air dryers on all submarines has been made mandatory the world over. However, the traditional absorption technology that is widely used in air dryers has its disadvantages. The desiccant granules in dryers turn into clay or become powdery over time that need to be replaced periodically. J.P. Sauer took up this challenge and developed a high pressure dryer with a membrane that efficiently separates water vapour from an air stream. The membrane consists of thousands of hollow fibres bundled together. As moisture-laden air flows through the membrane, it travels
through and around the hollow fibres. The fibre bundle is enclosed in a long tubular container that ensures efficient flow of air. Moisture is removed by selective permeation and dry air exits at the opposite end. The dryer is fitted before the final stage of the compressor and hence the name Inter-stage Membrane Dehydrator (IMD). It improves the life of final stage valves and piston rings. This new technology is also cost effective. Another big advantage of IMD is that it is maintenance free throughout its service life, except for periodic replacement of the pre-filter element. These coalescing pre-filters installed before the membrane dryer remove the bulk of the water vapour and any trapped compressor oil. Since the IMD does not need electricity, it is ideal for use in remote applications. Moreover, since it has no moving parts, it is also ideal for heavy duty installations and work efficiently in harsh environments including shipboard systems and power plants. Its initial cost is higher than a desiccant dryer but its overall life cycle cost is far below other dryers that offer the same air quality.
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MARPOSS INDIA Pvt. Ltd.
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TECH TRENDS
Higher Precision for Machining Centers in Automated LargeBatch Production
A
utomobile customers demand a variety of vehicle types and engines in accordance with highly diverse framework conditions, asking about differing vehicle sizes, motor types or engine power within the individual markets, depending on fuel costs, emission standards and tax measures. For automobile manufacturers this hampers any estimation of quantity progressions or capacity planning and the design of production lines. To meet customer needs, automobile manufacturers offer engines with the same number of cylinders but in differing performance classes, which also leads to an increase in variant diversity. Ever shorter vehicle product life cycles in combination with volatile markets therefore lead to changed production challenges for automobile manufacturers [1]. To meet such challenges, the aspect of flexibility is added to the classic production parameters such as quality, time and costs. For production lines for the machining of vehicle powertrain components (engine, transmission and axle components), this means departing from classic transfer lines with fixed timing and high productivity, and adopting lines with linked machining centers and higher levels of flexibility. In addition to the challenge of responding to fluctuations in demand in automotive sales markets, the future will also bring increasing legislative and end-user requirements regarding the emission of pollutants and fuel consumption of vehicles. One approach to dealing with such a situation consists of reducing friction in the powertrain, which in most cases would lead to increased quality requirements for the components
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Figure 1: Cylinder head machining in large-batch production (photo: MAG IAS GmbH)
to be produced. The interlinked machining centers used in production lines also have the task of implementing the demands of manufacturers in process-safe ways with large vehicle quantities (see Figure 1). The use of linear encoders in Closed Loop control in the feed axes of the machining centers contributes to meeting such diverse requirements. From transfer lines to linked machining centers Greater flexibility for variants, machines and capacity Transfer lines lack adaptability Because individual stations within a transfer line are designed for machining specific workpieces, these fixed, chained lines cannot be simply expanded by adding additional stations. To make available the maximum planned capacity requirement, it is therefore necessary to implement the main part of production line investment at the start of production (SOP). Because quantities slowly increase (line ramp-up) at the beginning of production or fall away (line ramp-down) at the end of the product lifespan, excess
production capacity is the result (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 is aimed at
TECH TRENDS have an advantageous chip fall, whereby less cooling lubricant or even minimum quantities of lubricant (MQL) are used to wash chips. Such machines can also be variably automated via easy front or top loading for workpiece supply, enabling use of the same machine model for various production lines even with different loading systems. Double-spindle machines, with only slightly larger support base areas, are sometimes used due to their higher productivity (see Figure 1).
Figure 2: Quantity flexibility—capacity availability vs. capacity needs [4]
expanding the production system with as much cost-efficiency as possible [2]. As a consequence, the large-batch production of vehicle powertrain components is now distancing itself from transfer lines and is increasingly adopting machining centers or transfer centers [3]. The increased flexibility of linked machining centers is directly related to the require-ment for highly rapid and economic re-sponses to fluctuations in demand. As an example, one demand is that differing vari-ants of a workpiece should be machined on the same production line without need-ing to adapt the setup (variant flexibility). Another approach is using additional machines to simply expand production lines. This could be called reuse flexibility, as the use of standard machines and their standardized linking enables simplified integration and reuse of such machines in other production lines. If line capacity is seen with respect to the complete lifespan of a manufactured workpiece, the fluctuations in demand outlined above also lead to differences between capacity needs and capacity availability in the production line. While with transfer lines only comparatively large jumps in production capacity can be achieved, production lines with linked machining centers enable capacity to be increased in smaller steps at production ramp-up. Such production lines can also
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be decommissioned again thanks to their high flexibility at production rampdown [4]. Figure 2 shows a step-by-step investment during the ramp-up phase of a workpiece to be produced, and the reduction in the ramp-down phase (quantity flexibility). Figure 3 shows an example of a production line layout for the mechanical machining of a powertrain component. The machining centers are illustrated linked by gantry load-ers and grouped into individual machining operations. A machining operation there-fore consists of several machining centers operated in parallel with the same process-ing content. Advantages of horizontal machining centers Horizontal machining centers are usually used for production purposes, and they
Features of large-batch automotive production In summary, the following characteristics for machining cubic workpieces in largebatch automotive production can be identified as follows: • Automated production with linked horizontal machining centers • One machine operator supervises eight to fifteen machines • A machining operation usually consists of several identically built machining centers operating in parallel with identical processing content • A workpiece is machined sequentially across several machining operations • A single workpiece is produced with several machining centers, meaning that several centers are responsible for tolerance conformity of the workpiece The last point in particular makes clear that the produced tolerances of a workpiece depend on the individual machines or sub-processes of the entire production sys-tem. In contrast to die and
Figure 3: Example of a production line for large-batch manufacturing (photo: MAG IAS GmbH)
TECH TRENDS mold production where workpieces are produced on one machine and supervised by a single ma-chine operator, with 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. Cubic powertrain components Machining process and tolerances The powertrain of a vehicle can be separated into engine, transmission and axle modules [1], and these modules in turn consist of further component groups such as the valve train and its components. The cylinder head, crankcase and transmission housing are examples of classic cubic components in powertrain production. Because of high quantities and related cost-efficiency, workpieces are normally manufactured to near net shape before mechanical machining. This means that the primary geometry of workpieces is already predetermined by the casting or forging process, e.g. when forging connecting rods or crankshafts, and this is reflected in the machining operations for cubic workpieces [5, 6]. Focus on drilling Figure 4 shows the machining operations for a cylinder head. Milling is relatively
low compared to drilling or similar machining, and this is understandable because the primary geometry of the workpiece has already been cast, apart from a few areas. Specified holes in castings, however, are manufacturable only at high cost or are not possible at all for complex geometries. They have to be integrated into the mechanical produc tion line using drilling opera-tions, so that their share of the machining process clearly predominates. The various machining operations also enable conclusions about the axis movements required for machining. Because of the drilling operations, most of the move-ments consist of positioning the tool to the workpiece and a single-axis feed and re-traction motion. And because the work-pieces usually have no free-formed sur-faces, during milling operations the motion in the working plane (via traverse in two linear axes) is sufficient in addition to a positioning motion. The predominant number of geometrical tolerances on the workpiece to be pro-duced is therefore determined by the majority of drilling operations required. In addition to diameter tolerances mainly influenced by the dimensions of the tool, such as reamers, workpiece drawings also contain tolerance specifications for position,
Figure 4: Machining operations & their share of the manufacture of a cylinder head [5]
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Figure 5: HEIDENHAIN linear encoder in a horizontal machining center
distance and hole depth. Linear axes determine dimensional accuracy Complying with specified tolerances is determined among other factors by the capability of the linear axes of a machine tool to achieve precise positioning (Figure 5). Depending on the workpiece or set of drawings, differing tolerance values and tolerance divisions for production features may exist. Figure 6 shows the distribution of tolerance (position, distance and depth tolerances) for a crankcase. The example shows that somewhat more than 30 % of the toler-ances analyzed are ≤ ±0.1 mm, and production features also exist on cylinder heads and transmission housings with tolerances of ≤ ±0.1 mm required by the designers. Examples are the position and depth tolerances of drill holes in the area of a cylinder head valve train as well as the bore axis distances of the main and neck bearing axes on a differential housing. Reliably complying with tight tolerance values To achieve the above-specified need for improved flexibility, producers make it their goal among other things to use standard machine tools in manufacturing, making it unnecessary to use additional specialized machines for individual production dimensions. This in turn means that, even if tolerance values are ≤ ±0.1 mm, they must still be complied with in a safe and reliable way with the machining centers installed in the production lines.
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TECH TRENDS drawing dimensions s = standard deviation
Figure 6: Distribution of position, distance and depth tolerances for a crankcase
Cubic powertrain components Capability analyses supply specifications for machine capability and process capability The tolerance values specified previously seem large compared to requirements in the die and mold production sector. It must be considered, however, that values for automotive workpieces initially correspond to the designer’s drawing specifications. Automotive manufacturers carry out statistical capability analyses on the machining centers to make sure that the machine tools and implemented production processes are capable of meeting requisite drawing tolerances over a long period with a defined safety margin to the tolerance limits [7].
pro-vides knowledge about the temporary scat-tering behavior with tolerances produced by a machine tool subjected to constraints that are as constant as possible (≡ short-term testing). The process capability aims to determine the long-term scattering be-havior of a machine under process con-straints (≡ long-term testing). See [7] for equations for calculating the indices based on the measured tolerance values of pro-duced workpieces, as well as for further information. Equation 1 specifies the variables Cm & Cp: Cm,Cp = T / (6 ∙ s)
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Target: Minimum scattering For uniformly high workpiece quality and minimum scrap rates, the target is to achieve lowest levels of scattering with tolerances produced, and therefore low deviations from the standard. Equation 1 can therefore be construed as follows: Cm,measured = T / (6 ∙ s) ≥ Cm (equation 2) or 6 ∙ s ≥ T / Cm (equation 3)
(equation 1)
T = tolerance range in accordance with Capability tests for machine & process For acceptance testing of the machine tools, 50 workpieces, for example, are pro-duced on the system or single machines and the distribution of produced tolerances is then evaluated using statistical methods. Capability specifications or capability indi-ces are defined for the capability tests. To determine the machine capability the indices Cm or Cmk are defined, and for recording process capability the indices Cp or Cpk. The indices Cmk and Cpk take into account a non-central distribution of measured tolerance values captured on several workpieces. Determining the machine capability
Manufacturers specify capability indices for the quality-relevant tolerances, and production machines supplied by the machine tool builder must at least achieve these during acceptance testing. With regard to the acceptance test, determining the indices leads to a further limitation of tolerance values specified in the workpiece drawing. Figure 7 demonstrates this with the example of a tolerance of T = ±0.1 mm under consideration of the machine capability specification Cm. Automotive manufacturers also specify feature classes for tolerance that are critical (Cm = 2.00), important (Cm = 1.67) or less important (Cm = 1.33) in relation to component functionality.
Cm,measured corresponds to the index derived from measuring a tolerated dimension
Figure 7: Correlation between the drawing tolerance specification & capability index Cm
TECH TRENDS on e.g. 50 workpieces produced during machine acceptance and the standard deviation calculated from them. Capability tests check compliance with maximum acceptable scattering Equation 2 demonstrates that the capability index resulting from the measurements becomes greater the lower the standard deviation is. The value (Cm,measured) from measurements on the workpieces must be greater or equal to the value of Cm specified by the manufacturer. If this is taken into account, specifying a capability index corresponds to specifying the maximum acceptable standard deviation by the man-ufacturer for a tolerated dimension (equa-tion 3 and Figure 7). For the example in Figure 7, with Cm = 1.67 this means that for the original tolerance of ±0.1 mm, 99.73 % of all tolerance dimen-sion values measured on various workpiec-es must be in the range of ±0.06 mm. As a consequence, the acceptable standard de-viation must have a maximum value of only ±10 µm. Achieving such values is a signifi-cant challenge for the linked machining centers in large-batch production.
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Error limits for machining Flaw sizes in the process and their effects The previous pages outlined the order of magnitude of tolerances on workpieces for vehicle powertrains. The question arises as to the percentage of available tolerance of a production feature that flaw size arising in the process depletes. If the total flaws are greater than the available tolerance, the machine tool or process cannot fulfill the specified machining task. In the following, the error limits that can occur on a machine tool e.g. due to workpiece clamping or thermal drift behavior on axes are therefore estimated, and the aim is to estimate the residual tolerance reserve by comparing the available tolerance with the existing error limits. This reserve enables the machine tool or process to compensate for unpredictable or difficult-to-control production influences. Index tolerance of workpiece clamping The loading of machine tools is usually automatic, using special loading modules such as gantry loaders. Before a workpiece is machined, it needs to be positioned and fixed in the clamping fixture of the machine, and because this must be carried out without manual intervention, positioning is usually done by index pins in the clamping fixture. This means that the mechanical fitting tolerance between the index holes of a workpiece and the index pins of the clamping fixtures in the production line must be considered. According to the drawing specifications, identical tolerance for the index holes is available for each workpiece produced on the production line, but the actually produced dimension varies from workpiece to workpiece. This also applies to the individual index pins of the clamping fixtures. As a result, constantly identical indexing deviation cannot be expected. The specified maximum tolerance ranges for the index holes and index pins should, however, be complied with in each case as rejects will otherwise be produced. This makes it possible to estimate an error limit.
With the above-specified cubic automotive powertrain components (cylinder head, crankcase, transmission housing), index holes with a diameter of 12 mm are often drilled. Clamping of the workpiece within the indexing pins is not desired because this can lead to excessive loads on the loading systems or workpiece clamping errors, and therefore to possible idle times in the production line. To avoid this, a transition fit of Ø 12 H7/js6 is assumed in the following. These specifications achieve the following maximum error limit for workpiece indexing in the clamping fixtures:
To manufacture features with tight tolerances, the workpieces are sometimes moved in a defined direction using thrust cylinders in the clamping fixture prior to clamping. This means the workpieces are radially pressed onto the index pins, so that from the central drilling axes only a maximum of half the error limit occurs (≡ ±5.88 µm). Because sliding units often make clamping fixtures more complex and therefore more expensive, they are not integrated in all machining stations. Tool change tolerances On the tool side, inaccuracies also occur during tool changes and depending on the tool interface used. In the machining centers of the above-specified production lines, main spindles and tools with hollow taper shank interfaces are normally used. In [8], the predominant repeatability of the hollow taper shank connection is specified as < 1 µm (axial) & < 3 µm (radial) (≡ ±0.5 µm axial; ±1.5 µm radial).
[ To be Continued in Next Issue. ] Courtesy: Heidenhain India Website: www.heidenhain.de
TECH TRENDS
Welding & The Automobile Sector
T
he Automotive Industry is one of the largest in the world and accounts for 7.1 per cent of the Indian GDP. At around USD 93 billion it amounts to approx. 30% of the turnover of the manufacturing sector and is a very important component of Indiaâ&#x20AC;&#x2122;s growth story.India manufactured more than 25 million automobiles in FY17 and is a prominent auto exporter with strong export growth expectations for the near future.
ADOR - GTAW inverter ChampTig 300AD And Champ Pulse 500
Around 47000 crores have been pumped into the auto industry in the last year alone and that is nearly a third of the current Indian automotive market. Car makers, both domestic and foreign, have lined up investments of almost $10 billion or nearly Rs. 60,000 crore over the next few years. Several initiatives by the Government of India and the major automobile players in the Indian market are expected to make India a leader in the two and four Wheeler market in the world by 2020. The Government plans to promote eco-friendly cars in the country i.e. CNG based vehicle, hybrid vehicle, and electric vehicle and also made mandatory of 5 per cent ethanol blending in petrol. Reductions in the workforce over the last several years have left the industry with fewer employees to monitor welding operations and the overall shortage of skilled welders has compounded the challenge. Whereas 10 years ago a large automotive supplier may have had one welding technician for 20 robots, today that ratio has increased to as few as one welding technician for every 50 robots â&#x20AC;&#x201C; or more. The most commonly used welding methods for automotive applications include resistance spot welding , resistance seam welding , metal inert gas (GMAW) welding, tungsten inert gas (GTAW) welding as also laser beam welding (LBW), friction welding (FW), and plasma arc welding (PAW). Ador Welding Offers a plethora of solutions through it wide range of Welding consumables, Welding equipment , Welding Automation, Plasma and Gas CNC based cutting systems encompassing most of these processes: Auto- Exhaust applications: The use of stainless steels in automobiles started when automobiles came to be equipped with 3 way catalytic converters to meet intensifying regulations over exhaust gas emissions. The requirement
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to have longer service life accelerated the switchover from hot dip aluminized carbon steel to stainless steel in this application. Today, stainless steel is used in almost all exhaust system parts from the cylinder head gasket to the tail pipe. The consumption of stainless steel in the exhaust system per passenger car varies from model to model but averages about 15kg per car. The stainless steel consumption is expected to increase in the exhaust system of diesel powered automobiles, mainly trucks, to meet the growing social demand for stricter exhaust gas emission regulations. Exhaust system materials are exposed to a variety of harsh conditions, and must be resistant to such degradation mechanisms as high temperature oxidation, condensate and salt corrosion, elevated temperature mechanical failure, stress corrosion cracking, and inter-granular corrosion. The exhaust gas emitted from automobiles is one cause of air pollution, and various efforts have been made to prevent this problem. One of the preventive measures is the system shown in the figure. The components downstream from the muffler of an exhaust system must have sufficient corrosion resistance to withstand the internal attack of condensed water containing these corrosive ions and external attack of these salts. The materials mainly used for these components are low-carbon ferritic stainless steel incorporating not less than 11% chromium. The components nearer to the engine in front of the muffler need high oxidation resistance, because they are heated to about 773K (500 ) during operation. The
Axle Welding Automation setup from ADOR
TECH TRENDS exhaust manifold, which is heated to the highest temperature, must possess both high-temperature strength and resistance to thermal fatigue. High-chromium stainless steel is now used mainly for these upstream components. As a result, the life of the exhaust system has been substantially extended. Stabilized ferritic stainless steels represent the best cost / benefit solution for exhaust system components: it gives designers optimal combinations that work both in elevated temperatures and complex corrosive environments. The exhaust system components are manifold, close coupled and underbody catalytic converters, flexible bellow, muffler, resonator, connecting pipes, flanges, and tailpipe. The part of the exhaust system containing the manifold, converter and the flex joint is named as hot end since this part of the system is relatively hot due to the hot exhaust gas passing through these components. The part consists of intermediate pipe, resonator and the muffler is named as cold end since the gas tends to cool down from the exit of the flex tube. The temperature of the hot end of the gasoline operated vehicle can be as high as 1050°Cwhile the highest temperature of the cold end is about 650°C. There are benefits of Nb regarding oxidation resistance at high temperatures. It has been demonstrated that Nb containing ferritic grades have better high temperature performance when compared to Ti single-stabilized or austenitic grades.
Stainless Steel and Carbon Steel plasma cutting systems:
shielding gases 98Ar+2O2 and 1-5CO2 mixed with Ar.
Resistance Spot Welders from the ADOR stable:
This is because Nb forms a thin, homogeneous and adherent oxide layer in the surface of the steel, avoiding spalling and reoxidation of the material during the exhaust system thermal cycling (the typical on/off operation of the car’s engine). It also results in lower loss of material which can be translated into higher life cycles of the component, meaning a longer life, reduced frequency of replacement and long term cost savings. Study on metal loss of different stainless steels at 950°C shows that with increase in Nb content, higher temperature oxidation resistance improves as Nb forms less porous and more adherent oxides which results in less spalling and less re-oxidation. ADOR offers comprehensive solutions Auto Exhaust Applications: Solid wire for GMAW welding: Miginox 430LNb : • Superior wire of unique chemistry stabilized with Nb. • Minimizes the consumption of nozzles and avoids the excess of projections during welding. • Best welding performance with
GMAW & Metal cored wires from ADOR for auto exhaust applications:
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Autoweld 400 : • Ferritic Stainless Steel solid wire. • High corrosion and heat resistance. • Suitable for joining and cladding of typical 17% Cr steels. • Best suited for ferritic martensitic chrome steels. Metal cored wire: Metal cored wires offer higher productivity in terms of higher welding current densities and hence higher welding speeds. It gives much higher range of welding parameters to weld without the danger of burn through. The above comes with an additional advantage of better root gap bridging ability. The above point is best illustrated in the graph below. Miginox MC 409 : • Ti stabilized metal cored wire that gives minimal / no slag. • Operates at higher current densities. • High deposition rate gives very good productivity. Both the solid and metal cored wires are supplied in layer wound condition in plastic spools with 12.5 / 15 kg wire per spool. ADOR evolves continually to meet the latest needs of the industry in its relentless pursuit of excellence.!! (Contributed by Ador Welding Ltd.)
Linear solutions global provider.
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ROLLON India Pvt. Ltd. - INDIA 1st ďŹ&#x201A;oor Regus Gem Business Centre 26/1 Hosur road, Bommanahalli Bangalore 560068, INDIA www.rollonindia.in - info@rollonindia.in
Linear Line
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Rollon is a global provider of linear motion solutions for several industrial sectors, such as: industrial machines, railway, automation, packaging and logistics, aerospace.
TECH TRENDS
Manufacturing gets “Smarter”
K Sudhakar, General Manager, MAC Machine Tools and Automation
A
ccording to IHS (an independent research organisation), in 2015, there were about 15.4 billion connected devices which will grow to 30.7 billion in 2020, and 75.4 billion by 2025. Products like industrial sensors, connected manufacturing machines, in-store analysis devices and workspace management applications will fundamentally transform manufacturing into ‘Smart Manufacturing’, driven largely by the fear of falling off on the wrong side of the divide between the ‘haves and have nots’ of digital manufacturing. What are the Challenges Indian manufacturers face? While almost every manufacturer has a vision to have a smart factory using various solutions of IIOT, they say that the ‘implementation’ of their goals is by no means an easy feat. The two factors challenging the implementation of a Smart Factory are: one, the plethora of electronic devices, protocols and IT infrastructure in the shop floor that are currently functioning require a unified plan for a secure connection to the enterprise and two, to have the IT teams and resources that develop a connect and convergence plan with the plant OT infrastructure which is isolated from corporate IT infrastructure.
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What’s the strategy that customers are deploying Customers have a myriad of options and are fully aware that they can’t go with a ‘one size fits all’ approach. One major step that customers have taken is a stronger collaboration between their operations teams and the IT teams. The IT teams work closely to identify the operational team requirements and strategize along with engineering teams to develop the IIOT strategy. So, manufacturing companies now want a two-pronged approach to this strategy. 1. Develop a unified platform that connects the two worlds of the shop floor and enterprise in a secure fashion and expose all the information required in a unified format. 2. Use this data / information from remote or in site to present it to various stake holders, MES systems and ERP systems. In partnership with Rockwell Automation and its alliance partners like CISCO, MAC Machine Tools and Automation offers IIOT and Smart Manufacturing solutions as a Platform Provider. MAC has partnered with various specialised integrators in the Control and MES domain to help customers implement their IIOT strategy. Connected Enterprise Smart manufacturing is the gateway to digital transformation. Connected smart devices open new windows of visibility into processes, data & analytics which enable better and faster decision making. Connected Enterprise converges plant-
Microsoft Slide Share Presentation (Slide No 5) by Marlon Luz
level enterprise networks & securely connects people, processes, & technologies Shop Floor Management & Improved Production Manufacturing Execution Systems (MES) provides standardized workflows to operators to ensure the highest possible production quality and regulatory compliance. By modelling your manufacturing process to drive out variability, MES can provide protection against loss of intellectual property. In addition, MES propels continuous improvement initiatives by providing new ways to analyse process data. It also connects your enterprise by closing the information loop from execution through data management. It is scalable and offers standard application library suites for common functions in the pharmaceutical, consumer packaged goods and automotive industries. A Secure Shop Floor Protect people, machinery and environment through Integrated Smart Sensors which provide a continuous flow of data to controllers, enabling operators to make better decisions in real-time. With Smart Sensors available for many applications - from pressure to temperature, motion to distance, level to flow and many more, users have a comprehensive view of their equipment and can quickly address issues that occur. Quality control Today, manufacturers rely on a myriad of quality management software programs and paper-based processes to achieve consistent production quality. The new Rockwell Software Quality Management application is an out-of-box, comprehensive quality management solution that allows manufacturers to easily model and enforce their plants’ in-process quality regimens. With this solution, customers can remove disparate systems and antiquated paper processes to help reduce the cost of quality compliance.
The new control system PNOZmulti 2 with up to 80% less energy consumption …
… than comparable products. The power consumption of the new base unit PNOZ m B0 is a minimal 0.8 W with 20 safe inputs and 4 safe semiconductor outputs (PL e, SIL CL 3) and a width of just 45 mm. Rely on 10 years of innovation from the market leader in safe control technology! Count on the configurable control systems, the worldwide safety standard for all machine types. The simple, graphics configuration tool saves engineering costs because you can create your safety circuit simply and intuitively on the PC. Visit us at the Hannover Messe, Hall 9, Stand D17.
Further information about the PNOZmulti Configurator: www.pilz.com + Web code: web10522
Pilz IndiaPvt. Pvt.Ltd Ltd Pilz India 201, Shankar Seth Road, Pune - 411Sahakar 042 Nagar NO 1, Pune - 411009 Office‘CYBERNEX’, NO 102 & 202, Delite Square, Near Swargate, Aranyeshwar Temple, Telephone: +91 (0) (0) 20 20 49221100/101/102, Fax(0) +9120(0)24213996, 20 49221103, www.pilz.in, info@pilz.in Telephone: +91 24213994/95, Fax +91 Web: Web: www.pilz.in, Email: Email: info@pilz.in
TECH TRENDS
Precision of a new generation
Eddy current displacement sensors from Micro-Epsilon occupy a special position amongst inductive displacement sensors. Insensitive to environmental influences such as temperature, pressure and dirt, they measure displacement, distance and position with high accuracy. The compact eddyNCDT 3001 model now offers even larger measuring ranges, thereby opening up new fields of application.
E
ddy current sensors from MicroEpsilon are unique among inductive measuring techniques. They provide reliable measurement results even in harsh, industrial environments at the highest precision and high bandwidth. Measuring via eddy current is based on the extraction of energy from an oscillating circuit. This energy is needed for the induction of eddy currents in electrically-conductive materials. Here, a coil is supplied with an alternating current, causing a magnetic field to form around the coil. If an electrically conducting object is placed in this magnetic field, eddy currents are induced which form a field according to Faradayâ&#x20AC;&#x2DC;s induction law. This field acts against the field of the coil, which also causes a change in the impedance of the
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temperature ranges. As eddy current penetrates insulator materials, even metal behind an insulating layer can be used as a measuring object. Even dust, dirt and oil do not affect the measurement. This immunity combined with the sensorâ&#x20AC;&#x2122;s robust, temperatureresistant design enable highly precise measurements in harsh, industrial environments. coil. This impedance can be calculated by the controller by looking at the change in the amplitude and phase position of the sensor coil. The principle can be used for measurements of all electrically conductive materials. The special coil wrapping of the Micro-Epsilon sensors enables very compact sensor designs, which can still be used across high
Inductive sensors based on eddy currents now offer even more flexibility The eddyNCDT 3001 series is specially designed for applications where conventional, inductive displacement sensors have often reached their performance limits. Their compact dimensions have to date only been
TECH TRENDS reserved for inductive sensors and proximity sensors. This compact sensor with integrated electronics stands out due to easy operation. In addition to the M12 housing, the powerful eddyNCDT 3001 eddy current sensors are now also available with an M18 housing covering measuring ranges from to 2mm to 8mm. These ranges open up new areas of use. The sensors are protected to IP67 and so are universally applicable in automation, machine building and machine design. Furthermore, these sensors are temperature-compensated up to 70°C. As the sensors are easy to use and provide an excellent price/performance ratio, they are particularly suitable for high volume and OEM applications as well as for salt water in offshore/marine applications. The high measurement accuracy and linearity as well as the high frequency response rate of 5 kHz are outstanding characteristics compared to conventional inductive sensors in the same price class. eddyNCDT sensors are factory-calibrated for ferromagnetic and non-ferromagnetic objects such as aluminum and steel. Customer-specific adaption to other materials is also possible. Oil gap in hydrostatic bearings Eddy current displacement sensors are for example used in large plant and machinery such as stone mills or telescopic installations which often work with hydrostatic bearings. These bearing systems are continuously supplied with liquid lubricant via an external pressure supply. The lubricant is pressed between the bearing surfaces, which are therefore continuously separated from one another
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by a thin lubricant film. The bearing surfaces are not exposed to any friction and hence operate wear-free. This enables sub-micrometer position control. Any disturbances in the hydraulics or pressure drops can have disastrous consequences, which could result in damage to the bearings and ultimately system failure, causing high maintenance and repair costs. The oil gap in hydrostatic bearings must therefore always be inspected reliably, which is possible by using the eddyNCDT 3001 eddy current sensor. The compact sensor is mounted horizontally to the bearing shoe and so is not directly exposed to oil pressure in the bearing. It measures through the oil film onto the opposing bearing surface. eddyNCDT 3001 sensors are easy to install and so are also suitable for ageing plants that need to be retrofitted. Micro-Epsilon has developed the eddyNCDT 3005 for integration into plant and machinery. The eddyNCDT 3005 is a new, powerful eddy current measurement system for fast, high precision displacement measurements. It provides ease of use and high measurement accuracy, offering an outstanding price/
performance ratio. Therefore, the sensor is ideally suited to OEM integration and mechanical engineering applications. The system comprises a compact M12 controller, a sensor and an integrated cable and is factory-calibrated for ferromagnetic or non-ferromagnetic materials. eddyNCDT 3005 sensors and controller are temperature-compensated, which is why high measurement accuracies can be achieved even in fluctuating temperatures. The sensors are designed for ambient temperatures up to max. +125°C but can optionally be custom engineered for temperatures from -30°C to 180°C. The measurement system is pressure-resistant up to 10 bar. Where high volume orders are required, customer-specific designs can be tailored to suit individual requirements. Unconditional precision eddyNCDT sensors offer extremely precise measurements and are used where micron accuracies are required. Being used in ambient temperatures from -40°C to more than 200°C, the eddy current displacement sensors are robust against temperature fluctuations.
TECH TRENDS
Central drive â&#x20AC;&#x201C; the new assembly from Junker
In the cycle of time - Precise and efficient parallel grinding process The central drive with center clamping chuck is taking over the centering and driving of the workpiece, e.g. hollow shafts for DCT transmissions. (Quelle: Junker)
C
ustomers need ever more technologically sophisticated but at the same time economical solutions. Central drive â&#x20AC;&#x201C; the new assembly by JUNKER. The central drive is a special drive system which clamps the workpiece in the center and drives it via a servomotor. This enables both workpiece ends to be ground simultaneously. The central drive is available in two different versions. First of all, one for crankshafts which are positively driven at the web contour. As a result the central drive replaces the driver (jaw chuck) and subsequently permits the parallel grinding of the flange and journal. Furthermore for workpieces which have a bearing point in the center.
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In this case, the central drive, with precision power chuck, is taking over the driving and guiding the workpiece. Depending on the workpiece contour, this enables simultaneous grinding of inside diameters, face ends and outer contours (outside diameters) of the workpiece, guaranteeing short cycle times and perfect correlation to the clamping diameter. The central drive is currently used on JUNKER platform 6 machines. Current applications: Crankshafts, gearshafts and gears. Our knowledgeable sales team is looking forward to provide you with additional information on the new assembly.
The central drive is a driving unit which is driving a crankshaft positively via a web contour. (Quelle: Junker)
FOR A COMPLETE HEALTH CHECK-UP OF YOUR ELECTRICAL EQUIPMENT
FIND THE PROBLEM… BEFORE THE PROBLEM FINDS YOU. • Thermal Cameras • Clamp Meters • Multimeters • Non-Contact Voltage Detector • Moisture Meters • Flex Clamps
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Images for illustrative purposes only.
Just like the human body, electrical equipment require a complete examination to identify any glitches. Whether the process is of installation, maintenance or repair, Extech’s testers and meters are always up for the task. To ensure smooth operation of your electrical equipment, Extech offers a wide range of test instruments that help you identify a problem before it occurs.
For more details call us on: +91-11-4560 3555 or write to us at flirindia@flir.com.hk
For more details call us on: +91-11-4560 3555 or write to us at flirindia@flir.com.hk
FLIR Systems India Pvt. Ltd. 1111, D Mall, Netaji Subhash Place, Pitampura, New Delhi – 110034 Fax: +91-11-4721 2006 | Webiste: www.extech.com
FLIR Systems India Pvt. Ltd. 1111, D Mall, Netaji Subhash Place, Pitampura, New Delhi – 110034 Fax: +91-11-4721 2006 | Webiste: www.flir.in
Extech Electrical & Find Problem Ad 18x25.indd 1
21/09/17 5:46 PM
TECH TRENDS
Total Thermal Vision for High Pressure Die Casting Machines Importance of controlling the surface temperature of Die
T
hermal Vision is an innovative technology for real time monitoring of the thermal map of a die surface for high pressure die cast processing of light alloys; a growing process in the automotive sector, which is strongly committed to reducing the weight of structures for improved fuel economy. The goal is to assist our customers in achieving the highest quality in their casting processes to meet the most rigorous demands, while providing, at the same time, an optimum die process monitoring solution together with best practice in die lubrication. Our equipment provides the key to efficient part quality and machine control in applications where thousands of die casts are performed monthly. A thermal map of the die surface is created by integrating infrared thermographic cameras in the machine, thereby making it possible to optimize the lubrication phase during the die casting cycle, and to obtain a deep knowledge of the process Conditions Die surface temperature is crucial for high quality, efficiency and faultless processes. A majority of defects in die casting
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processes, such as shrinkage, porosity, cracks, and blisters, is caused by an outof-control die temperature. To nip casting problems in the bud, it is mandatory to monitor, in real time and without interruption of the production cycle, the die temperature surface and related spray effect. High or cold die temperatures have a negative impact on tool life, start up and cycle time, as well as energy consumption and maintenance costs due to unnecessary use of thermal regulation, air pressure, and/or water based lubricant blow.
Solution Total Thermal Vision is a proven infrared thermography solution to capture and visualize the thermal map of the die surface. Years of experience and multiple applications in operations worldwide make TTV the optimal solution to increase die casting quality and overall equipment effectiveness (OEE). At the core of the equipment are the high performance IR sensor and image elaboration devices, both protected by a cylindrical stainless steel housing. Germanium glass (transparent to IR), protected by an air operated shutter and an air cooling system, allows the cameras
to operate in the aggressive foundry environment. Simple installation into machine and the friendly human interface allow casters to have immediate overview of die surface temperature distribution, without process interruptions. Max and Min surface temperature of Regions Of Interest (up to 10 R.O.I.s) of both half mold, trends and related alarms presented on the screen allow the operator to take appropriate countermeasure in the tool temperature setting and/or spraying optimization. Single images are stored for post process “big data” analysis, die programs archive, part ID and history, making TTV the unique die surface monitoring solution for advanced die casting production in modern foundries.
Benefits • Optimization of cycle time, thanks to spray lubrication and minimized tool cooling • Increased machine efficiency, thanks to reduction of production start time (warm up) • Increased die lifespan, thanks to optimal die surface temperature • Higher part quality, thanks to data analysis to set processes and a corresponding reduction of scrap • Cost savings due to less lubricant consumption and waste water • Better analysis of process failures to enable taking countermeasures and improving machine efficiency • Increase of production time due to minor and uncontrolled process stops • Process & part identification history.
TECH TRENDS
HxGN SMART Quality The online software platform for quality data and measurement resource management
Whether installed on a single production line, throughout a manufacturing plant or across multiple sites of an enterprise, HxGN SMART Quality’s tools for connectivity, statistical analysis and resource management enable businesses to take control of their data and work smarter
H
xGN SMART Quality from Hexagon Manufacturing Intelligence is an online quality data and measurement resource management software platform that brings information automation to quality management. The HxGN SMART Quality
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platform enables you to harness the quality data stream across multiple phases of manufacturing, providing knowledge through comprehensive statistical analysis, visualisation and workflow management, and enabling process optimisations that increase the competitiveness of your manufacturing business. Using technology proven in the ultra-efficient automotive industry, HxGN SMART Quality structures data intelligently to give deep insight into production and helps accelerate your continuous improvement process. The remotely accessible web-based HxGN SMART Quality platform enables users at various levels of the organisation to manage quality requirements along the product lifecycle in virtually real-time, allowing you to achieve a smart, data-driven approach to manufacturing.
• Collecting and storing quality data from any number of devices across multiple factories in one database • Analysing, visualising and reporting data in a manageable, user-specific dashboard format • Managing resources such as quality equipment, improving process workflows and organising operational tasks Based on a highly-configurable standard toolset, HxGN SMART Quality can be tailored to the specific requirements of your manufacturing environment without the need for extensive development or costly customisation work, saving time and money. Scalable to fit almost any facility networks and organisational structures, HxGN SMART Quality embeds seamlessly into your IT infrastructure.
TECH TRENDS
Modern Gear Manufacturing Equipment, Made in India
G
leason has been associated with many industries including Automotive, Jobbing Industry, Farm & Construction, core sectors like Energy (Wind Turbines), Industrial Gear Box Industry, General Engineering, Defence, Railways, Mining, etc. Gleason is a pioneer in providing total gear solutions including the design and calculation of gears as well as complete drivetrains, manufacturing of cylindrical and bevel gears with almost all technologies which include soft cutting, hard finishing, workholding, cutting tools and metrology solutions. Gleason has 14 plants all over the world to support global gear industry and developing newer technologies for modern & efficient production of gears. Gleason India was started in 1996 at Bangalore and has opened a new facility at Aerospace Park, Bangalore in August 2017. The new manufacturing and service plant provides many benefits to existing and new Gleason customers in
the Indian region: raising manufacturing and assembly efficiency, employing stateof-the-art process principles and quality tools and showcasing latest technology production equipment, resulting in products which respond to global top manufacturing standards. In the beginning, Gleason India supported the industry with bevel gear cutting tools and resharpening support for bevel stick blades and hobs as well as remanufacturing of older Gleason machines. This original activity has expanded and today we supply highspeed CNC gear hobbing machines up to 210 mm with the two current models to support automotive and small gear box industry: Genesis 130H & Genesis 210H. In 2017, Gleason further enhanced its product range to include a CNC gear shaving machine “Made in India” to offer a local economic shaving solution at a high technical level as continued support for our customers. Along with this, Gleason also supports the industry
in offering new gear shaving cutters and shaving cutter resharpening services using Gleason’s latest 410 SCG CNC Shaving Cutter Grinding Machine. Like the hobbing machines, the new shaving machine will also be supported with workholding systems (fixtures), locally manufactured by Gleason India. Hence, Indian customers will receive a complete, worry-free solution including machine, workholding and necessary tools to produce excellent quality at efficient cost. Gleason India has the necessary infrastructure to support all of these activities which will be augmented in the coming years as Gleason has longterm plans to bring more products to India while supporting more customers in the Indian marketplace.
High-speed performance made in India: The Genesis Series CNC Hobbing Machines
The new, modern Gleason Works India Plant at Aerospace Park, Bangalore - inaugurated in August 2017
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TECH TRENDS
Studer - the experts in internal and radius grinding There are good reasons why STUDER is replacing old models, which translate into increased customer benefit.
T
he main fields of application of the new S121, S131 and S141 radius grinding machines are the manufacture of dies – especially in the packaging industry –, where tungsten carbide and ceramic are primarily processed, and the production of hydraulic components such as axial pump pistons, guide plates and housings made of hardened steel, cast iron and copper. Other fields are the production of complex workpieces with several tapers greater than 20° to 90° in a single clamping, where the main applications are in watch and medical technology with extra-hard materials such as industrial ceramic, sapphire and tungsten carbide, as well as the manufacture of human implants for shoulders, knees and hips from ceramic and titanium. New market segment opened up New with the S141 radius grinding machine is, that the machining of larger
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workpieces is also now possible. For the user, this means in figures: The swing diameter above table is 250 mm for the S121, 300 mm for the S131 and 400 mm for the S141. External diameters up to 160 mm can now be machined with an external grinding wheel 250 mm in diameter. The maximum length of parts including clamping device is 300 mm for all three radius grinding machines, and the maximum workpiece weight including clamping device is 100 kg. There are good reasons why STUDER is replacing old models, which translate into increased customer benefit. First and foremost, a higher level of technology has been achieved with the new radius grinding machines. This is evident in the machine bed, which now comprisesofGranitan® and thus offers higher dampening levels, thermal stability and guidance accuracy. It is also reflected in the StuderGuide® guideway and drive system with linear motors, which features
high wear resistance, a long working life and high dynamics (interpolation possibility). The main benefit which customers can derive from the new machines is the extended range of parts possible due to the larger size of the machine, and the new dressing concept which, thanks to the new arrangement on
The S131 radius internal cylindrical grinding machine with 4-position spindle turret with direct drive has a swing diameter of 300 mm and grinds workpieces up to 300 mm.
TECH TRENDS www.mtwmag.com
The S141 radius internal cylindrical grinding machine for larger workpieces has a swing diameter of 400 mm and grinds workpieces up to 300 mm.
the B-axis (simultaneously swiveling workpiece table) is not only simpler, but also offers greater thermal stability and mechanical rigidity. The fact that the new S121, S131 and S141 are now also manufactured according to the Thun modular principle also means non-variable parts in maintenance and service and consequently a higher availability of service technicians. It also means harmonization of the components and, with the new design and improved ergonomics, an increase in the machine’s value. Powerful software Special mention should be made of the StuderSIM software in regard to the new radius grinding machines. With this
software, STUDER answers the question of what an operator needs in order to be able to machine complex parts – often in a single clamping. The answer: An assistant, with which workpieces – derived from a drawing – can be completely defined, all necessary geometric data for the grinding cycles can be generated and with which the grinding process can be checked and visualized by means of simulation on a PC or on the machine. StuderSIM is this powerful assistant. It is complemented by hardware which features the previously mentioned Granitan® machine bed and the StuderGuide® guideway and drive system with linear motors. It also includes X and Z-axes in a cross-slide arrangement as well as a cross slide, which in the
case of the S121 can either take one spindle, two spindles in parallel or two spindles on a hydraulic turret, and in the case of the S131 and S141 comes with a 4-position turret with direct drive. The machines are also equipped with a workhead on a simultaneously swiveling B-axis, a dressing spindle or a fixed dresser on the B-axis and a measuring probe on the grinding head. Other new features are, finally, the enclosure and the control console in the STUDER design. The S121, S131 and S141 radius grinding machines differ from the universal cylindrical grinding machines of the same name in a number of technical details. The B-axes of the radius grinding machines are set up simultaneously and offer interpolation (from -60° to +90°), while the universal cylindrical grinding machines have a swiveling table, which can be positioned from -10° to +20°. In addition, the spindles on the radius grinding machines are arranged at the rear of the turret, while this is the other way round on the cylindrical grinding machines: they are at the front. There are also differences in the dressing concept. The radius grinding machines have the dresser on the B-axis, while the cylindrical grinding machines are equipped with two swivelling dressers. Last but not least, the S121 to S151 cylindrical grinding machines use the STUDER operating system StuderWIN, while the new radius grinding machines use the StuderSIM operating system.
FEBRUARY 2018
MACHINE TOOLS WORLD
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TECH TRENDS
ROLLON: How to choose the right Telescopic Bearing The telescopic bearings from Rollon deliver high load capacity and rigidity for applications in harsh industrial environments. If your application requires one, there are some things you’ll want to consider like material and stroke options, load placement and life calculation. Here are some pointers to help you pick the right bearing for your application.
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ollon offers a wide range of telescopic guides with high rigidity, high load capacity, 200% extension and several accessories available. The new Hegra Rail family of telescopic guides includes guides with an extended length up to 200% greater than the closed length (overextension). The telescopic guides produced by Rollon are available with several accessories like locking systems, snaps or damping systems. Materials To minimize deflection, carefully consider all possible materials for your telescopic bearing. Some common
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materials, along with their pros and cons, include: • Aluminum: Even though it’s a good choice for lightweight and low duty applications, aluminum has more deflection than other materials. Rollon related products: Hegra Rail • Stamped Steel: Easily the most economical choice, stamped steel doesn’t handle vibration and shock loads as well as other materials. Rollon related products: Light Rail • Cold Rolled Steel: Cold rolled steel is another low cost option that doesn’t undergo heat-treatment. However, in case of heavy loads, pitting and denting occurs in raceways since the
ball hardness is greater than the rail and slider.Rollon related products: Opti Rail, Hegra Rail • Hardened Cold Rolled Steel: For the most robust designs, hardened cold rolled sliders and raceways are your best bet. Even though they’re most expensive to manufacture and assemble, this material lets you preload for better rigidity and less deflection.Rollon related products: Telescopic Rail. Stroke Options When picking a telescopic bearing, there are three stroke options to choose from: partial, full and over-extension. Partial
MGM-Pubblicità(210x297)_Layout 1 08/04/13 10.33 Pagina 1
HIGH QUALITY FOR YOUR MACHINERY
MGM brake motor main features
VARVEL production lines
• TEFC 3-ph asynchronous brake motor (0.09kW-130kW) • AC 3-ph brake (no rectifier) or DC brake on request • Oversized brake disc for higher brake torque, longer life and reduced maintenance • Fine and easy brake torque adjustment (as standard) • Very quick brake reaction time • Frequent START/STOP cycle applications • Manual brake release (as standard) • Hexagonal hole on non drive end of the shaft for manual rotation • Single speed or two speeds motors • All motors designed for inverter duty
• RS-RT worm gearboxes: 28 to 150 mm centres. One stage worm, helical/worm and double worm. • RD helical gearboxes: 50 to 2300 Nm. Two and three stages. • RN parallel shaft gearboxes: 180 to 3300 Nm. Two and three stages. • RO-RV bevel/helical gearboxes: 180 to 3300 Nm. Three stages. • RG precision planetary gearboxes: 10 to 230 Nm. One and two stages. • VR dry friction speed variators: IEC63 to IEC90 1 to 5 stepless speed range, 300 to 1500 rpm. • VS planetary speed variators: IEC71 to IEC112 1 to 5 stepless speed range, 200 to 1000 rpm.
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A new generation of electric motors and gearboxes for power transmission quality from the alliance of two dynamic italian companies. For those who want quality.
MGM-VARVEL Power Transmission Pvt Ltd Ware House No. G3 and G4 • Ground Floor • Indus Valley's Logistic Park • Unit 3 • Mel Ayanambakkam • Vellala Street Chennai - 600 095 • Tamil Nadu, INDIA • Phone: +91 44 64627008 • info@mgmvarvelindia.com • www.mgmvarvelindia.com REGIONAL OFFICE: KOHLI TOWERS • 4th Floor, Dapodi • Near Bharat Petrol Pump • Pune - 411012
TECH TRENDS
extension stroke refers to an extension length that’s 50 to 65% less than the closed length. Rollon related products: ASN, LPS In a full extension stroke, the extended length is equal to the closed length. Rollon related products: DE, DS, DSC, DBN, DMS, DRT, LTH, LTF, LFS, LFX, DRX/DRS With over-extension, the extended length is up to 200% greater than the closed length. Rollon related products: DSE, H2D, H2C, H2T Telescopic rails also come with dual or double stroke configurations, allowing loads to move in both directions while maintaining the same closed length. Load Placement Another important factor to consider is load placement. Your load’s center of gravity should be placed as close as possible to the centre of the moving element for even load distribution among the balls. Load calculations are usually made with the assumption that the load is properly distributed.
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When calculating the static load a safety factor S has to be used, it takes into account the basic parameters of the application and it can have a value between 1 and 3,5 in the following formula:
precision, occurring shocks and vibrations, the operating temperature, the ambient conditions and the lubrication. The service life can be calculated with the following formula:
Where P is the effective load, C the permissible load and S the safety factor. Life Calculation When sizing a telescoping bearing for continuous operation, make sure you use the right life calculation and dynamic load capacity. Some manufacturers express load and deflection specifications based on the slides being used in pairs, while others think of load capacity using a single rail. You should take the time to understand how the slides are rated and what specifications the manufacturer provides. The service life of a telescopic rail is dependent on several factors, such as the effective load, the installation
Lkm = calculated service life in km δ = load capacity factor in N W = equivalent load in N fi = application coefficient
For more information, Rollon India Pvt. Ltd. 1st floor Regus Gem Business Centre 26/1 Hosur road, Bommanahalli Bangalore 560068, INDIA Tel.: +91 80 67027066, Fax:+91 80 67027004 E-mail: info@rollonindia.in Website: http://www.rollonindia.in
Taming power quality is now child's play
When you use DigiVolt Stabilizers, Tranquil Ultra Isolation Transformers and Powercon Power Conditioners from Unity Controls, power quality is under total control and would no more hamper your production and product quality. These silent sentinels protect your sophisticated, high precision production equipment from the ill-effects of voltage, spikes, surges, transients, sags, noise and harmonics affecting AC power lines. Thus ensuring continuous uptime and enhanced productivity and consistent quality.
Intelligent Microprocessor-based, High Efficiency, Energy Savers specially designed for CNC machines
Our equipment are approved by major OEMs and exported (up to 2000 KVA) to countries in Europe, Middle East, Africa
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Active Harmonic Filters K-Rated Transformers Light Energy Management Systems
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and Asia Pacific. So leave power quality and energy management to the experts â&#x20AC;&#x201C; Unity Controls. With our nationwide network we are only a phone call away!
Contact us for Power Quality & Harmonic Audits to Conserve Energy and Save Costs.
The power quality & energy experts
D-137, TTC MIDC Industrial Area, Nerul, 405, Sapphire Arcade, 42 M.G. Road, Ghatkopar (E),400 Mumbai 400 077, India Navi Mumbai 706, INDIA +91-22-2501 3832 +91-22-2761 1872/ 33 / 4612 sales@unitycontrols.in www.unitycontrols.in
Ahmedabad l Bangalore l Chennai l Delhi l Gurgaon l Hardwar Indore l Jalandhar l Jamshedpur l Kolkata l Kanpur l Mumbai l Pune l Rajkot
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vijayshreyaarts@gmail.com
UNITY CONTROLS PVT. LTD
TECH TRENDS
Elesa+Gante hinges with safety switch finding greater usage Elesa+Ganter, makers of standard machine elements also has wide range of hinges with safety switch.
G
N 139.1 hinges with safety switch are used for hinged and opening protective equipment such as doors or covers on machines, in plants, in automation engineering and in the automobile industry. The hinge is compact and sturdy, making it the ideal choice for many applications. Classed as protective equipment, GN 139.1 hinges with safety switch can prevent hazardous situations as the contacts change their status from a defined opening angle forward. This switching point can be adjusted within the range +4°. The electrical switching elements
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are fully integrated in the Mechanical hinge and are invisible from the outside, allowing the hinges to be classed under IP 67 (plug-type version) and IP 69K (cable version). Two contact switches offer double safety! The concealed bolt attachment from the back also makes this hinge particularly tamper-proof. The GN 139.2 hinges are similar in design and differ externally only by featuring a connector plug, making them the ideal choice as add-on hinge with unchanged perfect appearance. Flat and angled mounting plates are available to mount the hinges, allowing them to be mounted from the front or in the clearance between door frame and door.
Oblong holes are designed for mounting to profile systems. In general, the GN 139.1 hinges with safety switch conform to many international standards and directives (e.g. CE and UL). The GN 330 cables with M12 x 1 connector round off this product range. v
TECH TRENDS
Demystifying Cloud There is lots of buzz around the cloud, a key technology driving a new era of smart manufacturing. Some potential adopters questions about the justifications for and security issues around adoption, but these can be easily addressed.
By Thomson Matthews, Software Product Manager, ANCA
T
he cloud computing megatrend has been hard to miss for consumers or businesses. Cloud-enabled platforms have transformed everything from transportation to accommodation, and helped create some of the world’s most valuable companies. As a matter of fact, 1.65 million business people rely on cloud data day in and day out. Adoption by enterprises has been swift. Technology research firm Gartner published a report in February predicting the pace of growth in public cloud services would reach its peak this year at 18 per cent, with a total value of $US 246.8 billion. Companies were pursuing cloud strategies, said Gartner, due to the “multidimensional value of cloud services, including values such as agility, scalability, cost benefits, innovation and business growth .” Despite these and other benefits, manufacturers appear to be slower adopters than those in other sectors. An Economist Intelligence Unit report published last year notes that “manufacturing appears to have something of a late start in cloud”. Adoption, however, was predicted to
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increase “significantly and rapidly”. The report’s respondents predicted that this reluctance will fade, and 71 per cent expected cloud would be a major factor within manufacturing in five years. In CNC machining and other types of manufacturing, the adoption of cloud computing - collecting data from many devices at one point - will be transformative, allowing intelligent, autonomous decisions throughout supply chains. The cloud is one of the “nine pillars” making up Industry 4.0 , and critical for the “Internet of Things” trend, which McKinsey predicts will create nearly $US 5 trillion in value in businessto-business settings annually by 2025 . The benefits Networked production comes with a number of benefits. A connected bank of CNC grinding machines, with real-time analytics presented through a browser, enables operators to see which machine is doing what and where there might be bottlenecks. Capacity can be optimised through floating work orders, enabling a company to get the most out of their investment
and to juggle smartly. With collected data we can use machine learning algorithms to analyse machine performance, learn when and how a machine will fail, and trigger preventive maintenance actions before failure occurs. Downtime can be minimised, with maintenance notification software (MNS)-based alerts telling an operator when there’s a problem and allowing them to intervene early. Predictive rather than reactive maintenance brings obvious benefits. Cloud-based communications can help alleviate the burden by eliminating maintenance, IT workload, and some of the costlier internal infrastructure, including servers and storage systems. Manufacturers don’t have to worry about data backup in case of system failure and power consumption can also be cut. Some popular, negative myths around cloud computing There are some enduring negative ideas that are inhibiting cloud adoption in manufacturing. Intellectual property security is high on this list. However, it is easy to get alerts in
TECH TRENDS www.mtwmag.com
cloud systems on potentially problematic activity based on behavioural analysis, for example if a worker is attempting a forbidden download from a machine. Secondly, cloud vendors provide data centre-grade security to customers. The credibility of a company like Amazon as a vendor depends on - among other things - the integrity of data security they can provide. Also, if you already share workplace data using, for example, Dropbox, then guess what? You are
already using a cloud service. There might also be concerns around viruses, though this should not be a problem where there are only outbound flows of data. Another reservation might be around cloud or vendor exit strategies. Both will be clearly covered in the terms and conditions when subscribing to a new service. ANCA’s cloud offering, for example, allows customers to export data at any time from on-premise to cloud or
vice-versa. Many of the concerns around using IoT cloud services have been seen previously in the world of cloud-based mechanical computer-aided design (MCAD) software, and these have faded over time. Nowadays offering MCAD in the cloud is pretty much essential for vendors, and it has driven benefits to customers including but not limited to performance, scalability, and cost The value of cloud-based connectivity on the factory floor will continue to grow as the Industry 4.0 movement accelerates. Right now, users can immediately gain from better planning, based on informed decisions, based on data. The EIU report mentioned above cites three waves of adoption for transformative technologies. First comes cost reduction. Then there’s doing what’s done now better. The third wave, though, “is the most fascinating— the creation of unforeseen, wholly new opportunities that no one planned for or expected.”
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TECH TRENDS
ReeR: A name to reckon with in the world of safety sensors The company offers a full range of light curtains, light barriers, laser scanners, safety controllers and interfaces
R
eeR is now the biggest manufacturer of safety sensors in Italy, and one of the major ones in the world. TWe are present in the whole industrialized world with an effective and qualified sales network. ReeR offers a full range of light curtains, light barriers, laser scanners, safety controllers and interfaces. The wide selection makes the catalog one of the most complete in the world of safety, thanks to the variety of models and especially to the application features studied according to the various needs of the users. The company actively participates in several National, European and International (IEC) Standard Committees on Machine Safety. In this way, ReeR is always in the forefront about products standard compliance. Today, not to mention the significant regulatory changes relating to the safety of the machines introduced since2010,the design and construction of the security of a complex piece of machinery depends largely by economic factors and needs for flexibility. Mosaic – a configurable controller Thinking about the current needs,
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ReeR has created the modular safety integrate controller, Mosaic. Mosaic is a modular, configurable safety controller for protecting machines or plants. Mosaic is capable of monitoring several safety sensors and commands including encoder and proximity for safety speed monitoring,concentrating management of these in a single, flexible device. Mosaic comprises a master unit M1, configurable via the MSD (Mosaic Safety Designer) graphic interface – provided with each Master unit at no extra cost – and a maximum of 14 expansion units connectable to M1 via the MSC proprietary bus. The Mosaic system can be equipped with a maximum of 128 inputs,16 OSSD pairs,16 feedback restart e/o interlock input and 32 signaling outputs. Expansion units are also available to permit connection for
diagnostics purposes to the most common industrial Fieldbus systems. The safety light curtains EOS4 and EOS2 (with a section of only 28x30 mm) are one of the smallest light curtains on the market (with all integrated safety functions). They can be connected to Mosaic, safety dedicated interfaces, contactors controlled directly or safety PLCs. All models in the range have been certified for protectiondegree IP 65 and IP 67 High resistance to infiltration by dust and liquids in a highly compact light curtain
Watertight enclosures allow EOS4 and EOS2 light curtains grids to be used in harsh working environments with exposure to water and steam. The small EOS WTF and WTHF cylindrical enclosure (only 56mm diameter) is IP 69K protection rate tested and can withstand up to 80 bar of water jets pressure at the temperature of 80°C. Thanks to its inert (non-toxic) components, no residuals are left when the light curtains are washed down or when they come directly in contact with food. This makes WTF and WTHF enclosures suitable for the Food & Beverage industry. The EOS WTF e WTHF light curtains, suitable for the Food & Beverage industry have also been certified by: ECOLAB, passing the material resistance tests, according to the cleaning procedures for food and beverage industry.
CASE STUDY
Stop at a dizzying height A permanent lift brings service technology materials almost to the very top of the highest building in the world - the Burj Khalifa in Dubai: the stop is at a height of 611 m. The service lift from Pega’s “Industrial Lift” range is fitted with Schmersal lift switchgear equipment.
T At 828 m Burj Khalifa in Dubai is the highest building in the world.
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MACHINE TOOLS WORLD FEBRUARY 2018
he Eiffel Tower is 300 m high, Cologne Cathedral 117 m and the Empire State Building 380 m. Burj Khalifa in Dubai towers over them all and at 828 m is the highest building in the world. The other superlatives of the building include the highest number of usable floors (163), the highest viewing platform in the world (555.7 m) and the highest restaurant (122nd floor). The service lift sets more world records, bringing material and personnel to heights greater than 600 m to this day. It was built by the Czech company Pega Hoist, which also supplied numerous temporary super high speed construction lifts for Burj Khalifa. Four Pega double lifts did the basic work in transporting personnel and material for the first 400 m during construction. Lifts with speed regulated drives were used for this purpose, permitting speeds of up to 100 m/min at full load. A number of additional smaller Pega construction lifts were implemented several times as construction progressed.
CASE STUDY www.mtwmag.com Position switches and door locks
The upper lift station is exposed to extreme conditions and provides access to the technical sector. Sturdy switchgear
Schmersal AV20 switchgear is responsible for locking the doors of the permanent lift at a height of over 600 m.
These temporary construction lift types were dismantled after the Burj Khalifa had been completed. But a permanent Pega service lift, whose stop is 611 m high, is still in operation. Here Pega installed a series IL 1012 industrial rackand-pinion lift. This upper lift station provides personnel with access to the technical section of Burj Khalifa above it. The machine cabin with the drive unit moves constantly with the lift roof: it is installed outside merely under glass and as a result is exposed to extreme conditions and the tower’s own movement, which in strong winds sways up to 1.5 m.
Like the construction lifts, Pega’s permanent lift is driven precisely and efficiently by speed variable drives. A programmable control creates the condition for standard compatible adjustment to individual deployment conditions. All Pega lift series are fitted serially with Schmersal lift switchgear. As system provider Schmersal has a complete range of lift switchgear in its portfolio. In lift type IL 1012 Schmersal series TVH335 position switches with safety function take care of upper and lower operational shutdown. It was developed for reliable use in a rough environment, as the sturdy metal housing suggests. Thanks to the wide range of operating elements that can deployed 4 x 90°, they can be adjusted flexibly to any application. Schmersal AV20 switchgear is responsible for locking the doors of the permanent lift at a height of over 600 m. Its special characteristic is the magnetic mode of operation for preventing accidental opening, which guarantees a high degree of safety and ensures the functionality of the door lock even given wide door leaf tolerances. The wide operating range of the magnets permits fast, easy installation and permanent, adjustment-free use. In addition, in the IL series – and as a result also in Burj Khalifa – series 236 position switches with safety function are used in the clamp brake. A TZ 422 switchgear device monitors the upper and lower emergency stop function of the car. The permanent lift and Schmersal lift switchgear have been in use in Burj Khalifa for eight years – and have proven their worth under demanding conditions. The climate alternates between great heat by day and cool nights. The humidity is high and due to the proximity to the coast, the salty air is also highly corrosive. This is not just a great challenge for steel structures, but also for all electrical and control components. For more information Web: www.schmersal.in
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PRODUCTS SHOWCASE
PRODUCT SHOWCASE The new Gast 86/87R Series of oil-less rocking piston compressors and vacuum pumps While other manufacturers have been busy selling rocking piston compressors that produce a lot of noise and less-than-ideal pressure, Gast has been quietly setting the new standard by re-engineering our oil-less rocking piston from the ground up. The result is a unit that delivers quieter performance, higher pressure, a longer life and greater application flexibility. The sleek, new 86/87R Series is not just another pretty product. It’s beauty runs deep as it performs in ways not yet seen in the industry. The patented crossover chamber design regulates and controls airflow to dampen sound and optimize performance, while delivering a wide range of pressure level options. Because the 86/87R Series can easily retrofit into an existing footprint, it’s also a smart, flexible solution for a wide range of markets and applications, viz. Environmental, General industrial, medical, printing & packaging, food and beverage, transportation, laboratory, and material handling.
Designed to performs
For Product Enquiry Contact Shavo Technologies Pvt. Ltd. Shavo House, S.No.21A/10B, Plot No,394 South Main Road, Hotel Cozy Inn Chowk Koregaon Park, Pune - 4112 001 Phoned: 020-2615 9641 Email: shavogroup@vsnl.com
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MACHINE TOOLS WORLD FEBRUARY 2018
“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.
PRODUCTS SHOWCASE www.mtwmag.com
4 Rolls Double Pinch Linear Guides – 4HEL 4HEL is the most precise and easiest to use series of 4-roll bending rolls with total pre-bending. Highly technological and innovative, 4HEL bending rolls assure high-productivity with a speed 3-4 times higher than a traditional pyramid bending roll. Moreover, thanks to their production methods, the 4HEL bending rolls can be effectively controlled through numerical control systems. All models of Faccin’s 4HEL 4-roll bending rolls are equipped with a rear side roll opposite the feeding side. Used as backing, this roll allows the plate to be aligned in an immediate and accurate manner. The plate, moreover, always remains pinched between the two central rolls, thus avoiding accidental slips. This not only optimises pre-bending and rolling operations, but it also assures safer and more precise machining, with the option of being handled entirely by a single operator and Full CNC. With the 4 Rolls configuration, the pre-bending operation does not require tilting the plate below the feeding level (as in traditional 3 roll bending rolls) so horizontal feeding tables may be used, for easier feeding of the plate into the machine. With the 4HEL 4 rolls there’s no need to leave free space on both sides of the machines, but only at the selected infeed side. With the 4HEL 4 rolls machine, the plate can be formed in one single pass. In fact after the first pre-bending, the plate is rolled to the desired diameter and then the second end forming is coming automatically. Cone bending processing made easier by tilting the side rolls and the pinching roll to respectively set the cone angle and drag the sheet at its largest development. The 4HEL machines are well known for their reliability thanks to their over dimensioned structure and the centralized Lubrication System. The Linear Guide Design (RGS) is increasing their bending precision minimizing the distance between the bending points. Special design solutions like the Double Bearing System (MCS) are expressly used to have a better absorption of the maximum loads. The combination of top quality components, the Hi-Tech Hydraulic of the FaccinAp and EPS system make the 4HEL one of the most technologically advanced Plate Roll on the market. 4HEL series CNC bending rolls - designed and built by Faccin - are the best solution to bend plates from less than 1m & up to 10m with thickness 5 to 150 mm.
For Product Enquiry Contact Faccin S.p.A. Via dell’ Industria, 19, 25010 Visano, Brescia - Italy Tel: +39 030 99 58 735, Fax: +39 030 99 58 771 E-mail: info@faccin.com Website: www.faccin.com
Standard equipment
Optional features
• Linear guides for roll motion (RGS) • 4 independent bearings supporting the lower rolls (MCS) • Bearing seats with double width (WHS) • Electronic synchronisation of roll parallelism (EPS) • Hardened and polished rolls and conical device • SIEMENS numerical control • Mobile wheel mounted control console • Faccin Advantage Package - FaccinAp • Centralised lubrication system (pump) • Emergency barrier around the machine • CE certified machine.
• Side motorised rolls • Automatic loading and unloading systems • Motorised feeding table • Automatic ejector • Central and side supports • Provision for hot rolling • Version with planetary guides (4HEP) • Integrated welding system • Special colors • CNC Siemens numerical control.
FEBRUARY 2018
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PRODUCTS SHOWCASE
2 out of 8 selectable safety functions One device for many applications
For Product Enquiry Contact DOLD Electric India Pvt Ltd (100% Subsidiary of E.DOLD & Sohne Kg - Germany)
B – 3 Vishranti Heritage, Gotri Road, Vadodara – 390 021 Call: +91 990 9001585 Website: www.dold.in
We extended again the safety functions of our multifunctional safety module UG6970 from the SAFEMASTER- family. It monitors two independent safety functions. They can be selected as desired from the basic functions emergency stop and safety door, choosable with cross circuit monitoring as well as from further basic functions like twohand circuits, safety mat/edge, light curtain and alternative switch. At this, the device offers maximum safety up to performance level (PL) e/ Kat 4 or SIL 3. The SAFEMASTER settings are performed without programming, simply and quickly via 3 rotary switches. With a narrow device only 22.5 m wide, two different safety circuits of machines and systems can be monitored simultaneously in a simple manner. In addition, the safety module features flexible starting conditions. For example, the device can be optionally activated via manual or automatic start. The connection methods are just as flexible. Apart from conventional screw-type terminals, cage clamp terminals are also available for simple and quick installation without tool. The plug-in connection blocks allows for quick device replacement in the event of service thereby offering additional saving potential. The SAFEMASTER is designed for 2-channel operation with adjustable cross fault monitoring. In addition, it features line fault detection on the ON-button. LED indicators and semiconductor signal outputs ensure quick diagnosis. The UG 6980 is available if only one safety circuit shall be monitored.
Steady Volt Servo Voltage Stabilizers Frequent voltage variations are a menace that can damage electronic components like power supplies, drives, PLCs, controllers, etc. Their effects are widely felt in CNC, printing and textile machines as well as laboratory, data processing, medical & telecommunication equipment. Frequent breakdowns of such machines are costly to repair. This apart, the downtime and frequent interruptions in operation brings substantial loss of revenue. Steady Volt from Unity Controls is a state-of-the-art Voltage Stabilizer designed to protect such equipment from voltage variations and its ill-effects.
Following are some of its unique features:
For Product Enquiry Contact Unity Controls Pvt. Ltd 405, Sapphire Arcade, 42 M.G. Road, Ghatkopar (E), Mumbai 400 077 Phone: 022- 2501 3832 / 33 E-mail: sales@unitycontrols.in Web: www.unitycontrols.in
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MACHINE TOOLS WORLD FEBRUARY 2018
• • • • • • •
Intelligent microprocessor-based system(available in new digital models) Digital interface with large LCD display and keypad Auto re-start, adjustable output voltage, trip bypass, fault list No hunting, oscillation and noise generation Innovative transformer design to minimize power loss Constant output voltage across a wide input voltage range Single phasing prevention, surge suppressor and EMI / RFI filter
With the best-in-class response time and correction rates, Steady Volt offers improved power quality and greater energy efficiency, thereby saving the cost of breakdowns and energy utilization. Apart from protecting your equipment from damage, Steady Volt also saves energy during continuous operations.
PRODUCTS SHOWCASE www.mtwmag.com
FARO® Offers the world’s best measurement ARM The FaroArm is the preeminent portable coordinate measuring machine (PCMM) that allows manufacturers easy verification of product quality by performing 3D inspections, tool certifications, CAD comparison, dimensional analysis, reverse engineering, and more. The FaroArm has become the global standard for arm technology and has been specifically designed to meet the diverse and ever-increasing requirements of both large and small-to-medium manufacturing customers. The FaroArm is built from nearly three decades of manufacturing innovation and experience to enable highly-precise and reliable 3D measurements of both large and small parts during production and quality assurance processes.
FARO QUANTUMS FAROARM The QuantumS is the most accurate FaroArm ever produced and delivers the highest level of performance to meet even the most challenging of tolerances. The repeatability and accuracy of the QuantumS is unparalleled and has been tested under the most extreme factory-stress testing to ensure consistent quality.
For Product Enquiry Contact FARO Business Technologies India Pvt. Ltd. Email: india@faro.com Website: www.faro.com/India
FARO QUANTUMM FAROARM The QuantumM features the same, ruggedness, durability and repeatability as its portfolio companion with an accuracy specification that makes it an exceptional mid-market alternative for applications that do not require as high of a performance specification as that of the QuantumS.
Welding Fume Extractor, King Extractor-II-MU 3 Welding Fume Extractor, King Extractor-II-MU 3 is a mobile mechanical high efficiency self-cleaning filter designed for workplaces. The filter cleans air from different kinds of dry dust, welding aerosols and other dry contaminants from most industrial processes. The filter cartridge is cleaned automatically without interrupting the filtration process. The cleaning extends the cartridge service periods and minimizes maintenance.
The Filter is designed for continuous indoor operation under the following climatic conditions: • • • • For Product Enquiry Contact Ador Welding Limited Akurdi Chowk, Chinchwad, Pune 411 019 Tel.: 020- 4070 6000 Email: cmo@adorians.com Web: www.adorwelding.com
Air temperature from +10 deg. C to +45 deg. C. Relative humidity : 80% at 25 deg. C The compact construction integrates the filter, extraction arm and fan The filter can be used at workplaces unreachable to other ventilating equipment, and • The filter requires connection to a general compressed air supply. The standard delivery set includes Built-in fan, Control console, Filtering cartridge of respective type, Spark arrester, Oil separator with reduction box for compressed air system, and Electrical grounded cable L= 5 m with plug.
FEBRUARY 2018
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PRODUCTS SHOWCASE
FLIR DM285 – Industrial Imaging Multimeter with IGM
For Product Enquiry Contact FLIR Systems India Pvt. Ltd 1111, D Mall, Netaji Subhash Place, Pitampura, New Delhi – 110034, INDIA Tel: +91-11-4560 3555 | Fax: +91-11-4721 2006 Email: flirindia@flir.com.hk Webiste: www.flir.in
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MACHINE TOOLS WORLD FEBRUARY 2018
FLIR DM285 is industrial, all-in-one True RMS digital multimeters and thermal imagers that can show you exactly where a hot spot or temperature anomaly is for faster troubleshooting. Featuring Infrared Guided Measurement (IGM™) powered by a builtin 160 x 120 FLIR thermal imager, the meters visually guide you to the precise location of a problem. You’ll pinpoint issues faster, more safely, and efficiently. Both multimeters are ideal for inspecting industrial-electrical, mechanical, HVAC/R, and electronic systems, and can be used for both benchtop electronics or in the field. The DM285 uniquely features Bluetooth® which enables wireless data transfer by connecting to the FLIR Tools Mobile app on compatible mobile devices. The DM285 is also compatible with the new FLIR InSite™ workflow management tool that allows you to prepare efficient survey routes, maintain accurate documentation, share information with clients, and file instant reports. • Identify energized and faulty equipment from a safe distance with non-contact temperature measurement • Save electrical parameter data and thermal images with onboard data storage • Solve challenging problems with the 18-function DMM including VFD mode, True RMS, LoZ, NCV, a built-in worklight, and laser pointer • Measure voltage, current, frequency, resistance, continuity, diode, capacitance, and temperature • Operate easily with an intuitive menu system • Rely on the meters’ drop-tested durability in any working condition • Change the battery quickly and easily with the ‘no tool’ battery compartment • See readings clearly on the TFT display with a wide viewing angle.
PRODUCT INDEX A
Gas Management
67
Precision Air Moving Products
67
AC I DC Geared Motor
83
Gauge
59
Precision Ball Screws
83
AC Linear Servo Motor
83
Gear Boxes
91
Precision Locknuts
69
Actuator Line
73
Gears, Racks & Pinions
83
Pressure Control Solutions
67
Air Compressors
25
Grinding Machines
17
Project Engineering Solutions
77
Alloy Wheel Machining Solutions
45
Ground Threads
49
Aluminium Profiles
83
Angle Encoders
47
Automation Products
77
B
R H Harmonic Filters
93
HHS & TCT Saw Blades
97
High Pressure Filtration
67
Hydraulic Press
85
Ball Spline
69
Ball Transfer Units
83
Ballscrew
69
Ballscrew Support Units
69
Inserts
Bending Machines
87
Instrumentation Fittings & Valves
67
Brake Motors
91
IOT
35
I FRONT GATEFOLD
K
C Cam Driven Systems
63
Centre Drills
KM Actuator
69
FALSE COVER
Chamfers
FALSE COVER
Clamp Meters
81
L Laser Tube Cutting Machine
Rack
69
Real Time Power Factor System
93
Reamers
FALSE COVER
Reffnlng Furnace
13
Rotary Encoders
47
S Safety Relays
75
Screwiacks
83
Sensor Systems
31
Slewing Ring
83
Spotting Drills
FALSE COVER
Spray Cleaning
51
Stabilizers
93
61
Static Elimination Solutions
67 83 67
Clamps for Linear Guides
83
Lathe Machines
21
Stepper & BLDC Motor
CNC Grinding Machines
43
Length Gauges
47
Surface Cleaning
CNC Horizontal Boring Machine
45
Light Energy Management Systems
93
CNC Lathe
45
Linear Actuators
83
CNC Smart Mills
45
Linear Encoders
47
Taps
CNC Solutions
29
Linear Line
73
Telescopic Line
73
Linear Motion Guides
83
Test Instruments
81
CNC Tool Grinding Machine
7
T 49, FRONT GATEFOLD
Consumables
77
Contouring Controls
47
Curvic Coupling
83
Machining Centers
Cycloidal Gear Boxes
79
Mass Flow Controllers
67
Tool Presetting & Measuring Machines
41
Metal Cutting Tools
57
Tube Bending Machine
61
Metal Forming Machines
19
Tube Cutting Machine
61
D
Thermal Imaging Cameras
M 9, 23
Dimensional Measurement Systems
89
Metal Working Fluids
11
Double Column Machining Centers
45
Metrology Solutions
55
Drill Tap Center
45
Milling Solutions
IFC
Drilling Solutions
IFC
Miniature Guide
69
FRONT GATEFOLD, FALSE COVER
Moisture Meters
Drills
Motion Toolpaths
E End Mills End Mills Cutters
Multimeters
Isolation Products Engraver Cutter
81 IBC 81
FRONT GATEFOLD FALSE COVER
O Oil/ Coolant Mist Cleaner
Energy Absorption & Vibration 67
Oxy-Fuel CNC Cutting Machines
83 77
FALSE COVER
P F
Pinion
69
Flex Clamps
81
Planetary Gear Box
69
Flexible Couplings
83
Planetary Gear Heads
79
Plasma CNC Cutting Machines
77
Position Displays
47
Power Conditioners
93
G Gas Flow Products
67
81
Threading & Grooving Solutions Tool Holders
IFC FRONT GATEFOLD
Tube End Finishing
61
Turning Solutions
IFC
Turnmill
BACK PAGE
U Ultra Isolation Transformers
93
Ultrasonic Cleaning
51
V Vacuum Drying
51
Value-Selling Training Solutions
71
Vertical Machining Centers
45
Voltage Detector
81
W Welding Equipments
77
3D Laser Processing Machine
FEBRUARY 2018
32, 33
MACHINE TOOLS WORLD
107
ADVERTISERS INDEX COMPANY NAME
PG. NO.
COMPANY NAME
PG. NO.
G
A
ACCUSHARP CUTTING TOOLS PVT. LTD.
57
ACE DESIGNERS LTD.
BACK PAGE
ACMEE - 2018
15
ADOR WELDING LIMITED
77
ANCA MACHINE TOOLS PRIVATE LTD
7
83
B BETTINELLI AUTOMATION COMPONENTS PVT. LTD.
GALA PRECISION ENGINEERING PVT LTD
51
PARADIGM TRAINERS PRIVATE LIMITED
71
GEDEE WEILER PRIVATE LIMITED
21
PARAGON MACHINERY CO. LTD.
43
PILZ INDIA PVT. LTD.
75
GODSON BENDING SYSTEMS PVT. LTD.
87
QVI INDIA PVT. LTD.
47
HOSABETTU HEAVY MACHINERY LLP
23
HYUNDAI WIA INDIA PVT. LTD.
49
I
C INSIDE BACK COVER
CNC SOFTWARE, INC.
9
INDO AFRICA B2B TRADE EXPO - 2018
99
INTERTOOL DELHI - 2018
27
RAVIK ENGINEERS PVT. LTD.
61, 97
RENISHAW METROLOGY SYSTEMS LTD
55
ROLLON INDIA PVT. LTD. - INDIA
73
D
MAC MACHINE TOOLS AND AUTOMATION
35
MACHAUTO EXPO - 2018
95
MARPOSS INDIA PVT. LTD.
59
25
MGM-VARVEL POWER TRANSMISSION PVT LTD
91
EPPINGER TOOLING ASIA PVT. LTD.
79
MICRO-EPSILON INDIA PRIVATE LIMITED
31
ERWIN JUNKER MASCHINENFABRIK GMBH
17
MITSUBISHI ELECTRIC INDIA PVT. LTD.
29
MMC HARDMETAL INDIA PVT. LTD.
INSIDE FRONT COVER
DOWEL ENGINEERING WORKS
85
E ELECTROTHERM (INDIA) LTD.
13
ELGI EQUIPMENTS LTD.
F FACCIN S. P. A.
19
FATTY TUNA INDIA PVT. LTD.
45 81
FEBRUARY 2018
67
SUPERSLIDES & BALLSCREWS CO. INDIA PVT LTD
69
TRUCUT PRECISION TOOLS PVT. LTD.
FALSE COVER
U UNITY CONTROLS PVT. LTD.
93
W
N
FLIR SYSTEMS INDIA PVT. LTD.
SHAVO TECHNOLOGIES PVT. LTD.
T
M
MACHINE TOOLS WORLD
89
R
HEIDENHAIN OPTICS & ELECTRONICS INDIA PRAIVATE LIMITED
63
Q
S
BIRLA PRECISION TECHNOLOGIES LIMITED
108
PG. NO.
P
H
APEX PRECISION MECHATRONIX PVT. LTD.
COMPANY NAME
WALCHANDNAGAR INDUSTRIES LTD.
53
Y YAMAZAKI MAZAK INDIA
32 - 33
YG-1 INDUSTRIES INDIA PVT. LTD.
FRONT GATEFOLD
YOUNG BUHMWOO INDIA CO. PVT. LTD.
11
Z NORD DRIVESYSTEMS PVT. LTD.
65
ZOLLER INDIA PVT. LTD.
41
DIFFICULT MATERIALS MADE EASY
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RNI No. MAHENG/2015/64267 Postal Reg. No. THC/173/2018-2020. Posted at Mumbai Patrika Channel Sorting Office G.P.O. Mumbai 400 001 on 15th of every month and Published on 10th of every month
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