Full Machining Range YG-1 Offers the full solution to your machining needs
Custom Solutions Drills End Mills Inserts Taps Tool Holders
Worldwide YG-1
YG-1 Industries (India) Pvt. Ltd.
www.yg1.kr
Plot No. 2C, Gate No. 2, Obadenahalli Industrial Area, Phase 3, Dodaballapura, Bangalore - 561203 Tel: +91 80 22044620, Fax: +91 80 22044645 Email: marketing@yg1india.com
Volume 03 No. 08 | January 2018 | ` 150
Pages 126 | RNI No. MAHENG/2015/64267
QUALITY CUTTING TOOLS An ISO 9001:2008 Certified Company
Tooling Solutions for Industries : Automotive
AerospAce
Die & moulD
GenerAl enGineerinG
TruCut Precision Tools Pvt Ltd
Chennai - India & +91-44-64990524 / 26350520 / 60509009 * marketing@trucut-tool.com : www.trucut-tool.com
Drills Endmills Reamers Chamfers Centre Drills Spotting Drills Engraver Cutter Custom Made Tools
CEO CORNER Metal Forming Industry: The road ahead The global manufacturing industry relies on metal forming machine tools for its core activities. Global economic activities and consumer spending influence the growth of industrial production, thus determining the growth of the metal forming machine tools market.The metal forming machine tools market in APAC is expected to exceed USD 10 billion by 2020, growing at a CAGR of almost 5%. In addition, high export activities of a wide range of manufacturing equipment and tools will lead to a surge in the demand for machine tools in the country. The metal forming machine tools market in EMEA is likely reach USD 4 billion by 2019, growing at a CAGR of over 3%. Europe holds a sizable share in the global metal forming machine tools market in EMEA. Italy, Russia, Turkey, Switzerland, and the UK are significant revenue contributors to the metal forming machine tools market in this region, together comprising for more than 20% of the global market. Germany held the largest market share in 2015. The demand for metal forming machine tools in the Middle East is expected to be driven by the rise in manufacturing and production activities, innovation, and continued research leading to development of high-quality machine tools. The growth of the construction industry in the Middle East will also significantly contribute to the growth of the market. The metal forming machine tools market in the Americas is expected to exceed USD 2 billion by 2020, growing at a CAGR of over 1%. The US is the largest manufacturer of consumer goods in the world; nearly 19% of the global output is produced by the country. The aerospace and defense, automotive, chemicals, telecommunication, and machinery industries find high growth in the country, thus triggering the need for machine tools. A rise in manufacturing and construction activities coupled with an increase in the number of motor vehicles will drive the demand for machine tools in the US. The growth in these industries will lead to an increase in demand for metal forming machine tools which help in reducing the overall manufacturing costs. Considering all above facts there will be growth opportunities in metal forming & has great road ahead which will lead this industry to new horizons.
CEO
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MACHINE TOOLS WORLD JANUARY 2018
ANCA Machine Tools Private Ltd 8/1 , Dr. M H Marigowda Road, Arekempanahalli , (Wilson Garden ), Bangalore - 560027, Karnataka, India T: +91 (80) 6759 2100, M: +91 96637 69911, E: indiainfo@anca.com, W: www.anca.com
www.mtwmag.com
Publisher & Printer Shirish Dongre
CEO Shekhar D.
Editor Shilpa Dongre
Assistant Editor Shweta Nanda
Marketing Team Ladoji Pendurkar, Amol Powle, Bhavin Shah, Bharat Shah, Vinod Surve, Kamlesh Balkrishna, Kavita Chaudhari
Contents
Vol 3 Issue 08 | JANUARY 2018
COVER STORY
Birla Precision: Transforming Growth Through Innovation
Designer & Layout Arun P. Shinde, Nandan S. Moghe, Dinesh S. Gawade
Online Division Ganesh Mahale
Circulation Executive Satish Kadam, Amol Ranshur Branch Offices (Zonal)
NORTH (Delhi & NCR regions) Sandesh Jain : 09810837877 / 09871602777
SOUTH (Chennai & Coimbatore) Y. V. Raghu : 09566141224 Bangalore Vaman : 09686721340
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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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56
Vedant Birla Chairman and Managing Director Birla Precision Technologies Limited
BUSINESS NEWS
18
Abhilash Tripathi takes over Heidenhain Indian operations
METROLOGY
IN FOCUS
CASE STUDY
18
Mastercam and WIDIA announce new tooling data solution
20
Integrated safety technology solutions from a single source
20
Extech Launches Compact EMF Meter Optimized for Extremely Low Frequencies
30
Marposs : The metrology expertise with technological perfection
34
Renishaw AM technology helps Swinburne electric car to best-ever Formula SAE result
TECH TRENDS
22
38
AMS new facility inaugurated in Peenya
One of a kind : Compact laser sensor with 500mm measuring range
41
24
40
42
Shell Lubricants displays flagship products and services at EXCON 2017
Renishaw partners with Advanced Digital Technology Foundation
Metrology service market: Growth with technology advancement TBD HS: Programmable System for non-contact high speed tool breakage detection
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 METAL CUTTING & GRINDING
CASE STUDY
TECH TRENDS
44
48
Making a success in the tap market is all about attitude
Thielenhaus: Fastest Bearing Finish in the World
AUTOMATION & ROBOTICS
IN FOCUS
Vol 3 Issue 08 | JANUARY 2018
CUTTING & TOOLS
TECH TRENDS
62 58
Cutting Tools: Analysing the trends
Productivity Solutions Thru Tooling
COMPANY PROFILE
60
Shark Line taps given extra bite
68
Autodesk, STM Tie-up A New Value Proposition for Manufacturing Sector
IN FOCUS
INDUSTRY SPEAK
92
98
72
We give strategic advantages to our customers from diverse industries
CASE STUDY
Fibro India: Eying the opportunities through MAKE in India initiative
Developing import substitutes for welding consumables is our biggest challenge
PRODUCTS SHOWCASE
78
Flexible robotic cell optimizes the CNC milling process 10
MACHINE TOOLS WORLD JANUARY 2018
74
Shavo Technologies offers high-tech tailor made solutions
118
120
119
121
Accusharp End Mills
Indexable Drills
Nexgen Refrigerated Air Dryers Super compact safety module
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
Mr. Arun Mahajan General Manager
AMT- The Association For Manufacturing Technology
Mr. A.P. Jayanthram Managing Director Heidenhain Optics & Electronics India Pvt. Ltd
Mr. GK Pillai Managing Director & CEO Walchandnagar Industries Ltd.
Editorial Index A Accusharp 118 Ace Micromatic 22 Ador Welding 106, 120 ANCA 44 Autodesk 68
K
B
N
Bettinelli Automation 72 Birla Precision 56, 124 D
DesignTech DOLD Electric Dormer Pramet
82 121 60
E
Elesa+Ganter ESI Group
90 90
F 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.
FIBRO India FLIR India
92 20
KUKA
78
M
Marposs India
30, 42
Mastercam
18
Micro-Epsilon
38
Nord Drivesystems
85
R
ReeR Safety Renishaw
96 34, 40
Rollon S
Schmersal
20
Shavo Technologies
74, 121
Shell Lubricants
GEM Equipments
119
Heidenhain India Hoshi Tools
18 58
Mr. Ayaz Qazi Director
Precihole Machine Tools Pvt. Ltd.
Mr. Suhas Belapurkar Director - Sales & Marketing ( Industrial Products) Sanjay Tools & Adhesives
Wohlhaupter India
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 JANUARY 2018
Mr. Jayant Vaidyanathan VP - Sales & Application Tsugami Precision Engineering India Pvt. Ltd.
MTW Overseas Associates USA Nancy TARTAGLIONE, Mepax USA n.tartaglione@mepax.com / usa@mepax.com
GERMANY Sebastian OLLIER Mepax Deutschland, Tel: +49 711 222 54 456, deutschland@mepax.com
FRANCE MEPAX SA, Romain CLASS Tel.: +33 1 39 02 77 78, FRANCE
SPAIN Sofiane JEDIDI Mepax 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
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W
For editorial contribution contact E-mail: shweta@divyamediaonline.com
Mr. Dinesh Khambhayta President MTMA-RAJKOT
48
U
Unity Controls
H
24
T
Thielenhaus
G
88
CHINA/South Korea/Taiwan Mepax - Konaxis Shanghai Julien PENARD Tel : (+86) 21 6252 2731/ china@mepax.com
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BUSINESS NEWS
Abhilash Tripathi takes over Heidenhain Indian operations HEIDENHAIN has appointed Mr. Abhilash Tripathi as Managing Director for its Indian operations effective 1st December, 2017. Mr. Tripathi has an Electrical Engineering degree from Malaviya National institute of Technology, Jaipur and an MBA in Marketing and international business from the prestigious Indian Institute of Foreign Trade (IIFT), New Delhi. He has almost 2 decades of industry experience in leading Indian and foreign multinational corporations at senior levels. HEIDENHAIN is actively present in the Indian market with its own fully owned subsidiary at Chennai, HEIDENHAIN Optics &
Mr. Abhilash Tripathi, Managing Director, Heidenhain India
Electronics India Pvt Ltd. since 2008. HEIDENHAIN India provides high level of sales, application, service and training support for its diverse customers in India from its Chennai facility and engineers based at
Bangalore and Pune. DR. JOHANNES HEIDENHAIN GmbH, Germany develops and manufactures linear and angle encoders, rotary encoders, digital readouts, and numerical controls
for demanding positioning tasks. HEIDENHAIN products are used primarily in high-precision machine tools as well as in plants for the production and processing of electronic components as well as in automated systems and machines. In addition, HEIDENHAIN products are also used in elevators, medical technology and others.
Mastercam and WIDIA announce new tooling data solution Mastercam developers worked closely with WIDIA to let users import 3D tool assemblies directly into Mastercam, validate them, and save them in their Mastercam file and/or Tool Library. Features such as automated filtering ensure that the holders and tools that are selected can work together for the particular job. Users of Mastercam benefit from having the correct tooling for the material and for the type of machining operation, plus an accurate 3D model that can be used for visualization and collision checking, in addition to the time savings. “We found that in the past, our customers complained of having to search through big complicated catalogs to find related parts, then having to request or build the assemblies from scratch for use
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MACHINE TOOLS WORLD JANUARY 2018
in systems such as Mastercam. With the integration of WIDIA NOVO and Mastercam, customers save significant time searching for desired tools and building 3D tool assemblies that can be brought directly into Mastercam for easy use by most shops,” says Rich Taft, Product Owner, CNC Software Inc. “Accurate tool definitions are a critical factor in modern CAM applications. Toolpath algorithms
take advantage of these definitions to provide safe and efficient motion. In addition, the models that we import from WIDIA NOVO help us to generate accurate in-process stock models that can be leveraged in subsequent operations. Customers can also make use of these models in verification and machine simulation to catch programming errors before the program ever gets to the machine tool.”
Chris Merlin, Director of Portfolio Commericialization at WIDIA, states ”One of the promises of digitalization in manufucturing is greater precision and speed through effective use of data; this is where integration is a must. Users want their systems to work together seamlessly, via simple solutions, without extra effort on their part. By connecting Mastercam and WIDIA NOVO, users can effortlessly join cutting tool data with machining data. The 3D models, drawings, and starting parameters are easily available for validation and programming processes. All of this leads to less misapplication of tooling solutions, more optimal machining strategies, and increased productivity with better quality in the manufacturing environment.”
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
BUSINESS NEWS
Integrated safety technology solutions from a single source Schmersal Group and Satech Safety Technology agree cooperation The Schmersal Group, leading international provider of machine safety, and Satech Safety Technology, one of the European market leaders for modular safety systems for industrial automation, have entered into a global sales partnership. The product ranges of the two companies complement one another perfectly, meaning they can now offer complete systems to protect people and machinery in industrial production. • Schmersal primarily develops and produces solenoid interlocks, safety sensors and safety controllers to keep guards safely closed which protect operating personnel from dangerous machine movements. • Satech focuses on developing and producing modular safety components such as safety fences, doors and accessories.
The Schmersal Group also offers its customers a wide range of safety services and is represented with production sites and sales companies all over the world, besides Europe especially in North and South America, India and China. With its patented mounting systems and a customised design software based on Inventor® and Autocad®, Satech develops tailormade safety solutions for individual
customer requirements and for different industrial sectors. Due to a large inventory of standard parts, the company can guarantee fast delivery even with large orders. “Thanks to the cooperation with Satech, we can now offer complete solutions from a single source to our customers who secure their machines with separating safety guards,” explains Oscar Arias, Chief Sales Officer at Schmersal
Group. “This means we can offer our customers the benefits of a one-stop shop: more convenience, quicker order processing and simplified communication processes. Our customers can also rely on the fact that Satech sets just as high standards in terms of the quality of its products as Schmersal does.” Xavier Garcia, CEO at Satech Safety Technology, stresses: “Because we are now able to benefit from the strong global sales network of the Schmersal Group, we will be even closer to our international customers. And due to the in-depth, long-standing know-how of our new sales partner Schmersal, we will increasingly offer consultancy services, especially when it comes to standards and statutory guidelines on machine safety.”
Extech Launches Compact EMF Meter Optimized for Extremely Low Frequencies EMF510 meter measures ELFs in 30-300Hz range Extech Instruments, (http://www.extech.com), a world leader in test and measurement tools, announced the launch of the EMF510, a singleaxis electromagnetic field (EMF) meter optimized for measuring extremely low frequencies (ELF). The compact new meter makes it easy to measure EMFs in the 30 to 300Hz frequency range, making it useful for applications from utilities to product development and engineering. The EMF510 features an informative, oversized dual display indicating both EMF reading levels and the selected EMF range. Users can measure EMF/ELF levels in either milliGauss (mG) or microTesla (µT) units in two ranges up to 2000mG (200µT) with +/-5% accuracy. Useful data functions include data hold, as well as minimum and maximum readings. A bright
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MACHINE TOOLS WORLD JANUARY 2018
backlight adds versatility for testing in dark job sites. The auto-power-off function preserves battery life and can be disabled for extended monitoring. The pocket-sized EMF510 is always ready for testing by utilities of EMFs found in the
generation, transmission and distribution of electricity, with power lines and substations, as notable examples. Product development and electrical engineers can use the EMF510 to quickly assess EMF levels generated by electrical components such as motors and blowers. Homeowners can use the meter to measure EMFs in household wiring and appliances from vacuums and hair dryers, to electric and hybrid vehicles. A wrist strap is useful for toting while a tripod mount lets users set up the meter with consistent placement to avoid variability in routine measurements (using an optional tripod, TR100). The EMF510 is backed by Extech’s one-year warranty and comes with three AAA batteries.
BUSINESS NEWS
AMS new facility inaugurated in Peenya 22nd December 2017 saw the beginning of yet another new phase in the remarkable journey of Ace Manufacturing Systems Ltd. (AMS) Exactly 12 years ago on the very same day, AMS moved out their small premises into the Existing 10 acres plot in Peenya. The Factory had a capacity to produce 1200 CNC Machining center in a year. From the journey of 3 machining centers in 1994 AMS grew rapidly to churn out 1200 machining centers during the previous financial year. Envisaging a growth in the coming year Mr. P Ramadas, Managing Director AMS, took the decision of expanding the Manufacturing setup and in a record time the new production facility for producing 1800 machines per year was built in a short period of 6 months. With today’s addition, AMS boasts of the largest facility in India for machining centers with a capacity of 3000 machines per annum and a strong vision to move on to 10,000 and then to 30,000 machines per year.
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MACHINE TOOLS WORLD JANUARY 2018
The facility was inaugurated today in presence of several of the doyens of the leading Indian Automotive Groups. A gala function earmarked the inaugural of the new facility. The program started with an invocation dance – Ganesh Vandana followed by the Auspicious Lamp Lighting. The Dignitaries on the Dias included who – is – who of the automotive industry; • Mr. Viji Santhanam – Managing Director M/s. Brakes India Group • Mr. V N Vijayaraghavan – Managing Director M/s. I M Gears Pvt. Ltd. • Dr. Manickam M - Chairman M/s. Sakthi Automotive Group • Mr. Gautam Maini – Managing
•
• •
•
Director M/s. Maini Precision Products Ltd. Mr. R S Zanvar - Chairman M/s. Shriram Foundry Ltd – Zanvar Group Mr. G Parthipan - CEO M/s. Rane TRW Steering Systems Ltd. Mr. Kohari san - Member of the Board, FANUC Corporation – Japan Mr. Steven Y Pai – Chairman M/s. Precision Motion Industries, INC.(PMI Taiwan)
It was also graced by the Directors of Ace Micromatic Group • Mr. A V Sathe - Chairman of Ace Designers & Pragati Automation Pvt. Ltd. • Mr. S G Shirgurkar – Managing Director of Ace Designers Ltd. • Mr. B Machado – Managing
Director of Ace Designers Ltd, The event was presided over by Mr. P Ramadas, Managing Director of Ace Manufacturing Systems Ltd. (AMS) and President of Indian Machine Tool Manufacturers Association. Customers and well-wishers of AMS from across India marked their presence for the Inaugural with the numbers crossing well over 1000. After the Lamp lighting, Mr. P Ramadas gave the welcome address followed by speeches by the dignitaries on the Dias. One common theme of most of the speeches was the Passion of Mr. P Ramadas for ensuring customer satisfaction at all cost and the proactive approach of the Ace Micromatic Group in driving the Indian Machine Tool Industry from the forefront. The grand finale was the unveiling of the Model of the Ace Manufacturing Systems Ltd. Plant followed by a visit to the facility. The Event concluded with a sumptuous traditional south Indian lunch on banana leaf.
BUSINESS NEWS
Shell Lubricants displays flagship products and services at EXCON 2017 Shell Lubricants, the global market leader in finished lubricants, displayed its flagship products at EXCON 2017 - the 9th International Construction Equipment and Construction Technology Trade Fair organised by the Confederation of Indian Industry (CII). The Shell booth was inaugurated by the Managing Director and CEO of J.C. Bamford Excavators, Mr. Vipin Sondhi, who appreciated Shell Lubricants’ great work in the construction space. Shell’s premium product portfolio was a highlight at the event held from December 12th to 16th at the Bangalore International Exhibition Centre (BIEC). Key highlights of the event included Gadus Demo Kits (developed to deliver best value through enhanced wear protection, long grease life and system efficiency) and an Interactive Demo Station showcasing equipment wise solutions for the construction sector. Shell believes that lubrication has the potential to deliver significant
enterprise value by reducing the Total Cost of Ownership (TCO) and enhancing equipment productivity. The event saw an impressive lineup of innovative services for various businesses which included Shell LubeServiceExpert, Shell LubeCoach, Shell LubeMatch, Shell LubeAdvisor and Shell Lube Analyst, a service which tests the condition of a lubricant to monitor and track any equipment’s performance. One of the outstanding features displayed at Excon was Shell’s AI-enabled chatbot, LubeChat, which is an interactive, intuitive, and integrated digital platform designed to offer myriad solutions pertaining to lubricant selection and use. The company also presented many of its flagship products in its Rimula, Tellus and Gadus ranges. These products help in protecting meticulously-designed machineries, and contribute to efficient operation by reducing lubricant consumption, extending the oil drain interval and lowering maintenance cost.
Commenting from EXCON, Ms. Mansi Tripathy, Country Head, Shell Lubricants, India said, “EXCON is a great platform for us to enhance our knowledge and forge strong ties with key stakeholders. We are excited to be a part of the event as it is an ideal platform for Shell Lubricants to showcase its userfriendly products while engaging with different customers, OEMs and industry counterparts. At Shell Lubricants, we strongly believe in driving growth by providing better assistance to our end consumers in terms of products as well as innovative technology solutions. We are always working towards delivering premium offerings to our valued customers to meet the rising needs across the construction sector.” Shell Lubricants was also one of the only two lubricant members of the steering committee for the event. Representing the company at the committee, Mr. Siva Kasturi, Asia Pacific Regional OEM Manager,
Shell Lubricants, said, “The country is witnessing a rising demand and growth in construction. The lubricants industry holds key significance in the operations of the construction sector. EXCON provides a great chance to highlight Shell’s products and technologically advanced services in the most effective manner. In addition to providing the highest caliber of products and services, we also strive to create a progressive ecosystem and initiate dialogue with key industry stakeholders.” Organized by the Confederation of Indian Industry (CII)- India’s Premier Industry Association, Excon 2017 is the largest construction equipment exhibition in South Asia as it witnesses the presence of more than 1000 exhibitors and 40,000+ business visitors. The event brings together different stakeholders from the industry to deliberate upon the challenges, opportunities and the best practices in the construction sector.
IMTMA Gears Up for IMTEX FORMING 2018 & Tooltech 2018 Indian Machine Tool Manufacturers’ Association (IMTMA) is organizing ‘IMTEX FORMING 2018 & Tooltech 2018’, a B2B exhibition of metal forming technologies at Bangalore International Exhibition Centre (BIEC), Bengaluru from 25th to 30th January 2018. The six-day exhibition serves as an important platform for the machine tool industry by showcasing the latest technologies in metal forming. Innovations in metal forming technologies,
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MACHINE TOOLS WORLD JANUARY 2018
robotics and automation, welding and joining, wire-forming and drawing, presses, die casting, hydro forming, sheet metal forming machines, presses for special applications, dies and moulds, hydraulic and pneumatic systems and elements, testing machines, and so on will be at display. The exhibition will feature several companies introducing new technologies to suit many user industries such as aerospace,
defence, automobiles, auto components, capital goods, electrical and electronics, earth moving and construction, food processing and dairy equipment, and many others. High level delegations from public and private sector industries will be present as trade delegations. Coinciding with IMTEX FORMING 2018, IMTMA is organizing an International Seminar on Forming Technology (a seminar on trends in metal
forming) on 24th January 2018. IMTEX FORMING 2018 & Tooltech 2018 will also feature events such as Connect (an awareness programme on machine tool industry), Reverse International Buyer-Seller Meet (an interaction platform for machine tool manufacturers and international buyers), i2 (IndustryInstitution) Academia Pavilion (an event for academia and industry to interact). All these are expected to see good visitor turnouts.
IN FOCUS www.mtwmag.com
METROLOGY
CONTENT IN FOCUS •
Marposs : The metrology expertise with technological perfection
30
CASE STUDY •
Renishaw AM technology helps Swinburne electric car to best-ever Formula SAE result
34
TECH TRENDS •
One of a kind :Compact laser sensor with 500mm measuring range
38
•
Renishaw partners with Advanced Digital Technology Foundation
40
•
Metrology service market: Growth with technology advancement
41
•
TBD HS : Programmable System for non-contact high speed tool breakage detection
42
JANUARY 2018
MACHINE TOOLS WORLD
29
METROLOGY
IN FOCUS
Marposs : The metrology expertise with technological perfection Mr. S.M. Sood Managing Director, Marposs India Pvt Ltd
Q. MARPOSS has leadership position in metrology industry, how did MARPOSS India manage this significant growth? Marposs started its operation in Italy way back in 1952 and the first product was an electronic gauge for grinding machine. It was a real innovation at that time since for the first time mechanics & electronics were combined together for a gauging solution on machine tools to increase productivity, improve quality, with drastic drop in rejection. Marposs, a world leader in metrology equipment provide a global answer to customer’s production quality control by making high precision equipment for machine tool control and for part measurement & inspection in the shop-
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MACHINE TOOLS WORLD JANUARY 2018
floor environment. From the beginning, Marposs adhered to the policy of being present in close proximity to customers to understand their quality requirements, investing continuously in R&D and giving utmost attention to customer satisfaction. With these objectives the company deploys economic & human resources & carries out its best commitment to offer top quality innovative products & applications developed in close cooperation & in simultaneous engineering with its customers. Following the same philosophy, Marposs India managed this significant growth by offering its customers a combination of advanced products, market knowledge & commitment to long- term partnerships.
Q. What are the plans to promote MARPOSS brand in India? Marposs is presently well known in automobile sectors & considering India will play an important role as a quality manufacturing hub for mechanical production, there is tremendous scope for Marposs in entering other sectors like, aerospace, energy, glass, medical etc. With the positive change in government policies, we expect these sectors to grow and plan to promote our products to them since precision is of utmost importance for each machining operation. For promotional activity we have been participating in all major Manufacturing & Machine Tools exhibitions to ensure that our customers are continuously updated on the new technologies /applications. We
When perfection makes all the difference ZEISS Car Body Solutions
: us at Visit 2018 ilion) X IMTE erman Pav
(G 2 o. 3A C-10 Hall N Stall No.
// PRECISION MADE BY ZEISS
ZEISS Car Body Solutions ZEISS is your one-stop partner for systematic quality assurance in car body construction: from measurement and inspection technology all the way to fixtures, quality data management and service. All products and services from ZEISS are compatible with each other – for maximum quality and productivity.
www.zeiss.co.in / Imt
METROLOGY
IN FOCUS have also started to focus on new potential industries by participating in specific fairs / exhibition /seminars.
Q. How about MARPOSS’s initiatives in measurement technology space? Which are your focus areas? Marposs plays very important role in measurement technology as a partner to engineering industries starting from initial project discussion till production of precision components. Machining processes are optimized with new materials/ tooling, Marposs offers Machine monitoring systems for continuous monitoring of cutting tools & machine condition. For high precision machining, these systems will be an essential part of each manufacturing line since high cost of parts demands zero defect production. Every manufacturing company wants to be equipped with flexible facilities due to frequent change of models & Marposs has developed expertise in providing retoolable measuring solutions with which similar parts of different dimensions can be checked without any compromise on precision, our optical solutions is a major step in this direction For companies, ready to adapt Industry 4.0, we are able to support customers to continuously monitor every product production process, guaranteeing its quality & analytical traceability. Statistical analysis of measuring data for process control is also an important tool to optimize any manufacturing process and improve overall productivity of the line.
Q. What are the market opportunities for MARPOSS products in India? How do you plan to position these products? Manufacturing of precision components, mainly for aerospace, defence & export of auto components will enhance opportunities for Marposs Products. To cater the demand of components with tight tolerance, Marposs uses feedback from measuring systems & thereby controlling machine tools. Eventually these measuring solutions
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will be used as an integral part of manufacturing line for ensuring the quality at each step & the final product. Marposs has been working globally in close co-operation with all important OEM’s and end users. In India, we also plan to share our knowledge & experience of other markets so that the latest developments for improvement in processes can be also implemented here.
Q. Can you brief us more about MARPOSS’s top line product range? Marposs is committed to provide any kind of measuring solutions desired by the market. We supply products ranging from an individual gauging component to turkey machines or fully automated lines to give a global answer to customer’s needs, supplying the metrology equipment in association with non destructive testing, leak testing & wide variety of sensors & machine tool controls. With the wide range of products and applications , today Marposs can cater to the needs of most of the industries from automobile, electronic industries, aerospace, biomedical, energy, glass, bearing etc. In last few years, Marposs group acquired new strategic companies to offer our customers, additional product lines to monitor & control important machining operations. These products include Machine Monitoring systems for metal cutting & metal forming industry. We plan to introduce these products in India to Machine Tools manufacturers as well as to end users who are interested in high precision & consistency in each operations
Q. What do you think are the strengths of Indian metrology industry & How it is positioning itself against the global market? Indian metrology industry has in due course of time acquired sufficient knowledge on high technical solutions. This skill & knowledge has not yet fully
benefitted the industry at grass root level. With the expansion in manufacturing sector,there is tremendous scope of enhancing our capability by utilizing the skill available here and working on technology transfer from more advanced countries. This will surely help in upgrading quality awareness at small & medium scale industries and making our industry to move faster for global participation.
Q. What are the key technological trends that are driving metrology industry? Manufacturing industries has trend to adopt technology to cater with demand of multiple models & the flexibility to produce variety of components on a single machine tool. Measurement technology should also support to achieve this capability to measure within least possible time. Post process measurement with optical technology is an innovative solution for such type of demand. Leakage testing in any housing/sub-assembly of engine is an important check for the performance of the engine & therefore becoming an essential part of the manufacturing process.
Q. What is your vision for MARPOSS India for forthcoming years? In the present scenario, quality in each manufacturing plant is essential to compete with global manufacturers. Marposs India is playing vital role in providing solutions for checking component before machining, during machine & final inspection. Also monitoring of machine as well as cutting tool condition has become essential for achieving overall accuracy of the component produced. Also, automation will be key prime mover, since the quality should not depend on operator’s skill, therefore automatic measuring solution will have huge potential to cater to these needs.
More Precision High precision sensor systems Compact laser triangulation displacement sensors Compact and lightweight High accuracy Small light spot for smallest objects Analog and digital output Integrated web interface with predefined presets
Laser-Line Scanner Up to 4,000 profiles/sec Up to 1,280 points/profile Very compact and extremely precise Fully integrated electronics
Optical Micrometers Measuring ranges up to 100mm Maximum resolution and accuracy Non-contact and wear-free measurement of diameter, segment, edge, position Ideal for process control
+91 20 2674 1009 | info@micro-epsilon.in | www.micro-epsilon.in
METROLOGY
CASE STUDY
Renishaw AM technology helps Swinburne electric car to best-ever Formula SAE result
M
etal additive manufacturing technology from Renishaw has helped a team of students from Swinburne University of Technology in Melbourne, Australia, to the University’s highest overall score in the latest Formula SAE competition. As well as being placed sixth overall, the highest position for a team from the University, the car recorded some of the fastest times in the speed trial part of the competition. Background
Formula SAE is a competition organised by the Australian branch of the Society of Automotive Engineers in which teams of students produce a prototype for a single-seat racing car and present it to a hypothetical firm for manufacture. The cars compete in a series of track tests. In addition, the teams are judged on the design and cost-efficiency of the car, and on a marketing presentation about their project. Along with the practical experience gained, the programme gives students the opportunity to work together in a dedicated, multi-disciplinary team to produce an impressive vehicle for the competition. The skills of the team are pushed to the limit to ensure that the design and the manufacturing methods used are innovative and robust. The team from Swinburne is made up of students in engineering, design and commerce, who work together to design, build, market and race their car. In 2010, the University was one of the first to enter an electric car in the competition. It has continued to race electric cars in subsequent years. Challenge
The fundamental problem in racing an electric car against petrol competition
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is the weight of the batteries. This means that the weight of all the other components must be minimised to make the car competitive. Team Swinburne is always looking for ways to reduce weight, including being one of only a few teams to base its car on a carbon fibre chassis, which is built at the University. Following the 2015 competition, the team undertook a detailed calculation of the energy used by the car in the various trials. One of the findings of this analysis was that the rotational inertia of the wheels during acceleration and braking was using much more energy than expected. Ryan Wise, the Dynamics Section Leader for Team Swinburne, was given the brief to reduce the weight of the wheels and so cut their rotational inertia. Lighter wheels would, in addition, improve the acceleration and braking performance, and enhance the responsiveness of the suspension. Ryan had been associated with the Team for the 2014 and 2015 competitions, and had been given responsibility for the suspension, wheels, brakes and steering for the 2016 car.
Solution
The use of additive manufacturing was suggested by one of Ryan’s colleagues in Team Swinburne following a general search of new materials and technologies being used by teams in the equivalent European competition, Formula Student. He had found examples of the use of the Renishaw technology by these teams and suggested that Ryan should contact the company. Ryan approached Renishaw’s office in Australia with a wheel from the 2015 car comprising a centre machined from an aluminium alloy, and a band also made from aluminium. Ryan worked through several design iterations, replacing the aluminium wheel centres with smaller ones made from titanium alloy by additive manufacturing. The new design also used a carbon fibre band in place of the aluminium one to give the maximum
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METROLOGY
CASE STUDY weight savings. Guidance in design optimisation for additive manufacturing was provided by Renishaw staff to reach an alternative design with which everyone involved was happy. Iterative FEA (finite element analysis) simulations were performed throughout the design process in order to predict the behaviour of the new component and to evaluate the benefits that could be gained. “One of the things that I loved about using the Renishaw additive manufacturing equipment was the ability to increase the complexity of my design,” said Ryan. “With parts that I had designed for traditional manufacturing methods, I had to be very aware of the size and shape of the cutting tools that were available as well as the added machining time that would be required by certain design features. By 3D printing the wheel centres, I was able to add in fine features that would be difficult to achieve using traditional methods and it cost nothing in extra build time.” Once the design had been finalised, Renishaw Oceania manufactured nine wheel centres to provide Team Swinburne with two full sets of wheels and an extra wheel for testing. The wheel assembly was designed so that each of the titanium components would require minimal post-processing. On removal from the AM equipment, the parts were stress-relieved in a vacuum furnace, removed from the build plate with wire EDM and bead-
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blasted. No further post-processing or machining was required. Results
The new design, with the titanium parts replacing the machined aluminium centres, and the broader carbon fibre band, reduced the weight of each wheel by 20%, resulting in a significant 75% reduction in rotational inertia, leading to measurable improvements in acceleration and braking performance. The additively manufactured wheel centres also contributed to an overall weight reduction of 1 kg per wheel, whilst also maintaining safety, leading to an overall improvement in the car’s performance that was evident in the results on the track. A big advantage of using Renishaw’s additive manufacturing technology was the ability to use titanium. “The amount of material for the initial billet, together with the machining time and experience that would be needed, had ruled out using titanium with traditional manufacturing methods,” explained Ryan. “Printing the parts required very little effort on our behalf and they were manufactured much more quickly than the last set of wheel centres that we made. I was surprised at the quality of the surface finish and that we required no finish machining.” “I think there were a few people who were quietly sceptical on seeing how thin
they were,” added Ryan. “I’ll admit that I was feeling nervous after the team next to us broke a wheel centre on the track. However, in the end, we gave them a good testing and they held strong. So it’s a credit to Renishaw to be able to achieve the material properties required.” As well as contributing to the team’s success, Ryan gained personally from working with Renishaw. “At the start of the year, I knew next to nothing about additive manufacturing of metals,” he admitted. “I soon learnt that, as with any other manufacturing technique, you need to consider the capabilities of the process during the design stage. After a few educational sessions from Renishaw on how the 3D printing system worked and where the issues might arise, I was soon able to adjust the design to be more achievable. We looked into some unique tricks, such as printing skins around an internal lattice to reduce weight and to keep the thermal stresses down. Once I understood the process, I found it surprisingly easy to come up with a design that was both light-weight and printable.” Ryan expects to see more teams using metal additive manufacturing in this year’s competition. “I lost count of the number of people that came into our pits, just to check out the new wheels,” he commented. “They looked incredible & we had no issues with them at all. A lot of people will have gone home impressed.”
NC4 non-contact tool setting system Non-contact tool measuring and broken tool detection on a variety of machining centres
Key benefits:
Specification:
• Reduce tool setting times by up to 90% and reduce scrap caused by setting errors
• ± 0.1 µm 2σ repeatability
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• Measures and detects tools of Ø0.03 mm or larger
• Broken tool detection cycles enable reliable unmanned machining
• Flexible systems – fixed or separate
• Increase productivity, improve quality and increase profits.
• Ultra-compact systems – just 30 mm wide and 35 mm high • Environmental protection – features patented MicroHole™ and PassiveSeal™ technology • Easy installation – ideal for retrofitting offering fast set-up
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20 6674 6200 or visit www.renishaw.co.in/nc4
Renishaw India [Pune] S.No.282, Hissa No.3, Raisoni Industrial Estate, Village Mann, Tal:Mulshi, Pune 411057 T +91 20 6674 6200 F +91 20 6674 6211 E india@renishaw.com
www.renishaw.co.in
NC4Advert A4(EN).indd 1
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METROLOGY
TECH TRENDS
One of a kind : Compact laser
sensor with 500mm measuring range The optoNCDT 1420 is by now also available with a measuring range of 500mm. It is therefore the smallest laser sensor in the market that offers such a large measuring range combined with high measurement accuracy. This smart laser sensor is suitable for logistics, warehouse automation and robotics.
T
he optoNCDT 1420 laser sensors offer a unique combination of speed, size, performance and application flexibility. Their high measurement accuracy and measuring rate enable dynamic displacement, distance and position measurements up to 4kHz. The new optoNCDT 1420-500 laser sensor is the worldwide smallest laser sensor with a 500mm measuring range and the fields of application are therefore wide-ranging. The compact optoNCDT 1420 is used in sorting tasks, warehouse logistics, warehouse automation and robotics but also in the electronics production, wood processing, medical engineering, laser engraving equipment and machine building. The optoNCDT 1420 laser triangulation sensors measure displacement, distance and position on a non-contact, wear-free basis. The small all-rounders provide high precision measurements along with a compact design, offering high performance across a wide variety of applications. Their innovative design and functionality
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was recognized with the Red Dot Award Industrial Design 2016. Further more, the laser sensors stand out due to their excellent price/performance ratio, an innovative web interface and their ease of use. The measurement task can be selected using the quality slider and can be further optimized using the video signal display, signal peak selection and individu-
ally adjustable signal averaging. The ROI function (region of interest) allows e.g. for interfering signals in the background to be filtered out. The multifunction button enables quick sensor commissioning for easy measurement tasks. For more information Web: www.micro-epsilon.in
Marposs Monitoring Solution for SMART forming
Process optimisation Machine protection Big data analysis Producion management Set-up help
Quality control
Tool protection Productivity increase
MARPOSS INDIA Pvt. Ltd.
147, Sector 7, IMT Manesar 122 050 - Tel. +91 124 4735700 | sales@in.marposs.com
METROLOGY
TECH TRENDS
Renishaw partners with Advanced Digital Technology Foundation
G
lobal engineering and healthcare technology company, Renishaw, has become a gold sponsor of North American based head and neck reconstruction organisation, Advanced Digital Technology (ADT) Foundation. As a result of this participation, Renishaw can share its knowledge and expertise in digital technology with industry clinicians and scientists. ADT Foundation is a volunteerrun organisation that was created to enhance the use of digital technologies in reconstruction of the head and neck. To do this, it brings together clinicians, clinical scientists and pure scientists. These experts share knowledge, findings and ideas at conferences, workshops and symposia. The aim of ADT Foundation is to identify new digital technologies that can transform this area of healthcare and is the only organisation that is dedicated to this specific application. Renishaw has been developing its expertise in using additive manufacturing to produce patient-specific titanium craniomaxillofacial (CMF) implants.
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These implants are produced from digital designs based on data from CT scans. Additionally, the implantation procedure can run more smoothly as the implants are specifically tailored to the patient. Through this sponsorship Renishaw can encourage industry collaboration and advancements by attending ADT Foundation events and speaking about its technologies, showcasing its products and running workshops. “Reconstruction is a life changing procedure for cancer patients with head and neck tumours,” explained Ed Littlewood, Marketing Manager of Renishaw’s Medical and Dental Products Division. “The procedure aims to improve cosmetic and functional deficits that can otherwise lead to psychological, physical and occupational disabilities. “With the introduction of pioneering digital technology and the communication and education support around the industry, clinicians will be able to avoid these detrimental consequences in patients.” “Renishaw is a pioneer in the development of additive manufacturing
and its applications,” explained Dr Dominic Eggbeer, Head of Surgical and Prosthetic Design at PDR and Treasurer of the ADT Foundation. “The company’s unique perspective as a global engineering company can give clinicians and other healthcare professionals the latest insight of a leading additive manufacturing expert. “Ultimately this could enable surgeons to treat more patients and save costs due to reduced surgery time and number of surgeries per patient. Patients will also benefit as they may only require one operation and their recovery time is likely to be reduced due to the accurate fit of the implant.” Renishaw is a world-leading engineering company with expertise in additive manufacturing for the healthcare sector. It partners with many industry bodies, charities and organisations to further the use of innovative products in healthcare, to improve procedure times and patient outcomes. For more information, Website: www.renishaw.com
METROLOGY
TECH TRENDS www.mtwmag.com
Metrology service market: Growth with technology advancement
T
he global metrology services market size was valued at USD 520 million in 2014. Increasing demand for precise components and parts from various verticals, which include electronics, automotive sector, and power generation is anticipated to spur the growth in metrology market. Outsourcing for the operation of services for a skilled workforce to third party vendors is also expected to drive the demand. Continuous technology advancements such as the use of GPS technologies to track multiple items and social factors such as increasing urbanization along with aging population are also anticipated to favor positively the demand. The increasing aging population is also expected to spur the demand in the healthcare sector. Surging demand for high-precision components in chief end-use sectors including electronics, automotive and power generation is anticipated to fuel demand over the forecast period. High accuracy and fewer tolerance limits requirement of many industrial sectors may lead to the huge adoption of Computer Aided Design and Computer Aided Manufacturing (CAD/CAM) based processes. Industries such as power generation, electronics and automotive are impelled to adhere to international quality standards for better services. Further, with
the intention of enhancing/maintaining the quality of the product, it is vital to have multiple measurement technologies ensuring precise measurements. Product Insights On the basis of product, the industry is segregated into Optical Digitizer and Scanner (ODS) and Coordinate Measuring Machine (CMM). Innovation in metrology software coupled with increased applicability of metrological instruments is expected to play a crucial role in the development of new customizable solutions. CMM is utilized to measure physical geometrical characteristics of an object and is anticipated to grow at a CAGR of over 7% over the forecast period. The segment further includes articulated arm, gantry, horizontal arm, and bridge machines. Rising demand for solutions such as calibration, repairing, machine installation, and retrofitting provided by CMMs is expected to drive consumption
Application Insights Demand for precise components and parts from various sectors which include electronics, power generation and automotive, medical, and aerospace is expected to boost volume sales over the forecast period Metrology services help in the process improvement by inspecting and measuring various elements involved in supply chain processes such as retrofitting, manufacturing, and others. These solutions find applications in different process industries for measurement of different machines and end-product sizes such as molding, cutting, and packaging. They have costbased offers; however, value-based offers are expected to increase over the forecast period. Competitive Market Share Insights Key players in the metrology services market include Danish Micro Engineering A/S, Optical Gaging Products, Inc., Nikon Inc., Optical Metrological, Renishaw Plc., Hexagon AB, Trescal SA, Carl Zeiss Corporation, and FARO Technologies Inc. Developments for launching new products, measuring technologies, mergers, and acquisitions for expanding the physical presence, and increased R&D are the few strategies adopted by the key participants in order to increase their presence.
Precision for People
Dimensional Measurement Systems
JANUARY 2018
MACHINE TOOLS WORLD
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METROLOGY
TECH TRENDS
TBD HS : Programmable System for noncontact high speed tool breakage detection
I
ndustrial realities, where productivity represents the priority to achieve, aim to implement tool measurement solutions, which prove to be quick, accurate and reliable. Aware of such need and willing to develop an application that could avoid affecting production efficiency, Marposs presented TBD, the Tool Breakage Detector, a time-saving laser-based solution for broken tool detection on machine. TBD on milling machines and machining centres permits to keep under control the process, thanks to a very short tool checking cycle. Fast and reliable detection achievable by the TBD allows to reduce production time and to avoid expensive work-pieces scrap due to wrong cutting process by damaged or broken tools. All functionality is contained within the TBD unit compact housing, which can be mounted outside the machine area, saving space on the table. It is possible to choose among different working modes, which endow TBD with a great flexibility. Switching the power to the maximum gives TBD the chance to recognize a tool placed at a longer distance (up to 2 meters), with a standard capability to check the breakage. If a smaller tolerance is required, the reduced power can be set obtaining a smaller beam. Furthermore, an user can choose the filtering level of the signal. In fact, during the checking cycle, some coolant drops could interrupt the beam or coolant stuck on the tool could create variation in the signal received. Setting “Hi Filter” makes the software of the TBD more restrictive in order to give the more reliable response. On the other hand, choosing “Low Filter” TBD responds in a faster way, as the filter is less severe. Lastly, it is possible to choose the appropriate range of spindle speed, up to 5000 rpm.
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The new TBD HS Marposs S.p.A. has recently introduced the new TBD HS, High Speed, on its wide range of products for tool checking on milling machines and machining centers. The new TBD HS is a programmable system for non-contact checking hi-speed tools, particularly committed to those applications where there is the need for hi-speed spindles, up to 80.000 rpm. Thanks to its rotary switch selector, the TBD HS is able to recognize the tool in two different ways, depending on the actual rotational speed, thus minimizing cycle times, generally crucial in this kind of process. Selecting “Quick Recognition”, the tool checking is performed for 10.000 rpm spindle speed and its multiples; on the other hand, it is possible to choose “Hybrid Recognition” if the speed is 1.000 rpm and its multiples or 10.000 rpm and its multiples. With a reflective, clean tool an impressive 150 msec checking time is achieved, approximately half the time compared to the standard TBD. High spindle speeds and small tool dimensions lead to the need for a fine
adjustment for positioning the TBD HS in a very precise way: that is the reason why an effective system has been designed to make accurate and easy the searching procedure of the tool verification position. Once TBD installed and tool approximately pointed, now is even more quick and simple to optimize the laser beam and to find the checking position. The tool breakage detection performed by the TBD HS is improved by the presence (upon request) of a blower for cleaning the receiver glass: taking advantage of the usual standard inlet, both in terms of air flow and pressure, it has been developed a solution able to protect the glass from swarf and scraps without increasing the air consumption. Moreover, when the conditions are particularly harsh because of the aggressive presence of shavings, there is the chance to substitute the standard protection glass with one in sapphire crystal: being 9 out of 10 its hardness degree on the Mohs scale, this kind of protection lets the receiver performance always at its maximum, no more damaged by the extreme machine conditions.
METAL CUTTING & GRINDING
CONTENT CASE STUDY Making a success in the tap market is all about attitude
44
TECH TRENDS Thielenhaus: Fastest Bearing Finish in the World
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CNC Machine Market: Faster growth with technology transformation
52
CASE STUDY
METAL CUTTING & GRINDING
Making a success in the tap market is all about attitude SK Precision is taking on the Tap market in Thailand and be the first domestic supplier to the region reducing their customers lead times and cost and improve service
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aps are notoriously complex to manufacturer but that isn’t deterring Thai manufacture SK Precision who are building their capabilities to be the first domestic supplier of taps to the Thailand domestic market. The Thailand Government understands that manufacturing will be a key driver of growth long term and has been encouraging companies
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to establish facilities in their territories through tax and other incentives. As a result, there is a flourishing automotive and aerospace sector that require suppliers. SK Precision has around 50 people working two shifts servicing their traditional market of cutting carbide tools and PCD tools. Tibordee Srikul president of SK Precision said: “We have been operating for over 20 years
and know the local Thai market intimately. We saw an opportunity in the tap grinding segment as until now companies could only source taps from overseas suppliers and that means longer lead times of up to three months and higher cost.” “Our customers want just-in-time products so they can reduce stock and inventory costs. Having a local supplier who can deliver taps in a short period
UNITED GRINDING:
MÄGERLE
BLOHM
JUNG
STUDER
Solutions for precision machining UNITED GRINDING Group The UNITED GRINDING Group is the leading manufacturer of precision machines for grinding, eroding, lasering, combination machining and measuring. We offer our customers comprehen sive services worldwide. www.grinding.ch
United Grinding GmbH – India Branch Office · # 487, D1 & D2A, 4th Phase, KIADB Main Road, Peenya Industrial Area, Bangalore – 560058 Tel: +91 80 3025 7600 · Fax: +91 80 3025 7603 · Email: info.in@grinding.ch · URL: www.grinding.ch
SCHAUDT
MIKROSA
WALTER
EWAG
CASE STUDY
METAL CUTTING & GRINDING
Taps are a difficult tool to manufacture. A complex application, the geometry and tolerances requirements take a lot of skill and knowledge to produce. At SK Precision we like a challenge and saw the combination of a gap in the market and a new application as something we could make a success - Tibordee Srikul, President, SK Precision
of time helps them achieve a more efficient supply chain.” “Tap’s are a difficult tool to manufacture. A complex application, the geometry and tolerances requirements take a lot of skill and knowledge to produce. At SK Precision we like a challenge and saw the combination of a gap in the market and a new application as something we could make a success.” “I didn’t want to be restricted to producing only one type of tap and after extensive market research we decided to invest in the Tap X because of its flexibility. Our investment in capabilities, both in technology and experience means we can now produce special and standard taps locally. But that is only the beginning, in the future I want to produce spiral tap, point taps and hand taps and forming taps.” “For me and my team it is all about attitude. We are always looking to the future to keep up to date on what technology and market trends are
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emerging. I like a challenge and I knew that there was great opportunity I could take advantage of. My philosophy is to take on a challenging market and develop it. Attitude is everything and that is how I make sure I am successful - I believe I can do it!” ANCA’s TapX Linear is leading the revolution in single setup tap manufacturing
ANCA was the first machine manufacturer to deliver to market a single setup machine for complete tap manufacture. Continuing this tradition of industry firsts, ANCA now offers the TapX Linear range of machines – the first single setup tap grinding machine with LinX linear motor technology on X, Y and Z axis. TapX Linear finds the perfect balance between proven designs combined with ANCA’s newest technologies. The rigid bisymmetrical column design on the solid polymer concrete base has been the foundation design
of ANCA machines over the years. Now, in addition, ANCA’s new LinX cylindrical linear motors and linear glass scales are fitted as standard on X, Y and Z axis for proven and unsurpassed long term reliability and accuracy. The result is a superior machine that ensures customers will meet ever increasing market demands of precision tap grinding. TapX machines are purpose built, with tooling, coolant delivery and automation specifically for production grinding of all types of taps, from M3 up to M50, whether in high speed steel or carbide. Clever tooling design means change over from one tap type to another can be done in minutes, not hours. This delivers greater flexibility in your tap production and results in increased productivity and reduced costs.
TECH TRENDS
METAL CUTTING & GRINDING
Thielenhaus: Fastest Bearing Finish in the World
Due to its extremely short auxiliary process time of 0.9 seconds, the KM 90 evo (here: a view of the working area) is currently able to achieve the quick-est roller bearings finish processing in the world.
Microfinish processing of 1 and 2 two-rowed bearing rings / Further develop-ment of KM 90 / Direct drive and HyperFinish available / Extremely short aux-iliary process times and changeover times / Conversion of ball bearing to roller bearing processing / Up to 30% shorter cycle times with higher quality due to optional double oscillation / Directly powered radial and linear oscilla-tion / Menu-driven programming and set-up processes / Sealing compensa-tion on the workpiece drivers / Time logging possible for setbacks.
T
hielenhaus Microfinish has introduced a new highperformance machine for the finest processing of the inner and outer rings of one and two rowed ball bearings and roller bearings and wave-like special types. The KM 90 evo, which has been designed both for quantity production as well as flexible pro-duction in small and medium scale production, is a further development of
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KM 90, a longstanding proven antifriction bearing processing solution from the market-leading manufacturer. All of the new technologies from direct drive are available for the new oscillation unit through to double oscillation HyperFin-ish with overlapping high frequency oscillation and a small stroke. The com-plete tooling process of the previous model can also be used for the new ma-chine.
Due to the extremely short auxiliary process time of 0.9 seconds, the KM 90 evo is currently able to achieve the quickest roller bearings finish processing in the world. The floor to floor time can be a sensational 3.5 seconds under the conditions of a direct link with an upstream grinding machine, for example, a deep groove ball bearing of an outer and inner ring Type 625. Furthermore the changeover
TECH TRENDS
METAL CUTTING & GRINDING
time between two good parts can be reduced to less than 20 minutes. The new fast runner for mass production can even be flexibly con-verted from radial to axial bearing rings and from ball bearing to roller bearing processing. With the optionally available HyperFinish technology 2.0, up to 30% shorter cycle times can be achieved by overlapping the main oscillation with an addi-tional high frequency oscillation. Thanks to the increased productivity, you will be able to do without additional machining stations and/or machines, resulting
With the KM 90 evo, Thielenhaus Microfinish has brought a high performance machine onto the market, which can be used with distinctively quick cycle and set up times, both for economic mass production of ball bearing rings, as well as for flexible production on a small and medium scale.
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MACHINE TOOLS WORLD JANUARY 2018
in operational cost savings. Due to the reduced oscillation angle, quality and shape parameters are also improved so that optimal dimensional accuracy can be achieved, particularly with 4 point bearing rings, for example. The direct drive radial oscillation for ball bearing rings makes it possible to ad-just the oscillation and approach angle, as well as oscillation frequency and stroke using the program. With the changeable direct drive for linear oscillation for roller bearing rings, the adjustment of the linear stroke can also be record-ed in the program. This also applies for the X-Z track position. The menu and image-driven programming with automatic program generation and calculation of the process parameter speed and stone grinding pressure from known indicators of cutting speed in m/min and specific grinding pres-sure in N/ mm² makes for easier handling of the machine. Menu-driven set up is also optionally offered. An innovative compensation for wear on the workpiece driver makes it possible to use reground drivers and significantly reduc-es tooling costs. The option of time recording for setbacks even with the KM 90 evo, demon-strates that Thielenhaus has developed in the direction of Industry 4.0. The machine comes with an integrated control cabinet in the extraordinarily com-pact dimensions of 2,063 x 1,026 mm so that it can even fit in spatially limited production chains.
For more information, Website: www.thielenhaus.com
TECH TRENDS
METAL CUTTING & GRINDING
CNC Machine Market: Faster growth with technology transformation
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he market of CNC machines is growing: on a global scale, it will reach the value of 93.45 billion us dollars within 2024. Innovations in this area, also aimed at reducing installation and maintenance costs, will share in a further sector evolution. According to a report published by Transparency Market Research, the global market of CNC will highlight the 6.3% CAGR (Compound annual growth rate) in the period included between 2016 and 2014, rising from a value of 52.68 billion dollars in 2015 to 93.45 billion dollars within 2024. The main factor that drives the growing adoption in the entire manufacturing industry of CNC machines is their capability of contributing in reducing human errors and in producing elements efficiently. The control and programming functions of advanced machine, enabled by the use of CNC machines, increasingly encourage the adoption of these systems in numerous sectors. The protagonists There is competitiveness among protagonists and all manufacturing companies are committed to the development of forefront and innovative products, to maintain their significant role on the market. The customers’ focus on the development of interconnected systems has grown, too. One of the five companies, which held almost 25% of the market in 2015, has focused on the development of new products as key business strategy. In 2016, for instance, the company presented a product line integrated with CNC to allow enterprises to
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rely on better industrial automation structures and to permit machine tool manufacturers to create unique functions. A second company released a new CNC generation with improved user interface to enable a better surfing experience. Smarter and smarter instruments User-friendly software platforms are revolutionizing the manufacturing industry, supplying specifications in terms of tolerances and finishes and allowing the addition of characteristics upon designers’ or customers’ initiative. In the milling ambit, the component size is limited by the machine performance and by the cutting depth required by a function in the part. Lathe functions allow successful machining of components up to 18(457.2 mm) of diameter, but special cases can be executed for bigger workpieces. The choice of materials is fundamental in determining the workpiece function and cost. The engineer must define the important characteristics for the material design, hardness, stiffness, chemical resistance, heat-treatability and thermal stability, just to mention some of them. The solution allows considering a broad variety of metal and plastic materials and materials customized upon demand. Simple designs, or with more complex shapes with slots and spaces, can be created using the CNC machining process. If the component is more complex, which means shaped geometry or more faces to be cut, it is also more expensive, owing to the further installation or cutting time of the workpiece on the machine.
The 5-axis technology The 5-axis machining performances allow the production of various complex parts in more convenient manner. The coordinated motion enables the manufacturing of several complex elements more efficiently because their configurations are drastically reduced, higher cutting speeds are reached, more efficient tool paths are generated and better surface finishes are possible. Using the 5-axis technology instead of the conventional 3-axis one, a lower number of configurations is necessary to create a part with complex geometry. While using a 5-axis machine, the machine and the part in motion allow the cutting tool to remain tangent to the cutting surface. Costs and reduction of cycle times are reached because more material can be removed with each tool point; the use of 5-axis performances on the shaped geometry results in better surface finishes. Controllers with ultra-fast CPU Among innovations, in CNC ambit, it is worth highlighting the controllers with ultra-fast CPU. The new type of CPU grants controllers higher operational speeds than standards, enhancing the system output. The fast processing of the CNC programme assures very low cycle times while the higher power of the PLC supports the highspeed processing of articulated ladder programmes. The optical fibre use for the data transmission maximizes the optical communication between CNC and drives and allows perfecting the system reactivity and the machining precision. The new CPU decreases also the quantity of additional components to be adopted for the application
TECH TRENDS
implementation. This results in a minor number of possible error sources and in an improvement of the product quality, besides a cost reduction. Thanks to the new functions, CNC allow managing efficiently both turning and milling operations. The multi-axis/multi-channel control, improved, allows attaining a further reduction of cycle times and an optimized synchronization among channels. In a new series of this model, a 4th generation control is offered for high speed, precision and quality machining. The new regulation includes functions intended for reducing cycle times in case of simultaneous acceleration/deceleration and shares
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METAL CUTTING & GRINDING
in reducing the machine vibrations during the high-speed machining. The new adjustment offers more precision with the same machining times or the same precision with shorter machining times. The innovative turning centres become able to use servomotors instead of spindle motors for rotary tools. Using each of the servo-axes equipping multihybrid drives as rotary tool contributes in the resizing of machine tools, with advantages in terms of costs. The programme management is simplified by a capacitive touchscreen display. The icons equipping the display allow recalling functions and operational menus quickly, tool icons
show the tool geometry, its status and the point direction whereas the graphic check function in 3D supports an advanced three-dimensional graphic simulation to test more complex machining programmes. A new model avails itself of a vertical 19-inch display with screen subdivided into two independent visualization windows, each of which can show a software keyboard, a displayer of documents or other applications. Moreover, are available models that manage different access levels freely set for single operators, to improve the safety of data and machines and to avoid operational errors.
CUTTING TOOLS
CONTENT COVER STORY Birla Precision: Transforming Growth Through Innovation
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TECH TRENDS Productivity Solutions - Thru Tooling
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Shark Line taps given extra bite
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Cutting Tools: Analysing the trends
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COVER STORY
Birla Precision: Transforming Growth Through
Innovation
Vedant Birla Chairman and Managing Director Birla Precision Technologies Limited
Q. Being the key player in the industry, Please brief us company’s journey from Inception & share some of the milestones achieved? Indian Tool Manufacturers (ITM) - A Division of Birla Precision Technologies Limited, pioneered in the year 1937, the manufacture and supply of High Speed Steel Cutting Tools in India. Intensive research and development work has been an integral part of ITM’s total operation on a continuous basis. ITM Products popularly known as “Dagger Brand” made from the finest High Speed Steel and conforming to stringent international standards are now exported to the European and American Markets apart from being sold throughout India through an extensive Distribution Network.
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Tool Holder division - Birla Precision Technologies Ltd (BPT) the erstwhile Birla Kennametal Ltd was established in 1986, as a joint venture between Kennametal and Birla Precision and was called Birla-Kennametal. We manufacture Tool holders, Collets, Chucks, Shrink fit adaptors and hydro grips, among others in this division. BPT continues to be a exporter worldwide –USA, Germany and APAC, in recent times to the Far East including China supplying rotating tool holders in AT3 class. Besides, BPT also sells in domestic market in a large way to other major customers. Our Foundry and Automotive division which manufactures Castings and caters to some of the big league names like Honeywell, Sundram
Fastners and Cummins among others. Precision Components division is 100% exports division, which manufactures engine components, shafts, etc. for various automotive clients abroad. It is now just getting into Domestic Market.
Q. Please brief us about company’s infrastructure & what are the technology alliances that has been made in order to out-front the competition? We have 4 plants located Maharashtra 1 in Nashik & 3 plants in Aurangabad. We have 9 branch offices across India & a distribution network of 300+ dealers across India and also opening 3 New Branch Offices to be closer to the customers.
COVER STORY www.mtwmag.com
We are investing heavily in R&D and will be adding new products in coming years to provide value added solutions to our customer.
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?
Q3) What are the products manufactured by your company?
R&D is a continuous process and helps in pushing the limits of the products & creating better solutions to customer demand of high productivity & quality. As the emission norms are getting stringent we are seeing that customers are asking for more close tolerances with higher feed rates to meet the demand. R&D is playing a major role in meeting these demands & grow the business. We aim to put more effort on R&D and launch new products in the coming days. We are also working on diversifying along with changing customer needs, for which we have certain plans.
An extensive range of High Seed Steel Cutting Tools in various grades (M2, M35, M42, & T42) and a catalogue product range of various types of Drills, an assortment of Milling Cutters, Reamers, Taps and Tool Bits are manufactured in cutting tool division. We have recently added High end product range “PANTHER� Taps and Drills to give better solutions to our customers. Shortly we will be launching PM Taps and Through Coolant Taps to our esteemed Customers. We manufacture rotating tool holders, collets, pull stud, and work holding mandrels in our tool holder division.
Q. What is your marketing strategy for India? Our primary focus is to connect with new customers and increase more business with current customers and give custom solutions. We are also focusing on SMEs. Most of the sale in this segment happens through strong dealer network. With over 300 dealers across India we have one of the largest dealer networks in the Cutting Tool Segment.
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? We are quarterly conducting the product benchmarking exercises of our product not even with the best in the market but with all peers. We have a process to develop New Products which requires the Product to be passed / approved through different screens and MakerChecker System.
Q. According you what are the factors affecting to your business? Market is getting stabilized after GST implementation. The effects of such major reforms are yet to take place which could prove to be a important factor right now to see growth.
Q. What are the key technological trends that are driving the industry? We are already at the verge of industry 4.0. Industry 4.0 is the current trend of automation and data exchange in manufacturing technologies. Over the Internet of Things, cyber-physical systems communicate and cooperate with each other and with humans in real time, and via the Internet of Services, both internal and cross-organizational services are offered and used by participants of the value chain.
Q. How do you perceive the future of the industry? Technology will drive the industry in future & it will hold the key in the long run. The industry competition will definitely grow, however will help to benefit the customer & supplier in a greater context.
Q. What is your vision for your company for near future? Our vision is to be a world class organization and a Global supplier with unwavering focus on our customers and our young team, offering in term of value chain & quality of the products. In long run we want to be recognized as world leader in engineering solutions to our customer.
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CUTTING TOOLS
TECH TRENDS
Productivity Solutions -
Thru Tooling
Riyazuddin Pasha M. Head - Developments, Hoshi Tools (P) Ltd
H
oshi Tools (P) Ltd, is a constituent member of Mac Group, situated in Peenya Industrial area, is engaged in Design - Development & Manufacture of special purpose indexable insert type cutting tools, as its core product category and precision engineering and aerospace components being additional manufacturing activity. Founded in 1994, Hoshi has established itself as one of the pioneers in manufacturing of cutting tools and precision engineering components. It is because of systematic orientation, by a team of well qualified and proven technocrats who had envisaged the need to enter the global market. Strict adherence to international quality standards and delivery schedules being our motto has paid us good measure in getting domestic as well as global
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orders. The company has taken a giant leap forward and has bagged valuable orders from overseas. Our potential has evinced a keen interest in several overseas organizations, which are desirous of placing orders on us. Our Machine shop, equipped with, around 15 VMC Machines – 3 axis thru 5 axis, four turning centers, well supported by conventional machine shop, equipped advanced CAD/CAM set-up, quality control equipment, super-drilling and laser etching machines, to manufacture complex tool holders, which guarantee performance of high standards. We are also taking up manufacturing of precision engineering & machine components, aerospace development & supply on a regular supply basis. Hoshi today is confident that it can meet complex challenges from its growing customer base, in India and abroad. In order to meet ever increasing demands of our customers, we have been identifying & stream lining our capabilities, evolving through modern technology and finding ways for shorter delivery schedules & solving problems at work site, so as to broaden the scope of our services and to assure, how best we can serve our customers. Our customers have benefited in reducing cost of production through our recommendations for cycle time reduction and number of set-ups of machining of their components. To quote an example, at one of our customer of long time, we have replaced
three tools required earlier for machining automobile crank case, combined into one tool thus reducing number of process and cycle time, resulting in 40% reduction in production cost, more parts per shift, thus adding to the customer’s profit. Our comprehensive tooling solutions for components such as connecting rods, cylinder blocks, crank cases, valve seats, brake calipers etc among several automobile industries and valve bodies, API Sealing ring grooves among oil and gas industries have been well appreciated by the customers, resulting in repeat orders from them for us. Further in a move, to broaden the spectrum of tooling solutions, we have been in the process of having understanding with mutually consenting business partners, especially of international reputation. In this regard, we have successfully having the dealerships of M/s AKKO – of Turkey, for Standard Turning, Milling & Drilling Solutions and M/s PINZBOHR, of Spain, for Modular Boring Program, both these companies have long history of successful tooling solutions background. This way we would be able to meet entire tooling requirements of customers. Our customers include leaders in automobile industries, machine tool builders, MNC Tool manufacturers, ancillary units to auto and machine tool industries, aerospace units etc, located domestically as well as overseas. We hope to be able to serve more and more customers in future.
DRILLING
BORING
REAMING
BURNISHING
THREADING
SPECIALS
WORK SMARTER, STREAMLINE, AND SAVE. Today’s manufacturing brings many challenges. Fortunately, we have more solutions than ever. Contact us today and we can provide the right tool for your unique holemaking and finishing needs.
Wohlhaupter India Pvt. Ltd. An Allied Machine & Engineering Company B-23, B Block Community Centre Janakpuri, New Delhi - 110058 Phone: +91 11 41827044 Email: info.india@alliedmachine.com info.in@wohlhaupter.com Website: www.wohlhaupterindia.in
CUTTING TOOLS
TECH TRENDS
Shark Line taps given extra bite
D
ormer Pramet has expanded its Shark Line program of material specific taps with two new designs. With its unique combination of substrate, coatings and design features, the popular applicationbased range offers high levels of process security and performance across a range of engineering materials. Each tap features a color ring on the tool shank denoting material suitability, promoting quick and easy tool selection. The latest additions are to its yellow ring range for structural, carbon and low alloy steels (E412) and its blue ring range for stainless steels (E414). Both new taps feature a spiral flute angle of 48°. This facilitates smooth and fast chip evacuation, making them ideally suited to threading deep blind holes up to 3xD. A special three radii profile with constant rake angle all along the
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flute length leads to better control of cutting properties and prevents the nest formation of chips. This, in turn, promotes increased productivity by minimizing machine downtime. Chip evacuation is further facilitated by a back taper which reduces chipping on the last threads of the taps. This feature also reduces torque when the tap reverses, resulting in longer tool life. Other material types covered by the Shark range include red ring for alloy steels, green ring for aluminum and white ring for cast iron. All are manufactured from a unique powder metallurgy tool steel, different to any other HSS-E-PM. This provides an unbeatable combination of toughness and edge strength.
For more informtaion, Website: www.dormerpramet.com.
CUTTING TOOLS
TECH TRENDS
Cutting Tools: Analysing the trends
C
utting tools have highly engineered coatings and geometries for all types of manufacturing methods and materials. It should be no surprise. Trends in the manufacturing industry drive trends in metal cutting insert development. Changes in work piece materials, manufacturing processes and even government regulations catalyze parallel advances in metal cutting tooling technology. As manufacturers continually seek and apply new manufacturing materials that are lighter and stronger—and therefore more fuel efficient—it follows that cutting tool makers must develop tools that can machine the new materials at the highest possible levels of productivity.
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By fine-tuning combinations of tool material compositions, coatings, and geometries, toolmakers enable users to make more parts faster and at reduced manufacturing costs. The development process is continuous and interactive. Nonferrous Fulfillment A good example of material-driven tooling development is the growing selection of tools for machining aluminum. In the quest for fuel efficiency, the use of aluminum in vehicle manufacturing is constantly increasing. While in 1980 aluminum made up approximately 3 percent (representing 34 kg/75 lbs) of a typical midsize car, that proportion had risen to about 5 percent by 1990. Forecasts for cars of the future
indicate that aluminum usage will rise to between 10 percent and 20 percent of the total vehicle weight, with engine blocks, cylinder heads, and housings being major contributors to consumption. Although uncoated carbides and polycrystalline diamond tools presently dominate the turning, milling and drilling of aluminum/silicon alloys, the increasing aluminum usage has hastened the development of thin film diamond coated carbide cutting tools (Figure 1, at left). Diamond coated tools offer wear resistance comparable to polycrystalline diamond materials, while also providing multiple insert edges and the ability to support complex chip control geometries. The dual advantages of high wear resistance and geometric flexibility make
CUTTING TOOLS
TECH TRENDS diamond coated tools excellent candidates to replace uncoated carbides as well as expensive PCD cutting tools. Diamond coating is being extended to more difficult tool geometries including drills and end mills. And, for hypoeutectic aluminum as well as magnesium alloys, titanium diboride (TiB2) coatings applied by the physical vapor deposition (PVD) process offer productivity advantages (Figure 2, below). New Irons In The Fire Gray cast iron, another mainstay of vehicular manufacturing, frequently is being replaced by stronger, tougher nodular cast irons in components such as housings, crankshafts and camshafts (Figure 3). However, the strength and toughness that make nodular irons desirable workpiece materials also make them difficult to machine. Tools to machine these irons must resist abrasive wear and endure interruptions in the cut, as well as be capable of productive cutting speeds and feed rates. Nodular irons typically would be machined with carbide inserts featuring chemical vapor deposition (CVD) coatings. CVD coatings have been commercially available for about 30 years, and the fact that more than half of the inserts sold are CVD coated testifies to the effectiveness of these coatings. However, the high temperatures
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(about 1,000°C) involved in the CVD process create an embrittlement called “eta phase” at the coating/substrate interface. Depending on its extent, the embrittlement can affect performance in operations involving interruptions of cut and inconsistency of workpiece microstructure such as found in some nodular irons. Recently developed medium temperature CVD (MTCVD) coatings have shown a reduced tendency to formation of eta phase. MTCVD coated tools offer increased resistance to thermal shock and edge chipping compared to conventional CVD coated tools. The result is greater tool life as well as increased toughness compared to high temperature CVD coatings. Sharp for Steel . . . and Others Physical-vapor-deposition (PVD) coatings also offer advantages over CVD coatings in certain operations and/or workpiece materials. Commercialized in the mid1980s, the PVD coating process involves relatively low deposition temperatures (approximately 500°C), and permits coating of sharp insert edges. (CVD coated insert edges are usually honed before coating to minimize the effect of eta phase.) Sharp, strong insert edges are essential in operations such as milling, drilling, threading and cutoff, and for effective cutting of long chipping materials such as low carbon
steels (Figure 4, at below). In fact, a wide range of “problem” materials— such as titanium, nickel based alloys, and nonferrous materials—can be productively machined with PVD coated tools. From a work piece structure point of view, sharp edges reduce cutting forces, so PVD coated tools can offer a true advantage when machining thin walled components. The first PVD coatings were titanium nitride (TiN), but more recently developed PVD technologies include titanium carbonitride (TiCN) and titanium aluminum nitride (TiAlN), which offer higher hardness, increased toughness, and improved wear resistance. TiAlN tools in particular, through their higher chemical stability, offer increased resistance to chemical wear and thereby increased capability for higher speeds. Recent developments in PVD coatings include “soft” coatings such as molybdenum disulfide (MoS2) for dry drilling applications. Combination soft/ hard coatings, such as MoS2 over a PVD TiN or TiAlN, also show great potential, as the hard (TiN or TiAlN) coating provides wear resistance while the softer, more lubricious outer layer expedites chip flow. Running Dry Government mandates also can
CUTTING TOOLS
TECH TRENDS affect cutting tool development. In some countries, increasingly strict environmental regulations governing the disposal of cutting fluids are resulting in increased use of dry machining. While dry machining is not appropriate for every process and workpiece material, in some cases careful selection of cutting tool material can enable a user to minimize or avoid the use of coolant. A cutting tool with a thick alumina coating can allow increased feed rates in the machining of steel, reducing contact time of the insert with the workpiece and minimizing exposure of the tool to high cutting temperatures, and thereby enabling productive dry machining (Figure 5, below). In addition, advanced coatings such as PVD TiAlN can provide good performance in dry machining or in minimal coolant systems. As mentioned previously, lubricious PVD MoS2 coatings can also facilitate dry drilling and tapping. A focus on dry machining will spark further effort to develop cutting tools with high resistance to thermal load. Cermets For NearNet Cermet cutting tools (also effective in dry machining applications) are one facet of the cutting tool industry’s response to nearnetshape manufacturing trends. These trends entail efforts to lower manufacturing costs by casting and forging components to near their final (net) shape, thereby reducing the number of machining operations necessary to complete a part. Fewer heavy roughing operations are required, and the need for tools engineered for semifinishing to finishing duty expands. Development of cermet tools is one way tool manufacturers are addressing this need. Cermets, comprised mostly of titanium carbonitride (TiCN) with a nickelcobalt binder, are hard and chemically stable, leading to high wear resistance. Cermets work best in materials that produce a ductile chip, such as steels and ductile irons. Their increased speed capability enables them to machine carbon, stainless steels and ductile irons at high speeds
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while producing excellent surface finishes. Recently developed cermets combine excellent resistance to deformation and chemical wear with a degree of toughness that enables them to be used in semi finishing as well as finishing operations. PVD coatings further enhance the performance of cermets on a wide variety of workpiece materials. Machining The Hard Way Both environmental/governmental factors (disposal of coolant/swarf) and economic concerns (the high cost of grinding) are accelerating the replacement of grinding by machining in the processing of hardened workpieces. The cutting tool industry is constantly developing and evaluating tools engineered to provide maximum productivity in hard-machining operations. These tools include superhard materials such as polycrystalline cubic boron nitrides, as well as ceramic tools. Coatings, which reduce frictional heat and promote longer tool life, are among the new concepts being utilized in tools for hard turning (Figure 6, at left). In field tests, coated superhards have outlasted other PCBN tools by 20 to 100 percent. Coatings have also proven effective on ceramic tools engineered for hard turning. In situations where the hardened workpiece doesn’t have roughness or other interruptions, coated ceramics offer more cutting edges and lower cost, and can be a cost effective alternative to PCBN tools in hard turning. Updated Ceramics For Difficult Materials Development efforts in ceramic tool technology are enabling these hightech tools to move into new areas of application. While recently developed silicon nitride tools offer improved fracture resistance compared to their predecessors, their relatively low resistance to chemical wear has limited their use in the machining of nodular cast irons (Figure 7, below). However, wear
resistant CVD alumina coatings have expanded the application range of silicon nitride based tools to include these difficult to machine irons. Regarding alumina (A1203based) ceramics, the addition of silicon carbide whiskers offers increased productivity in the machining of Inconel and similar high strength, high temperature alloys in the aerospace industry. Single crystal whiskers deflect cracks in the alumina matrix and thereby improve fracture toughness of the tool. Geometric Progression Perhaps the common thread through all manufacturing is the drive for increased productivity and reliability. As metal cutting operations become increasingly fine tuned, the relationship between cutting tool micro (cutting edge preparation) and macro (rake face topography) geometry is becoming more and more important. Chip control, tool life, workpiece finish and accuracy can be greatly improved by applying the proper combination of micro and macro geometries in conjunction with the proper substrate and coating. Control of the chip, dissipation or deflection of heat via restricted contact topographies, and reduced cutting forces as a result of positive rake surfaces all lead to the improved performance of today’s modern molded cutting insert geometries. Advances in tool manufacturing technology are making possible more precise matching of macro geometries and hones to specific machining applications. Productivity First True breakthroughs in cutting tool technology occur, but they are rare. Most tool development comes from development, refinement and innovative combinations of existing tool materials. The direction for this development begins with the analysis of the characteristics of the materials being machined, includes the demands of specific operations, and involves ongoing communication between toolmaker and end user.
AUTOMATION & ROBOTICS
CONTENT IN FOCUS Autodesk, STM Tie-up - A New Value Proposition for Manufacturing Sector
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COMPANY PROFILE We give strategic advantages to our customers from diverse industries
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Shavo Technologies offers high-tech tailor made solutions
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CASE STUDY Flexible robotic cell optimizes the CNC milling process
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Addressing Design Development Challenges Through Simulation Driven Platform
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TECH TRENDS Rollon Gantry Robot Boosts Tire Bead Production
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IN FOCUS Autodesk, the renowned American multinational software corporation,recently announced a tie-up with S&T Machinery Pvt. Ltd (STM), an eminent supplier of quality machinery and most soughtafter machine models based out of Coimbatore. This will enable a ‘one stop shop’ model for STM to sell value to the customers and offer an integrated hardware and a software solution. Customers will benefit more from this model as they will get original licensed Autodesk software along with the best-in-class machine tool built by STM in collaboration with Manford of Taiwan. Engineering Review was invited to the new manufacturing facility of STM at Coimbatore to witness the new CNC machines manufactured incorporating Autodesk Software. On the sidelines of the Customer Meet organized by STM, P.K. Balasubbramaniian spoke to Pankaj Gauba, Head of Digital Manufacturing, India & Middle East, Autodesk to ascertain more details of the value proposition for customers and how this business model would eventually help the larger manufacturing sector in India. Excerpts: 68
MACHINE TOOLS WORLD JANUARY 2018
AUTOMATION & ROBOTICS
Pankaj Gauba, Head of Digital Manufacturing, India & Middle East, Autodesk
Autodesk, STM Tie-up A New Value Proposition for Manufacturing Sector Q. You are a renowned name in software solutions for design. What are the solutions you offer to the manufacturing sector?
Q. You have already made a dent in digital manufacturing. What’s the significance of your tie-up with STM Machinery?
We offer CAM software for all milling and turning solutions. Our key offerings are PowerMill, PowerShape, FeatureCAM & PowerInspect.
The S & T Group based in Coimbatore which has been in the business of supplying machine tools, accessories and providing machining solutions for over two decades, has recently expanded its manufacturing activity in collaboration with Manford Machinery of Taiwan.
Perform �unlimited For your maximum productivity, we set ourselves no limits. The biggest robot portfolio in the low payload class is still growing – and providing a maximum boost to your productivity. KUKA offers the right robot solution to suit your specific application for perfect machining, precise continuouspath applications or fast handling. Discover your KR CYBERTECH robot now at www.kuka.com
IN FOCUS The JV, S & T Machinery Pvt. Ltd., manufactures machining centres in India to make advanced technology more accessible and more affordable for the Indian manufacturing industry. Software is the soul of any machining centre. STM have tied up with us for incorporating Autodesk software in all themachining centers produced by them and shipped from their new facility.
Q. With this, are you setting a new trend? You can call it a new business model. Software is costly. If you take the mould & die industry for instance, the manufacturer may find it difficult to invest in software at one go. At the same time, we do not want to deprive him of the benefit of technology. So we have given him the option of subscribing to the software for a term of 1, 2 or 3 years. The advantage is that he can own the software at a fraction of the original cost. After one year, he can opt to upgrade the software to suit the new generation machine or high end application. So in effect he is going in for OPEX rather than CAPEX. This gives a great advantage to the customer in the Indian environment.
Q. What’s the technological edge you would be giving to your partner? We are a 35 year old company with cutting edge technology and a global presence. Autodesk has a legacy of building strong products by actively investing in R&D. Our endeavor would be to keep enhancing all our software ability with the changing needs of the customer.
Q. What are the value added propositions you would be making? If you take the instance of STM, our CAM software is preloaded in their CNC machines. This helps the customer to get the most out of his investment. More importantly, he gets the benefit of a sourcing a solution through a single supplier.
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AUTOMATION & ROBOTICS Q. What’s your contribution to enhancing precision and productivity? Autodesk products across the CAD, CAE & CAM portfolio focuses on enhancing our customers’ productivity and deliver precision outcomes in what they deliver to their end customers. Our business model strongly works on customer feedback and that becomes the foundation of enhancing our product abilities on a continuous basis.
Q. What’s the scenario of digital manufacturing in India and how do you propose to make a positive contribution? In India, digital manufacturing is a reality. The pace of adoption of technology is gathering momentum. However, we anticipate significant changes in the landscape in the next five years. Time was when China used to rule the roost. They thought they could service everyone. But slowly and surely China is losing the momentum, and the shift is happening to India. Indian entrepreneurs are taking up the challenge. The changes in regulatory framework, sentiments, competition, and economies of scale – everything seems to be in favor of India. The Government is also doing its bit to encourage investments. So things are really looking positive for Digital India.
Q. How do you create awareness of the integrated solutions you can offer to the industry? Through our innovative initiatives and investments ahead of time. Our new business model like the tie-up with S&T, too is helping in creating awareness and ensuring our visibility. We shall have more of such tie-ups covering major manufacturers and geographic locations. We also arrange road shows and participate in relevant exhibitions and conferences.
Q. Is Indian industry geared to switch to high tech manufacturing? With many multinationals having
set up shops here, Indian industry is surely geared to switch to high tech manufacturing for specific products going into high-end applications. We also see a new breed of enthusiastic entrepreneurs eyeing at high-tech manufacturing to cater to niche markets. The environment is conducive, and the Government is also proactive and encouraging.
Q. How do you convince the customer of the benefits of automation? I don’t think the Indian customer needs convincing for automating his workflows. It’s always a question of when is he ready to invest and increase technology adoption in his factory or company. Every company goes through this cycle and rate of adoption increases exponentially once the benefits are experienced.
Q. How do you look at the future of digital manufacturing in India? Digital Manufacturing has huge head room in India as the benefits are quite clear. Our Government under various initiatives like ‘Make In India’ encourages local manufacturing. With the increased participation by multinationals to manufacture locally, the overall environment is becoming more conducive and people are adopting technology faster than earlier days.
Q. What are the support services you can offer to the industry to enable it go in for more and more automation and reap the benefits? We are committed to the Indian manufacturing industry to provide our CAM software and support it with pre- and after-sales service. We shall continue to educate and guide the customers on the right selection and application to optimize benefits of technology and automation.We offer professional on site trainings to our customers for a fee to ensure that they get the best out of their investment in our software.
COMPANY PROFILE
AUTOMATION & ROBOTICS
We give strategic advantages to our customers from diverse industries
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 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
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conform to international standards. The company’s quality systems are ISO-90012008 certified. Strategic advantages
Over the years, Bettinelli Group and CDS Indexers have become synonymous with high quality automation products and technologies. “Our design and manufacturing systems have furnished competitive and strategic advantages to numerous industries in pharmaceutical, automobile, manufacturing, packaging and a plethora of other sectors. And for automation functions, our solutions are invariably preferred by companies,” says Rupesh Paparaju, Director, Bettinelli Automation Components, India. The Indian subsidiary, headquartered in Pune, serves its customers in India by providing installation, commissioning, and after-sales support. It also offers technical consultation. In the pharmaceutical industry cam driven systems are used in filling, blister pack, tablet making and packaging machines. In automobile industry, they are used in pallet transfer tables, assembly machines, painting applications and test rigs, just to mention a few. In machining industry, they are used with advantage in
Parallel Shaft Indexer
Rotary Indexing Tables, TR Series
Rupesh Paparaju, Director, Bettinelli Automation Components, India
deburring, lapping and pressing machines and in transfer lines. In SPM & robotics, they find applications in transfer lines, station loading, sequential operations and so on. Inwelding, these indexers are inevitable in positioners, synchronous welding, robotic welding and component transfer. Packaging too is a major application area. Cam systems are used in box filling machines, wrapping machines, cartoning and capping machines. Indexers are also used in casting, printing and cosmetics industries. Closer to the customer
The Indian arm of Bettinelli, based in Pune, Bettinelli Automation Components Pvt. Ltd., is highly customer-centric. “Our presence in India means quite something in fostering a symbiotic relationship with our customers. It helps us to match our world-class products with our eminent customer support,” underlines Paparaju, Director, who has built up a team to improve Bettinelli’s response time. “CDS are high-tech products which lend themselves to enhance the operational efficiency and productivity at the customer’s end. We stay close to the customer to understand his needs and offer customized solutions within the shortest possible time to ensure peak uptime of his equipment and operations”, he adds. - P.K. Balasubbramaniian
AUTOMATION & ROBOTICS
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
AUTOMATION & ROBOTICS
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
CASE STUDY
AUTOMATION & ROBOTICS
Flexible robotic cell optimizes the CNC milling process KUKA KR AGILUS loads and unloads machining centers in a flexible robotic cell
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ANNORITZER Medizintechnik GmbH & Co. KG in the German town of Tuttlingen is one of the leading manufacturers of repair parts for medical instruments. Founded in 1975, more than 60 percent of their products are exported, primarily to countries in the European Union, the U.S., Australia and New Zealand. Endoscopy is a specialization area of DANNORITZER Medizintechnik. Whether for repairing existing instruments or manufacturing complex new instruments, for biopsy forceps or rigid and flexible endoscopy, for standard instruments or built-toorder products – the company offers its customers a broad portfolio of solutions. MRC flextray with flexible drawer system
As a result of high international demand, Dannoritzer Medizintechnik GmbH was
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no longer able to maintain long-term supply in the area of CNC machining using the existing production sequences. With wbt automation GmbH & Co. KG, the company found an integrator specialized in the automation of machine tools and manufacturing processes and requested that it implement a robot-based solution. The specification: due to the shortage of labor, the time-consuming organization of shift work is to be eliminated in the future. Beyond this, qualified employees are to be relieved of monotonous loading and unloading tasks. The solution: the “MobileRobotCell (MRC) flextray” robotic cell developed by wbt with automatic loading and unloading performed by a KUKA KR 6 R900 robot from the KR AGILUS series. Since September 2015, the MRC flextray with its flexible drawer system
has been in use at DANNORITZER Medizintechnik. “Thanks to its flexibility, precision, speed and relatively small space requirement, the robot is the best solution for us to increase productivity. It allows us the possibility of operating the CNC machine in a second and third shift without personnel,” notes Production Manager Julian Dannoritzer in explaining the advantages. Additional robot training for the machine operator or CNC set-up personnel was not necessary thanks to the comfortable user interface. Low-friction rollers, a docking station and coding allow for maximum flexibility
At DANNORITZER Medizintechnik, the Haas VF-2SSYT machining center is equipped with fixtures and tools before the flexible MRC flextray arrives. The pallets are then loaded with raw or semi-
Linear solutions global provider.
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ROLLON India Pvt. Ltd. - INDIA 1st oor Regus Gem Business Centre 26/1 Hosur road, Bommanahalli Bangalore 560068, INDIA www.rollonindia.in - info@rollonindia.in
Linear Line
Actuator Line
Telescopic Line
Actuator System Line
Rollon is a global provider of linear motion solutions for several industrial sectors, such as: industrial machines, railway, automation, packaging and logistics, aerospace.
AUTOMATION & ROBOTICS
CASE STUDY finished parts and fed in by means of the graphical user interface on the the robotic cell. The KUKA KR 6 R900 with a special white paint finish opens the drawer containing the pallets, removes the parts and places them in the clamping fixture. “The parts are accessible for inspection and various parameters can be monitored to ensure process reliability without having to interrupt the automation,” adds Julian Dannoritzer. The KUKA small robot is impressive in this application, demonstrating its maximum speed with the utmost precision. The compact KR 6 R900 distinguishes itself by ideally covering the working space with a reach of 901 mm at a maximum payload of six kilos. “The robotic cell we developed can process up to four drawers, each with two component-specific pallets, and is thus also highly suitable for small and medium batch sizes,” explains Joachim Burkert, CEO of wbt. Individual expansions – such as a deburring station, a testing device,
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inspection part outfeed (PLC drawer) or a measuring device – can be easily tailored to specific customer requirements. Using its own docking station with integrated machine interfaces, the MRC flextray is positioned safely and precisely at the desired machining center. “Thanks to the low-friction rollers, the mobile cell can be easily moved manually to the next application area, docked and started,” stresses Burkert. The MRC flextray uses an internal coding to detect the corresponding machine to which it is docked and automatically makes the required programs available to the operator. Additional robotic cells for further work steps
“Depending on the equipment and the area of use, the cell’s hourly rate is between six to eight euro,” stresses Burkert. This enables rapid payback on the procurement costs. For Dannoritzer Medizintechnik, the investment has
already been worthwhile. The robotic cell and the milling center work reliably together. The parts count can be calculated over longer periods and it was possible to increase the runtimes of the milling center. “The use of new milling technologies has rendered downstream processes superfluous, not only streamlining the process, but also improving the quality of the products,” notes Julian Dannoritzer. Dannoritzer Medizintechnik was able to eliminate previous error sources resulting from manual clamping and to monitor processes better. “We are very satisfied with the solution. As a result, we will automate further products in the long term. Additional robotic cells – for example, for short part turning or further assembly steps – might also be attractive for us,” concludes the Production Manager.
For more information, Website: www.kuka-robotics.com
CASE STUDY
AUTOMATION & ROBOTICS
Addressing Design Development Challenges Through Simulation Driven Platform
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uto Original Equipment Manufacturers (OEMs) are looking to their suppliers to be their development partners by moving up the value chain. Suppliers are expected to partake in joint Research & Development (R&D) activities by being involved right from the conceptual stage, thereby adopting a more collaborative approach to the entire product development process where they contribute at each stage of the development cycle. The key factors for automotive supplier competitiveness are: • Reduced product development time. • First time right products. • High value offerings with superior technology at affordable costs. To achieve these above mentioned goals, OEMs are insisting component suppliers invest in simulation technologies.
Focus on Simulation by Automotive Suppliers
Overcoming engineering challenges faced by automotive suppliers. Automotive suppliers are facing many challenges in having in-house simulation capabilities compared to that of OEM’s, the primary challenges being upper caps on budgets & constraints of hiring expert manpower and retaining them. Access to relevant data to validate the designs and establishing robust virtual/ test methodologies to match OEM expectations is another concerning factor for the suppliers. Simulation Tools that the Supplier Segment Needs
The majority of expectations are to find out cost effective, reliable methods and solutions which can lead to better, lighter, faster and low cost engineered products. One of the ways to overcome these challenges is to invest in simulation
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technologies that require an affordable initial investment, the ownership cost of which is low, the codes are reliable & proven, and the suite of tools provide suppliers access to a broad range of solvers (a true multi-physics environment) helping them pick and choose the solvers as per their simulation requirements. Another important factor in consideration is that these tools need to be easy to use and the existing manpower should be able to learn quickly and develop proficiency so that they can harness the full potential and derive maximum benefits that these tools have to offer. The need for solver technologies addressing various physics is very dynamic. Their usage cannot be accurately predicted in advance and therefore investing in multiple solvers is not a commercially viable solution for the organization. Altair HyperWorks® through its patented Units based licensing system gives customers access to multiple solvers under one umbrella. Users get access to different solvers addressing multiple physics, which helps them to apply the correct one based on the
challenge at hand, thus making it a smart choice for the organization to achieve robust product design through reliable & accurate simulation tests, at an affordable investment. Meanwhile the major engineering decisions can be made easy with predictions through simulation. About Endurance Technologies
Endurance Technologies is one of India’s leading automotive component manufacturing companies. Starting with two aluminium casting machines in FY 1986, we have grown to operate 18 plants in India and 7 plants in Europe. Today Endurance Technologies is the largest aluminium die casting manufacturer (Source: Aluminium Casters’ Association of India) in India and one of the leading automotive component manufacturers in aluminium die casting (including alloy wheels), suspension, transmission and braking systems. About Endurance R&D
Endurance Technologies, has Innovation & Technology as its key focus areas &
CASE STUDY believes that R&D activities are critical to maintaining a leadership position in the industry and providing a competitive advantage as it seeks additional business with new and existing customers. It has four dedicated R&D centers for each of their product businesses: three in Aurangabad (one each for suspension, transmission and braking systems) and one in Pune (for aluminium die casting). These R&D centers are supported by Advance Engineering Group from CAE, RLDA, Electronic Control Systems, Failure Analysis, Advanced Materials & Tribology point of view. Endurance has a dedicated Intellectual Property (IP) cell which is actively involved in evaluating every possibility of patent registration. All R&D centers are approved by the Department of Scientific and Industrial Research (DSIR). It has expansion plans in Aurangabad, Maharashtra, India to develop an automotive proving ground (test track) spread over 29 acres, which it expects will be operational by the end of 2018. The proving ground construction activities have already commenced. Simulation Implementation at Endurance Technologies
In the early stage of in-house simulation implementation at Endurance Technologies, HyperWorks was being adopted primarily for pre and post processing due to its extraordinary FE modeling solutions. During the stage of establishing high fidelity finite element modeling for our applications, HyperMesh® has been used extensively to build analysis models for Structural, Thermal, Computational Fluid Dynamics (CFD), and Multi-body solutions and OptiStruct® for durability analysis with HyperView® as standard post processing. With constant support, Altair team helped us in exploring and implementing various HyperWorks solvers at Endurance Technologies. Altair Solution Offerings
Altair HyperWorks offers a wide range of simulation applications – which includes Linear Static, Non Linear Implicit /
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AUTOMATION & ROBOTICS Explicit, Multi-body Dynamics (MBD), CFD, Electromagnetic, Optimization etc. in the form of HyperWorks Units (HWU), to address specific industry requirements. For example, most of HyperWorks applications are available for 50 HW Units. A user can access any application, which takes up requisite set of HWUs and returns them to the common pool on network server once he is finished with his work. This flexibility allowed us to start exploring HyperWorks solvers for different applications, involving Linear & Non-Linear analysis (OptiStruct), Crash & Impact simulations (RADIOSS®), Kinematic & Dynamics simulations (MotionSolve®), Flow Dynamics (RADIOSS FSI/AcuSolve®). HyperWorks Solver Adoption
At the stage of solver evaluation, exploration and test validation process, there was a need of maximum handholding and knowledge transfer. A strong collaborative activity with Altair & DesignTech (business partner of Altair) technical team stretching over extended period over four years for a variety of simulation solutions helped us in benchmarking the appropriate simulation methodologies. Through these collaborative initiatives, we were able to establish a simulation approach suitable to our design and development process that ensured we developed better products faster and with greater accuracy than before. Here are few of the real-time cases listed for which simulation approach has been well established at Endurance Technologies. • Telescopic suspension virtual validation using RADIOSS & MotionSolve. • Strength and Vibration analysis using OptiStruct. • Design correlation with tests using HyperStudy® and HyperGraph®. • Clutch performance studies using MotionSolve. Altair HyperWorks helped in smooth implementation of variety of CAE simulations during product design
& development stage at Endurance Technologies, India. Endurance Achievement
Adoption of Altair simulation solutions effectively facilitated the achievement of reliable results, with test correlations, study product behaviour under several conditions and constraints, and also the exploration of various ‘what- if’ scenarios. These tools helped us articulate and measure the costs and effects of possible design errors, while helping us arrive at simple yet accurate solutions for our complex engineering problems. Today HyperWorks technologies are playing a vital role in product development cycle and simulation has become an integral part of NPD process at Endurance Technologies. Endurance has developed its own Virtual Verification Process which is automated with the help of Altair Enterprise Solutions Group in order to cut short simulation lead times & improve the results consistency. Future Road-map on Simulation and HyperWorks at Endurance Technologies
Integration and automation of advance processes in HyperWorks will be a new area to explore as it would help companies capture & establish best practices or ideal approaches to address complex, frequently solved problems and thus reduce to a great extent the duplication of work or repetitive efforts. We plan to explore other offerings under HyperWorks solutions, viz. Click2Cast®, solidThinking Inspire®/Evolve®, which can strengthen our engineering judgments and shorten our design and development cycle on our product-line. Going forward, Endurance Technologies plans to venture into full vehicle level design activities and anticipates an increased application of HyperWorks technologies in the area of optimization and design of experiments. We believe that Altair’s further research into HyperWorks solutions and continued investment in addressing newer physics will address emerging domains there by enabling Endurance address newer challenges upfront with simulation.
AUTOMATION & ROBOTICS
CASE STUDY www.mtwmag.com
NORD DRIVESYSTEMS akes engineering easier for marine equipment supplier Navalimpianti, an experienced Italian marine equipment provider, is using products from NORD DRIVESYSTEMS to improve its efficiency levels
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or their extensive drive program that enables suitable configurations for almost all torque, speed, and duty type requirements, NORD DRIVESYSTEMS also ensures that adequate extras and options are readily available to facilitate operation in challenging environments. This was a particular boon to Italian ships outfitter Navalimpianti, as they found that adapting drives for maritime use no longer required a great application-specific engineering effort. Components and systems for maritime applications must be especially rugged and durable because of their continuous
exposure to a moist, salty atmosphere. In addition, suitability for widely differing operating temperatures becomes necessary for ships that pass through several climate zones. Navalimpianti, an experienced Italian marine equipment provider, used to individually select and procure all required equipment including electric drive components. All configurations and adaptations of the drive solutions were then done in-house to comply with rigorous demands, all to ensure totally reliable performance for many years. Obviously, this required a very substantial effort. All of that changed almost instantly
Navalimpianti manufactures marine equipment such as this window cleaning platform with safety rails
when Navalimpianti found that drive provider NORD DRIVESYSTEMS was able to flexibly implement the required options from their standard catalog, and supply suitable drive systems everywhere in the world. Navalimpianti not only found the high gearbox quality and reliability more than satisfactory, but especially appreciated the German drive manufacturer’s readiness to implement specifications such as IP66 ingress protection or stainless-steel output shaft fittings. A number of other applicationspecific features were then jointly defined by the customer and NORD, whose engineers were able to draw on decades of experience and advise on the optimum drive selection and configuration. Rain or shine – drives move Skydomes
Sliding glass roofs for swimming pools are among Navalimpianti’s developments for cruise ships
Individually designed for each ship, Navim Skydomes are a standout product in the portfolio of the experienced passenger vessel outfitter. These elegant sliding glass roofs are composed of numerous movable segments and are equipped with a motor. When they are completely closed, they keep out wind and rain and enable air conditioning of the upper deck. The glass roofs add value to any cruise ship because they allow the year-round use
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Featuring protective coatings and stainless-steel shafts, the winch drives for the work platforms are equipped for maritime use
of outdoor swimming pools, which are among the main attractions for many travelers. They are opened and closed gently and quietly by specially configured NORD drives. Two or four parallel-shaft geared motors are used depending on the span and weight of the roofs. In addition to a high resistance to maritime climates, these drives must withstand the chlorine-saturated atmosphere around the pool. Notably, they must ensure failure-free operation for many years, because once the roof is installed, they are not easily accessible for maintenance or repairs. Drive over board – window cleaning on the high seas
Moving window cleaning platforms into position is another task NORD drives take care of. “We are outfitting two ships right now,” says Silvano Lonzar, chief designer at Navalimpianti, “one with six and one with seven motorized window cleaning platforms for the ship’s right, left, and stern side.” Four bevel and worm geared motors per window cleaning system power the winches that move the platforms horizontally along. The worm-geared motors are selfholding and therefore need no brakes to stop. The fans of the vertically installed motors are protected from rain ingress by double canopies. Further safeguards in
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NORD DRIVESYSTEMS supplies robust, low-maintenance drives fortified against salt and chlorine for the sliding pool roof
this outdoor application and its salty and chlorine-saturated atmosphere include terminal boxes sealed with epoxy resin and stainless steel hollow shafts. A fivelayer coating for offshore operations with sturdy multi-component paints ensures class C5 corrosion protection according to EN 12944. Satisfied end customers
Over the years, NORD systems in Navalimpianti products have proven
their mettle in numerous installations. The drives can be directly installed and put into operation by the OEM without any extra engineering effort. Commissioning has also become a smoother, more efficient process with NORD solutions, because the drive systems do not require a separate acceptance test or end user training. “The reliability of NORD products boosts our own overall reliability for our customers,” Lonzar says. “In fact, since we have been using NORD drives, we have experienced no service call, no drive failures. Our group image benefits greatly from that. What is more, NORD is able to fulfill our wishes very quickly and supply suitable solutions. In the past, we had to wait a long time until drives were delivered with documentation according to our specifications. From our experience, NORD can usually configure a standard drive from their catalog straight away. So, the selection takes little time and the delivery times are very short. Since we do not have to build weather-proof housings for the drives anymore, we save a significant amount of time.” Working with the Italian subsidiary of the NORD DRIVESYSTEMS Group, Navalimpianti can rely on the manufacturer’s global sales and service network. This, too, is important to Lonzar: “Before we chose NORD, we made sure to confirm they could supply products and materials in uniform quality around the world. In this regard, as well as in respect to cost efficiency, NORD passed the supplier selection process with flying colors.”
TECH TRENDS
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artell Machinery Systems is a global manufacturer of highly engineered industrial manufacturing equipment for the tire and rubber, oil and gas and wire and cable industries. With more than 75 years in business and over 8,500 machine builds, the company now offers a variety of automatic transfer and storage systems, bead handling systems and bead measuring equipment. For the pick-and-place component in one of its machines serving the tire and rubber industry, Bartell specified a custom Y-Z gantry robot from Rollon Corp. This particular Bartell machine makes tire beads-steel cables coated in rubber and wound to a particular geometric shape. With the help of Rollon’s gantry robot, the pick-and-place system transports finished tire beads to automated carts at the end of the production line. Bartell needed to automate this part of the process because the machine’s cycle time is roughly four cycles per minute, far too fast for a shop floor worker to keep pace with. Here’s a closer look at how Rollon’s gantry robot fit the bill:
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AUTOMATION & ROBOTICS
Rollon Gantry Robot Boosts Tire Bead Production A Fully-Customizable System Bartell custom designs its machines to meet very specific application requirements and plant layouts. For the pick-and-place system in the tire beading operation, the robot system needed to be fully customizable. Bartell explored several options before deciding that a multi-axis system from Rollon was the best fit. Rollon’s Y-Z gantry robot moves anywhere from 3 to 6 meters horizontally, and 1.8 to 2.4 meters vertically. For the tire beading application, it is imperative that the actuator is not belt-driven and that it is quiet enough to meet the customer’s stringent noise requirements. Belt drive actuators previously used in this application had failed due to high thrust forces. Further, due to the machine’s long travel requirements, ball screws were not an option. After ruling out these two drive systems, it was determined that a rack and pinion design could handle the loads, and Rollon’s Tecline actuator was specified for the job.
Stable & Precise Motion Guaranteed Because the Tecline actuator used in this gantry robot features a rack and pinion design, there is no belt slippage or breakage to worry about. Instead, hardened sloping tooth racks guarantee stability and precise motion. In addition, the noise levels are well below Bartell’s maximum allowable value of 75 dB. With regard to machine size, the two-meter vertical Z axis length requirement is easily achieved and offers the required level of torsional rigidity. Rollon’s standard beam lengths can go up to 12 meters, with longer lengths available as jointed versions. The required acceleration of 2 m/s2 and thrust force of 222 ft/lb. are well within Rollon’s 10 m/s2 and maximum load limit. In addition, a centralized lubrication system ensures that maintenance requirements are kept to a minimum. About the Actuator Because Rollon manufactures its custom linear modules to meet a wide range of application requirements, Tecline rack
AUTOMATION & ROBOTICS
TECH TRENDS www.mtwmag.com
and pinion actuators are designed to handle payloads from 5 to 2,000 kg. In addition to Bartell’s tire bead transport system, Tecline actuators are easily integrated into other applications such as robotics, palletizing equipment, production lines and logistics and manufacturing machines with Cartesian axis movements. Tecline actuators feature several benefits over competing designs: • Quick and easy assembly. • Simplified maintenance • Wide range of integrated solutions.
• Fully customizable. • Reliable technical support. Actuator construction features solid beams made of extruded aluminum profiles, a high-performance aluminum casting alloy plate that is preset for tool assembly and fixed and oscillating roller slides that can be adjusted through an eccentric bushing. Other features include: • Caged ball roller sliders. Systems are supplied with caged ball roller slides, which reduce friction between
the guide rail and slide, increase service life and minimize lubrication requirements. • Perfect alignment. All profile anchor supports must be perfectly aligned. When mounting the linear axes in parallel, it is important to verify parallelism between the linear units themselves, as well as the coplanarity of all head surfaces. • Permanent lubrication. Roller slides and V-shaped rollers come with a permanent lubrication system. When used properly, this feature eliminates the need for maintenance and increases the average service life of handling systems such as pick-andplace transport systems. Box - Tecline Actuators at a Glance: • Rack and pinion drive system achieves fast and silent movement. • Hardened, sloping tooth racks guarantee stability and precise motion control. • Flexible range of payloads possiblefrom 5 to 2,000 kg. • Impressive speed and accelerationmax. speed of 4 m/s and max. acceleration of 10 m/s2. • Multiple beam lengths available to 12 m; longer beams possible as jointed versions. • High torsional rigidity enables smooth and precise motion. • Hardened and ground steel guide rails boost system stability and performance. • Pre-assembled systems easily installed in 2 or 3 axis Cartesian robots. • Safe, reliable motion guaranteed with sturdy adjustable-position safety stops with dampers. For more information: ROLLON INDIA Pvt. Ltd. 1st floor, Regus Gem Business Centre 26/1 Hosur road, Bommanahalli Bangalore 560068, INDIA Tel: +91 80 67027066 Fax: +91 80 67027004 Email: info@rollonindia.in Wbsite: www.rollonindia.in
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Elesa+Ganter range of Mini indexing plungers made of steel or stainless steel for thin-walled sheet metal Elesa +Ganter, makers of standard machine elements, have enlarged their indexing plunger range with more “mini indexing plungers”.
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n general, the mini indexing plungers boast the smallest of dimensions. They are designed especially for thin-walled sheet metal. Zinc-plated, blue chromatised steel and stainless steel versions are available. The indexing pin and the pressure spring are made of noncorroding stainless steel. The fixed knob is made of mat black plastic. The mini indexing plungers are turned in with the help of the knurled knob or the hexagonal stem. The GN 822.1 mini indexing plungers feature a permanently
ex- posed hexagonal stem, allowing this design version to be fixed in place with an open-end spanner. All mini indexing plungers (GN 822 and GN 822.1) are available with and without indexing lock. The designs with indexing lock are used in applications where the indexing pin must not protrude temporarily. A notch prevents the disengaged knob from turning inadvertently or working loose through vibrations. Using noncorroding steel (GN 609) and stainless
steel bushings (GN 609.5) allows the thread length of the mini indexing plungers to be adapted to the wall thickness of the application in hand. For more information, Website: www.elesa-ganter.in
Virtual Prototyping helps Gazelle Tech develop an innovative vehicle that reduces energy consumption by half
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ith the car market expected to double in the next 20 years, and fossil fuels becoming scarcer, disruptive and innovative green, light cars must be developed. Developing these types of vehicles, which can be produced close to the ultimate customer, presents an interesting opportunity to reduce the total CO2 footprint. With cutting-edge technology, that is exactly what Gazelle Tech is working
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to do to decrease our carbon footprint yet still offer mobility to all. Gazelle Tech, a French startup company created in 2014, is the first peri-urban composite vehicle manufacturer of its kind. Their vehicle is currently under development and the industrial version is expected to be released in 2018. It features a composite chassis and body technology that makes it one third the weight of its competition and reduces energy
consumption by half. The model will be offered in both gas and electric versions for a B2B market in France, as well as emerging countries in Africa and Asia. Read the full story. Benefits Gazelle Tech is developing a new production method for an innovative, low carbon impact vehicle, , with the objective of offering sustainable transportation to all. Using ESI Virtual Performance Solution, they’re able to: • Reduce time to market by eliminating physical prototypes • Ensure a safe, lightweight vehicle design • Realize the necessary design adjustments for an overall optimal design
To meet the expanding global supply market requirements, Muratec has been a global leader in supply of Turning machines with advanced automation solutions. It is fully prepared to provide the most appropriate level of automation solution to meet the growing demand in India for medium to high volume global supply market combined with highprecision Standards. It also caters to the rapidity increasing volume requirements of the domestic Indian automobile industry. Our MW/MS Series Twin and Single spindle automated turning machines and MD series turning centers have more than 10,000 installations worldwide. We are proud to say that, “MURATEC MOVES YOUR CAR�. MURATEC machines are available in a wide range of chuck sizes: capacities ranging from 6" to 15" chuck size. These advanced, precision turning machines come with highly reliable, integrated, intelligent CNC 3 axis servo controlled gantry loader for smart, fully automated, flexible workpiece load/unload operations. Globally Proven Solutions, Abundant Experience in Automotive Parts Production
Best Selling Machine
Muratec, world’s first manufacturer of servo driven ram turret punch press introduces leading innovation in sheet metal industry MOTORUM 3048TG. MOTORUM series does more than to achieve high reliability and high speed processing. This machine enhances overall productivity through process integration of bending, forming, tapping and other processes, together with reduction of time needed to set-up and program.
MOTORUM series punch presses are available in various models to meet diversified needs of sheet metal industry. These machines are worldwide popular for its design features, rigidity, high speed productivity, environment friendly design features of minimum power consumption, low noise and high profitability to customers. Motorum series machines have more than 1,350 installations worldwide. MURATEC the leading name in automation is fully prepared to offer sheet metal automation solutions to meet the growing production demands in India. Muratec Ball Screw Press Brake BB4013 is driven by AC servo motor & ball screw mechanism.
The New 300kN Solution Latest Technology from the Inventor of the Electric Turret Punch Press
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Fibro India: Eying the opportunities through MAKE in India initiative
Vivek Nanivadekar Executive Director, FIBRO India
Q. Please brief us about company’s Indian & global reach ? FIBRO India, 100% subsidiary of FIBRO GmbH, was established in 2008. FIBRO India is only manufacturing facility outside Germany. FIBRO has two distinct operations- Standard parts also known as Die components, and Rotary Tables. FIBRO started way back in 1958 in Germany catering to the reputed sheet metal die makers who in turn were supplying pressed components to Mercedes Benz, AUDI, VolksWagen etc. FIBRO are the pioneers in the Rotary Table. There are basically two types of applications for Rotary Tables one in the Automation and second in the Metal cutting, for which FIBRO has the largest range in both segments Rotomotion and Rotocutting respectively. FIBRO India has been manufacturing fast moving standard parts like guide elements, oil less guide elements, spring plungers, cam slide units etc. catering to domestic as well as international markets. We have been adding new products and their variants every year catering to the Global market
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requirements. Now we are putting up the new plant for manufacturing ROTOMOTION Rotary Table which would be in operation from May 2018. Our Thrust is ‘Making in India’ and our moto is ‘German Precision, Crafted in India.’
market soon. We are in a process of creating the infrastructure to meet the market demand. FIBRO Germany has started working on ‘Industry 4.0’ for rotary tables. We will certainly keep you updated on the progress in due course of time.
Q. Please also highlight the latest initiatives in your industry domain?
Q. What are the market opportunities for your company’s products in India?
The Sheet metal forming industry is on the rise in India and thus the Tooling industry. Secondly there is tremendous pressure on lead time as well as on the cost at every stage of new product development. This will drive the local manufacturing of tooling with reduced lead time and cost competitive. The use of cost competitive quality standard parts will help the Tool makers to deliver the results. That is where FIBRO India has a role to play. At FIBRO India we are manufacturing standard parts and keeping the stock of fast moving items to support the local Tooling industry to reduce their lead time. Similarly, there is the substantial growth anticipated in automation sector. Therefore, it was decided to manufacture the Rotary/ Indexing tables in India to cater to this sector. FIBRO India will be making these tables for the world
As per the TAGMA survey report the Tooling industry is expected to grow at CAGR 11% in next three years. Besides, India is considered as developing economy. Due to initiatives taken by the government like ‘start up India’ ‘Make in India’ it has opened the doors in IT as well as manufacturing sector. Now the IT is working hand in hand with manufacturing more than in the past. I firmly believe India can become Global manufacturing hub sooner than later. Therefore, I see the great potential for FIBRO products in Indian manufacturing sector. With our wide range of Standard Parts and Rotary Tables we can serve the entire manufacturing sector. We are working very closely with the industry to understand it`s requirement as we believe in offering the solution than the product.
IN FOCUS Q. What is future prospect for your industry? As said earlier increase in Automation will call for increased no. of rotary/indexing tables. We are ready to customize the rotary tables to suit the application. Similarly, shorter lead times with quality in Dies & Molds will compel even small tool makers to use quality standard parts in their tool design. The use of not so good quality standard parts may result in the frequent break downs of the tools during the production which would incur the loss of production in addition to the cost of replacement of the substandard parts. Instead if you use right quality standard parts in the beginning though may be little expensive, it will turn out to be more economical in a long run. We are in the process of creating awareness and educating the toolmakers, so that market will expand.
Q. Is there any plans for expansion & new investment in terms of product development or new technology adoption to cater the demand of the industry? As mentioned above we are expanding
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our manufacturing facility. Our new plant is under construction which would be operational in the mid of 2018. We will be adding couple of new products in the range of standard parts as well in rotary/Indexing tables. We will keep you updated on the new product development from time to time.
Q. What is the top line product range & Is there any plans to launch new products? Our top line products are those standard parts which are manufactured at FIBRO
India like guide elements, spring plungers and Sliding CAM units apart from the Nitrogen Gas Springs for which we are market leaders. Whereas in rotary tables our range of ‘FIBROTOR’ tables for automation are our top line products. Couple of new products are lined up for the local development which will be launched one after another. FIBRO has recently introduced Highly Efficient Indexing Ring Table FIBROTOR RT.0750 for assembly Automation in automotive, electronics and consumer goods industry. This table offers shorter indexing time, soft acceleration, higher indexing accuracies etc.
Q. What is your vision for your company? To put it in simple words ‘Working closely with the customers, understanding their problems/ difficulties/challenges, FIBRO India will provide precision technical solutions thru. Standard parts and Rotary Tables to the toolmakers, Automation and general manufacturing industry by adapting innovative, cost competitive manufacturing methods.
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ReeR :50 years of expertise in safety automation More than 50 years of quality and innovation. Founded in Turin, Italy in 1959, ReeR distinguished itself for its strong commitment to innovation and technology. A steady growth throughout the years allowed ReeR to become a point of reference in the safety automation industry at a worldwide level. The Safety Division is in fact today a world leader in the development and manufacturing of safety optoelectronic sensors and controllers. ReeR is ISO 9001, ISO 14001 and BS OHSAS 18001 certified. Q. How long has been ReeR active on the market? ReeR has been operating since 1959. Our 60 years of experience in the safety sensors industry allow us to deliver high quality products for most of today’s industrial applications.
Q. Why is it important to install safety devices on a machinery? Installing safety devices is important to guarantee the safety of operators during all phases of a manufacturing process and to keep the accident and near-accident level as low as possible.
Q. What is the difference between a sensor and a safety sensors? A safety sensor is a device that is engineered to provide maximum safety also when failures occurs. A safety sensor will always contribute to shut down the machine also in case of sensor failure. An ordinary sensor may fail to do so whilst leaving the machine running, this is the most critical situation for operator safety.
Q. How is this achieved? In order to achieve this all safety devices have a built-in redundancy circuitry that always allow safety functionality also
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when failure occurs. It is important to use safety devices across the whole line by connecting safety sensors to safety relays or safety controllers, guaranteeing that a safety channel is implemented across the whole line.
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Q. What happens if I connect a safety sensor to a control PLC? A standard control PLC does not have the capabilities of reading and interpreting feedback signals from the safety device. In an event of a failure of either the PLC or the safety device, there could be a possibility that the machine will not shut, hence jeopardising the operator’s safety.
Q. What is the difference between Type 2 and Type 4? The main difference is in the ability of withstanding internal failures. With a
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Q. Are ReeR safety sensors manufactured according to the norms? Absolutely, all our safety sensors are manufactured according to the European Machine Directive 2006/42/EC. The CE mark has been obtained by the German TUV. For more information Web: www.reersafety.in
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INDUSTRY SPEAK
Developing import substitutes for welding consumables is our biggest challenge: Satish Bhat Satish Bhat, Managing Director, Ador Welding Limited
Q. You are a name to reckon with in the field of WELDING. What precisely is your niche?
Since its inception in the year 1951, Ador has significantly contributed towards nation building. Ador Welding is a complete welding and cutting solutions provider with the following key businesses:
• Welding consumables business which comprises welding electrodes, wires & fluxes, flux cored wires, hard-facing electrodes and wires and many more. • Welding Equipment business which has the latest equipment for SMAW, GMAW, GTAW and SAW processes. • Welding Automation; PPE and Gas cutting products and accessories & CNC based Gas and Plasma cutting equipment. • The Project Engineering business of Ador Welding is into the manufacture of flares and heat exchangers, pressure vessels, incinerators, and has also forayed recently into EPC contracts internationally. • Ador Welding has been an enabler to the industry in imparting welding skill with its training and development programmes through its wholly owned subsidiary the Ador Welding Academy Pvt. Limited.
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Ador welding is in the forefront in developing the latest technologies in-house through its Technology Development centre in Pune. We have recently attained the highly creditable NABL accreditation for our Consumables lab in Pune which speaks volumes for the quality standards maintained by the company. Ador Welding embarked upon a digitization program a few years back, and today, according to industry experts, we have some of the best digitalised systems. We have constantly strived towards our ambition to become ‘The Best-in-Class’. We cater to every industry in the manufacturing sector viz; nuclear, wind, thermal, defence, railways, infrastructure, automotive, steel and many more. Ador Welding is perhaps the only
company in the welding industry to have grown and surpassed its best year sales revenues every year in the past decade. Q. What are the product / technological innovations you have showcased recently?
We have recently launched our own Pulsed-MIG machine Champ Pulse 500. This indigenously manufactured high quality world-class inverter welding equipment has been conceptualized, designed and manufactured at our Technology Development Centre in Pune. This product exhibits all the features of the latest inverters available in the market. Our inverter welder Champ T 400 has won the India Design Award for its impeccable design. King Cut Pro 2500 is the latest addition to our Hi definition CNC plasma cutting range. We have developed many new welding consumables to cater to niche market segments and for projects of great national significance. These are some significant steps towards Ador’s vision in achieving the best-in-class global standards of manufacturing and development. Q. Would you like to share any differentiated offer you could make to
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INDUSTRY SPEAK the mission of ‘Make in India’ and are working in close coordination with the top government establishments in the country to develop import substitutes especially for welding consumables an there has been significant development on this in the recent past. Another differentiating capability is that the entire Ador’ range is developed and manufactured in-house. Unlike most others in the welding fraternity we don’t buy and sell. We have the only “clean room” in the country for the manufacture of inverter welding equipment. Our Welding automation and Project Engineering design teams are extremely capable in developing customized products to meet specific customer requirements. Innovation is in our DNA and a conscious effort is always made to present cost-effective and quality solutions to the customer. Our sales and service network is unparalled in the welding industry. Our welding Inverter model “Champ T 400” has recently won the India design
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award for the best Industrial equipment design. Ador has successfully managed to create a fine balance between the two extreme parameters i.e. price and quality. Last but not in the least, we pride ourselves in being known as a complete welding solutions provider and offer the entire gamut of welding products and solutions to the industry. Q. Have you planned any customer engagement programs or expansion plans as a part of your growth strategy?
Our presence in India for more than six decades as a leading player in the welding fraternity and the goodwill of the Ador brand has been achieved by fostering a symbiotic relationship with our customers.In the digital era, embracing a customer-centric mind-set across the organization is the need of the hour and our knowledge of the Indian market has helped us in providing prompt customer service. In a survey conducted by a leading consulting agency for CII on the customer centricity index for the top companies across sectors in India to measure the preparedness of Indian companies to compete with top global
Champ Pulse 500
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players, Ador performed admirably well and were invited as a key member of a panel discussion on the subject. However, a successful customercentric culture does not happen overnight. We follow various proven practices in AWL so as to maximize our customer satisfaction index, minimize the response time to customer, continuously reducing the trend of warranty failures. Our growth in the last decade and our growth plans for the future stand testimony to the fact that we have worked very closely with our customers and will continue to do so. Q. What’s the shape of things to come in your field which would be exciting and trendsetting?
The automobile industry is forecast to grow rapidly in the near future. Investments in high speed railway coaches, metros, defence, shipbuilding and aerospace manufacturing hubs are taking shape in line with the government’s ‘Make In India’ programme. Automation in welding and the use of robotic welding is the need of the hour as we strive towards becoming a worl- class exporter of engineering products. Robotic solutions offer the much needed skill and repeatability to critical jobs on mass manufacturing lines which makes them absolutely vital in this age of consumerism. IOT AI ANN are being put to good use to help create impeccable ‘first time right’ welding process planning in the west and a slowly but surely finding takers in India. Developing import substitutes for welding consumables is our biggest challenge as this will define India’s path towards being a top quality manufacturer to the rest of the world.
INDUSTRY SPEAK
We see Exponential Growth in businesses allied to critical manufacturing in the years ahead : G.K. Pillai G.K. Pillai, Managing Director, Walchandnagar Industries Ltd.
Q. You are a name to reckon with in the field of Hi-Tech Manufacturing. What exactly is your niche?
Walchandnagar Industries Ltd (WIL) is one of the very few diversified heavy engineering conglomerates in India. Today WIL’s niche is in manufacturing and supply of critical components for strategic sectors – Defence, Aerospace, Missiles, Nuclear and Gearboxes. WIL’s USP is the fact that it has a long and established record of successfully delivering diverse equipment ranging from weapon systems, launchers, missile sub-assemblies, core nuclear reactor equipment (Calandria, Heat Exchangers, Support Tank, etc), motor-casings for ISRO’s PSLV and GSLV launch vehicles and marine gearboxes for Indian Navy
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ships and submarines. Some of our marquee customers include ISRO, NPCIL, DRDO/DRDL, Indian Navy, ATVP, etc. A versatile manufacturing facility at Walchandnagar (130 km from Pune), established expertise in fabrication and machining of exotic materials as well as a well-trained and experienced set of people (management staff and operatives) are our core strengths.
in terms of product design (as most of the equipment are made-to-design) but more from the manufacturing process perspective – development of niche tooling for critical welding needs of missile sub-assemblies, development of proprietary welding techniques for exotic materials like Ti Alloys, achieving DIN-1 standard in gear grinding operation, etc. are some of the successful innovations at WIL.
Q. What are the product/technological innovations you have showcased
Q. Would you like to share any
recently?
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Technology and manufacturing process related innovations are a part of our everyday existence. There have been numerous innovations across many of our current offerings – not necessarily
end users with tangible benefits?
While our core business clientele is of a repeat nature owing to our long legacy of partnership with them, certain key offerings which may be of interest to
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INDUSTRY SPEAK potentially new customers are as follows: Versatile fabrication capabilities to cater to a host of sectors – process equipment (including oil & gas, petrochemicals and chemicals), earth moving equipment, materials handling equipment, railways, etc. WIL has a 56 acre piece of land along the waterfront at Dahej in Gujarat. This facility is ideally suited for fabrication of heavy pieces of equipment – some of which have been mentioned above. With this and also the land available at Walchandnagar (our plant location), it is possible for WIL to ramp up in heavy engineering sectors like defence and nuclear. Gearboxes across wide range of industrial applications – general engineering, cement, sugar, hydel, railways, etc. WIL has also recently expanded its footprint in the marine gearboxes market to cover “Offshore Patrol Vessel” gearboxes for the Indian Coast Guard as well.
Centrifugal machines (both batch type and continuous type) primarily for the sugar industry. However these machines also can be tailor-made to suit the requirements of chemicals, agroprocessing industries, etc.. WIL also has two product divisions – a foundry at Satara in Maharashtra and an instrumentation division (making temperature and pressure gauges) at Dharwad in Karnataka. Our foundry specializes in making heavy castings (both cast iron and SG iron) upto 12 tons – ideally suited for sectors like machine tools, earth moving equipment, materials handling, automobiles, etc. Q. Have you planned any customer engagement programs or expansion plans as part of your growth strategy?
Customer engagement (especially with our strategic customers) is an on-going process. This keeps happening through regular interactions. Recently we had the Chairman & MD of Bharat Dynamics
Ltd., Mr. V. Udaya Bhaskar visiting our plant to flag off the 600th set of integrated missile sub-assembly. We regularly have such interactions with very senior level delegations from our major customers. As far as expansion plans are concerned, WIL has recently completed a CAPEX cycle to shore up capacity in aerospace manufacturing. Plans are afoot to do the same for its missile subassembly manufacturing operations. In fact in practically all segments of our strategic businesses including nuclear plant equipment, defence and gearboxes, we see scope for expansion. The logic is that we see exponential growth in these businesses in the years ahead – indigenization of defence supplies, indigenous NPPs, increase in launch frequency of satellites, etc. are some key policies of the government which clearly point to this trend. Ours being a capital intensive industry, the final decision to selectively invest in CAPEX would ultimately hinge upon fructification of actual orders of which we are quite hopeful. Our current order book of INR 970 Crore with 60% of it comprising strategic businesses gives us confidence. Q. What’s the shape of things to come in your field which would be exciting and trendsetting?
• Some key pointers towards development/action in our fields of operations are: • Increased spending on defence preparedness / thrust on indigenization • Overall increased spending on infrastructure leading to greater demand for capital goods • ISRO’s ambitious plans to increase the launches per year • Building of 10 indigenous Nuclear Power Plants (NPP) in India • Revival of sugar industry in key markets like Uttar Pradesh • New technologies on the horizon – composite materials, additive manufacturing, internet of things (IOT), etc.
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TECH TRENDS
Automation in sheet metal cutting and welding The paper examines welding and cutting process trends in the sheet metal and plates used in various industries like automobiles, infrastructure, ship building, aerospace industries, wind tower manufacturing etc. Productivity gains in arc welding are reviewed, and the increasing use of laser cutting and welding, as well as laser-arc hybrid welding, particularly in Europe, is discussed and explained. Some friction technologies are already widely adopted, but they could make more impact with further development. Electron beam welding could also be used with economic benefit in some situations, but as with all non-arc processes, it will only be adopted if significant gains in productivity and cost reduction can be created to justify the more specialist welding equipment required. Many productivity improvements can come from non-welding activities in the fabrication process. 1. INTRODUCTION Leadership in manufacturing (welding and Cutting) can come from addressing the factors of QUALITY, COST, PRODUCTIVITY, SAFETY and CONTINUAL UPGRADATION OF TECHNOLOGY. Inflection in Metal Fabrication Technology has taken place in the Manual / Semi-Automatic Welding Power Sources - (Digital control inverters), Welding Automation - (Developments in HNG SAW, HNG MIG, Tandem MIG / SAW, Friction Stir, Electron Beam, Saddle Welding Automation, Robotics, Laser spot welding, Hot wire TIG, Orbital systems, automation with hybrid welding systems like Plasma – MIG, Laser - MIG) and major advances in the cutting processes (Precision Plasma, Laser Cutting, Waterjet cutting etc.). This paper reviews current trends in arc welding and cutting processes used for Sheet metal processing and will discuss some of the newer processes which are beginning to replace arc welding for such steels, or have potential to do so in the next 10 years. 2. ADVANTAGES OF AUTOMATION a. Consistency in weld result - Error Proofing: A welding supervisor can limit the amount of changes an
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b.
c.
d.
e.
operator can make during a program, preventing him from accessing the override screen through the use of a key switch or password. Multiple parameters for multiple weld-run: In addition to the ability to adjust parameters between weld passes, operators of microprocessorbased welding machines can also program changes to weld parameters during each pass, which offers distinct advantages for certain applications. Store parameter for sharing on other machines with same applications: A microprocessor-based power source can store programmed welding procedures on data cards. This allows the operator to easily transfer programs developed on one machine to other machines being used either in the same facility doing the same type of work. Quality control: Microprocessorbased machines can immediately alert the operator if weld parameters fall outside pre-selected limits. Parameters can be directly to a quality-control computer program for storage or statistical analysis. This eliminates time-consuming radiography in many applications. Date storage and records: It is now
very easy to display a set of welding parameters and operator or supervisor can observe the welding procedure. Moreover, the data can be printed in the form of reports, which can be presented to the customer as quality assurance procedure. f. Quicker Weld-Fault diagnostics lower repair time: The system can be stopped if the measured values cross a certain preset variation limit. It is possible to stop the machine in out-oftolerance conditions. This enables the operator to perform timely functions and take necessary steps to prevent the deposit of faulty welds. 3. TANDEM MIG AND ROBOTIC WELDING Significant improvements in productivity are nowadays hard to gain in this mature process. In gas-shielded MIG/MAG processes, the growth of tubular wire over solid wire is still slow despite the deposition and bead shape benefits of the former although tubular wire usage is higher in the USA and Japan compared to other parts of the world. The lower price of solid filler wire, particularly in Europe, is still a dominant factor that continues to favour their use. Self-shielded cored wires are still widely used in the USA but
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TECH TRENDS less so in Europe because of the fall-off in fabrication of large offshore installations. Care is always needed in selecting selfshielded wires if weld metal toughness is a critical design factor. Schematic of Equipment for TANDEM MIG
Fig. 1: TANDEM MIG
Advantages of TANDEM MIG: • Exceptional welding speeds • High weld metal deposition rate • Superior weld quality: ◊ Reduced heat input ◊ Resists burn-through on thin materials ◊ Maintains low spatter levels ◊ Produces good penetration on thick materials ◊ Improves bead wetting at weld toes ◊ Resists undercut • Bead profile control • Lowers production costs • Increases productivity The greatest potential for productivity improvements comes from using robots. Japan still leads the work in new robot
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installations per annum, but generally robot take-up for welding is still majorly for the automobile sectors. Robots are being employed in situations where product repetition and/or tonnage throughput are high, combined with relatively standardised designs. Robot profile cutting is increasing in usage and in Japan, some building frames are now being welded on robot lines and agile robots are also used for site welding building column joints at height. The applications most suited to robot use involve butt and fillet welds in the fabrication of beams, welding of stiffeners to beams, welding of end plates and the assembly of panels or decking. A likely trend is to ‘take robots to the work’ and use them for large part and sub-assembly manufacture in cells which house autonomous vehicular robots. These robots, mounted on moving platforms are manoeuvred around the parts to be welded and are capable of all-positional welding using the MAG process with tubular wires, (Fig.2).
Fig.2. Schematic diagram showing autonomous robot vehicle navigated by vision system, being used for all positional MIG / MAG welding
4.NARROW GAP SAW In submerged arc welding, multi-wire, iron powder additions and narrow gaps are common ways to increase productivity. However, the use of tubular wires is increasing in popularity and can offer better weld quality compared to solid wires in some situations, e.g. when submerged arc welding of primed plate. In building and bridge construction MIG/MAG welding is more suited to automation and is now beginning to replace submerged arc welding, reducing costs and distortion significantly.
5 . LASER – IN CUTTING AND WELDING Low power CO 2 lasers were originally developed in the late 60s for cutting and welding operations, while Nd: YAG lasers entered the market only in the early 1980s. In the shipbuilding and off-road vehicle sectors, higher power lasers (3-10kW CO 2 and 2-4kW Nd:YAG) have become popular in the last decade because their use brings more precision in dimensional control, and greater accuracy in assembly, as well as the additional advantages of high cutting and welding speeds, and cleaner working. Laser cutting is now an essential route to accurate assembly in steel fabrication. Parts can be cut to a precision of ±0.3mm in 10 metres compared to ±1-2mm for conventional plasma cutting. Sub assemblies can then be arc welded to tolerances of a few millimetres in 15 metres, with the same lasers being used for marking and hole drilling on the cutting table. Even though arc welding is still regularly used for assembly of laser cut parts, cost reductions can be dramatic because of the improved accuracy of assembly and the potential for eliminating distortion correction and other processing operations downstream from welding. Direct costs have been cut by up to 50% using lasers for cutting in many shipyards, and this shows the extent of benefit which could follow from more widespread use of laser cutting in building, bridge and public infrastructure construction.
Fig.3. A typical laser welded sandwich panel and advantages over conventionally stiffened panels
6. LASER-ARC HYBRID WELDING There is tremendous interest in the use of CO 2 laser-arc or Nd: YAG laser-arc for steel construction at the present time. The concept has been around since 1978 and was actively developed in Aachen in the late 90s using high power CO 2
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Fig. 5.Schematic diagram of the FSW process: (A) Two discrete metal work-pieces butted together, along with the tool (with a probe). (B) The progress of the tool through the joint, also showing the weld zone and the region affected by the tool shoulder.
Fig.4a. Nd:YAG laser - MAG hybrid process being developed for land pipeline girth welding. Picture of the welding head
Fig.4b. macro section showing MAG root and cap beads & central hybrid weld bead
lasers in combination with one or two MAG torches directed into the same weld pool in series with the laser. Already one shipyard in Germany has such a system in production on a panel line, the process replacing submerged arc welding. The advantages of moving from simple arc processes to a hybrid laser-arc system include higher joint completion rates and associated control of distortion. As noted above, laser systems alone are usually not sufficient to cope with variations in joint gap in large structures. However, where plates are thin, it is possible to produce stiffened panels successfully by laser welding. 7. FRICTION TECHNOLOGIES There have been many exciting develop-
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ments in friction welding and probably more process innovation in the last decade than in the previous 40 years when friction welding first came on the scene. In the context of metal joining and construction, friction stud, radial friction and friction stir welding are good examples of more recent approaches, with friction stud already being used in the production of sandwich structures comprising steel skins and a concrete core and for welding attachments in high volume such as shear connectors and reinforcing bars to end plates. Attachment of anodes under water to offshore installations using steel studs and electrical connections to railway lines are other applications of friction stud welding. APPLICATIONS Shipbuilding and Offshore, Aerospace, Automotive, Railway Rolling Stock, Fabrication
8. ELECTRON BEAM TECHNOLOGY There have been several key improvements in this process in the last decade which have made EB welding increasingly attractive for large-scale fabrication of steel structures such as buildings and
bridges. The two main areas of improvement are in gun development and reduced pressure technology. Reduced pressure electron beam welding system Reduced pressure EB welding using chamber pressures of around 1mbar has been another major step forward in simplifying EB welding operations. The beam shape and beam penetration at, say 5mbar, is identical to that at the more conventional pressure for EB
Taming power quality is now child's play
When you use DigiVolt Stabilizers, Tranquil Ultra Isolation Transformers and Powercon Power Conditioners from Unity Controls, power quality is under total control and would no more hamper your production and product quality. These silent sentinels protect your sophisticated, high precision production equipment from the ill-effects of voltage, spikes, surges, transients, sags, noise and harmonics affecting AC power lines. Thus ensuring continuous uptime and enhanced productivity and consistent quality.
Intelligent Microprocessor-based, High Efficiency, Energy Savers specially designed for CNC machines
Our equipment are approved by major OEMs and exported (up to 2000 KVA) to countries in Europe, Middle East, Africa
Our Allied Products: n
Active Harmonic Filters K-Rated Transformers Light Energy Management Systems
n
KVAR MAX - Real Time Power Factor System
n n
and Asia Pacific. So leave power quality and energy management to the experts – Unity Controls. With our nationwide network we are only a phone call away!
Contact us for Power Quality & Harmonic Audits to Conserve Energy and Save Costs.
The power quality & energy experts
D-137, TTC MIDC Industrial Area, Nerul, 405, Sapphire Arcade, 42 M.G. Road, Ghatkopar (E),400 Mumbai 400 077, India Navi Mumbai 706, INDIA +91-22-2501 3832 +91-22-2761 1872/ 33 / 4612 sales@unitycontrols.in www.unitycontrols.in
Ahmedabad l Bangalore l Chennai l Delhi l Gurgaon l Hardwar Indore l Jalandhar l Jamshedpur l Kolkata l Kanpur l Mumbai l Pune l Rajkot
l l
vijayshreyaarts@gmail.com
UNITY CONTROLS PVT. LTD
TECH TRENDS
welding of 5 x 10 -3 mbar. This reduced pressure option does away with the need for large vacuum chambers and worries about leaks and seals. Simple mechanical pumps and local seals are sufficient to achieve ~1 mbar. These systems are also more tolerant to fluctuations in working vacuum pressure, gun to work distance and work-piece cleanliness. 9. WIND TOWER MANUFACTURING – SPECIALIZED CUTTING AND WELDING PROCESS APPLICATIONS Wind Tower fabrication employs extremely precision applications of metal cutting and welding processes like gas cutting triple torch, with Single pass three torch cutting Automatic setup which provides High accuracy, Capacitive height adjustment, Infinite rotation of cutting head, Automatic angle adjustment 20 - 50° (Option for 30 - 60°). In addition, plasma cutting system is used with Automatic Setup, Highest Accuracy, and Bevel angle adjustment: +/- 52°, Initial height setting with tactile sensor, Cutting height adjustment via automatic arc voltage sensing process. Precision High end CNC Plasma cutting process is utilized with high degree of automation needed to guarantee consistent quality. Programming software, Numerical control and Automatic rotating bevel tools are used to dispense with manual tasks. Automated SAW systems with Twin Wire, Tandem, Tandem – Twin and
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MACHINE TOOLS WORLD JANUARY 2018
Multi – wire systems are used along with customized welding heads, wire feed systems, joint tracking systems, Column and Booms, TELBO systems, Rotators and Positioners. In addition, Tractors and Fit – up units are all used for this application and also for many other welding applications. 10. CONCLUDING REMARKS Where will engineering construction be in five years time? Productivity improvements can come from many different areas in the total fabrication process, e.g. general design, detailed design, contract drawings, CNC
instructions, cutting and profiling, welding, inspection, finishing etc. It needs to be realised that optimising the welding process and procedure in isolation may have only a small effect on overall productivity. As an example, fabricators in the bridge and building sector continue to make big improvements in reducing the cost per tonne of steel fabricated by focussing on efficiency improvements in non-welding operations. These non-welding areas will continue to receive much attention in the next few years. For example, 3D solid modelling is expected to be at the heart of the improvement process enabling virtual assembly, direct instruction of cutting and welding machines, computer modelling of metal processing and welding operations and optimising of welding sequences. In addition automated inspection and data gathering will increase in usage to give more comprehensive Quality Assurance. Productivity improvements could also come from greater standardisation in steel specifications and in joint details and from modularisation of large structures to reduce the time spent on site fabrication and erection. Use of new welding processes and an increased use of automation and robots will take place slowly and gradually, only being justified where the introduction creates significant gains in productivity or cost reduction. As such, these changes can be expected particularly in situations where skilled labour is short, where welding cells can be kept fully occupied or where customised, made to order components are needed. (Contributed by Ador Welding Ltd.)
For more information Web: www.adorwelding.com
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PRODUCTS SHOWCASE
PRODUCT SHOWCASE Accusharp End Mills Accusharp Cutting Tools Pvt. Ltd. are well established Manufacturer of a wide range of Carbide Metal Cutting Tools. The wide range of our metal cutting tools includes Drills, End-Mills, Reamers, Cutters, Inserts, Gun-drills, etc. One of the niche items from our entire product range is End-Mill Cutter. Various types of End-Mill cutters are manufactured as ‘standard’, as well as, ‘special’, according to customers’ application requirements.
Types of our End-Mill Cutters: • • • • •
Straight End-Mill Slot End-Mill Profile End-Mill Ball-Nose End-Mill Serration End-Mill, etc.
Sizes: Size ranging from Ø 2mm to Ø 32mm
Raw material used: These End-mills are manufactured from Tungsten Carbide supplied by international brands. We have modern facilities, machines, and process equipment for manufacturing these products.
Operational Features:
For Product Enquiry Contact Accusharp Cutting Tools Pvt. Ltd. W-242, J Block. MIDC, Bhosari, Pune - 411026. Phone: 020-27129016, E-mail: ayaz@accusharp.co.in Website: www.accusharp.co.in
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MACHINE TOOLS WORLD JANUARY 2018
Our End-Mill Cutters of high productivity with operational quality performance offer customers: • Enhanced productivity while milling nickel, stainless steel and titanium alloys • Desired surface finish • Extended tool changing frequency, and set up • Performance consistency for longer tool life • All this helps customers for: » Better material removal rates, » At reduced operational Cost » Improved work piece component Quality Benefits to users: ‘Cut Fast & Cut Cost’!
PRODUCTS SHOWCASE www.mtwmag.com
Steady Volt Servo Voltage Stabilizers Frequent voltage variations are a menace that can damage electronic components like power supplies, drives, PLCs, controllers, etc. Their effects are widely felt in CNC, printing and textile machines as well as laboratory, data processing, medical & telecommunication equipment. Frequent breakdowns of such machines are costly to repair. This apart, the downtime and frequent interruptions in operation brings substantial loss of revenue. Steady Volt from Unity Controls is a state-of-the-art Voltage Stabilizer designed to protect such equipment from voltage variations and its ill-effects.
Following are some of its unique features:
For Product Enquiry Contact Unity Controls Pvt. Ltd 405, Sapphire Arcade, 42 M.G. Road, Ghatkopar (E), Mumbai 400 077 Phone: 022- 2501 3832 / 33 E-mail: sales@unitycontrols.in Web: www.unitycontrols.in
• • • • • • •
Intelligent microprocessor-based system(available in new digital models) Digital interface with large LCD display and keypad Auto re-start, adjustable output voltage, trip bypass, fault list No hunting, oscillation and noise generation Innovative transformer design to minimize power loss Constant output voltage across a wide input voltage range Single phasing prevention, surge suppressor and EMI / RFI filter
With the best-in-class response time and correction rates, Steady Volt offers improved power quality and greater energy efficiency, thereby saving the cost of breakdowns and energy utilization. Apart from protecting your equipment from damage, Steady Volt also saves energy during continuous operations.
Nexgen Refrigerated Air Dryers
For Product Enquiry Contact GEM Equipments (P) Ltd. SF No.103, Avinashi Road, Arasur, Coimbatore 641 407 Phone: 0422-2363800 / Email: sales@gemindia.com
The Nexgen Refrigerated Air Dryers from Gem Equipment are known for engineering excellence, innovation and reliability.The heat exchangers are designed to provide worry-free, highly efficient heat transfer whether you are processing simple fluids, viscous solu8tions, or particulates. They feature honey comb construction of aluminium fins, true cross-flow for greater effective temperature differences, non-clogging larger cross-sectional area for air flow, integral air-air and air-refrigerant exchanges, with stainless steel demister moisture separator, robust non-corrosive grade aluminium, and larger heat transfer area for higher efficiency. The rugged electronic panels display both inlet and dew point temperatures. They incorporate a Tripper module with alarm for compressed high discharge pressure, compressed low suction pressure, expansion valve malfunction, auto drain valve function and fan motor cycling. Introduction of speed control is one of the major developments towards the optimization of refrigeration systems based on average load. For periods of high cooling demand, the compressor speed can be increased which results in a higher refrigerant flow and thus higher cooling capacity and vice versa during periods of low cooling demand. Compressed air purification equipment must deliver uncompromising performance and reliability while providing the right balance of air quality with the lowest cost of operation. As a quality-centric group, Gem ensures that its dryers are test at each stage of assembly as per ISO 7183 or relevant standards. It maintains stringent engineering practices throughout the production process to achieve higher reliability. Gem’s state-of-theart ISO 9001-23008 certified facility is equipped with dedicated men and machines to chisel out products of impeccable quality and reliability.
JANUARY 2018
MACHINE TOOLS WORLD
119
PRODUCTS SHOWCASE
Indexable Drills
For Product Enquiry Contact Wohlhaupter India Pvt Ltd B-23, B Block community centre, Janakpuri, New Delhi-110058. Phone: 011-41827044 Email: info.in@wohlhaupter.com
High productive & flexible drilling is easy to be done with Allied Machine & Engineering’s (AMEC) indexable drills. Wohlhaupter India brings to you AMEC’s range of indexable drills from 9.5mm to 142mm. Wohlhaupter India is the subsidiary of Wohlhaupter Gmbh, Germany, an Allied Machine & Engineering group company, USA. Deep drilling with adjustable diameters in same drill body is possible for different material and machines. Just change the insert and get a different diameter on same drill body. Also core hole drills, burnishing tools, expandable reamers are all available. Range of boring tools includes diameter 0.4mm to 3255mm boring heads in digital & analog types, boring kits, adaptors, boring & facing heads. We also do servicing of our boring heads as an exclusive support to the customers. Technical teams are present all over India for your support.
KING CUT PRO – The Large Gantry Type CNC Cutting Machine Ador’s KING CUT PRO is a CNC portal cutting machine which is very precise and reliable. The machine has one head for plasma sheet metal cutting and one head for flame cutting of sheet metal with a dual side longitudinal drive with AC motors. The standard equipment comes with a basic machine package with CNC controller, one torch, central gas diffusion with manometers and a remote flame ignition.
The following equipment are supplied as required by the customer: Additional Equipment: • Plasma power source KJELBERG with machine torch • Programming software MOST 2D • Support table for sheet metal with segment extraction system • Extraction-filter system • Laser position indicator for determining the cutting point Optional : • Extension of the longitudinal rail • Additional cutting head
The CNC Controller – Phantom:
For Product Enquiry Contact Ador Welding Limited Akurdi Chowk, Chinchwad, Pune 411 019 Tel.: 020- 4070 6000 Email: cmo@adorians.com Web: www.adorwelding.com
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MACHINE TOOLS WORLD JANUARY 2018
The Phantom brings you the performance of a cutting edge CNC that is built on more than 40 years of experience in the motion control and cutting industries. This controller is designed for multiple axis cutting machines and features the latest advances in CNC technology on a proven platform engineered to increase productivity, reduce costs and enhance profitability. The software provides flexibility, ease of operation and technologies that put Ador’s experience and expertise in your operator’s hands, resulting in extremely good cut quality and high productivity. The Phantom can operate any cutting machine and interface with virtually all plasma systems. Following are its standard features: Bright touch screen interface, Touch screen interactive display, Expandable shape library, True multi-tasking environment, Fast Dxt file conversion, Go to(Job interrupt), Quick plate alignment, and Monitor & track consumables. Advanced Plasma Process Control (Plasma Process Wizard) is available as optional extra. Ador offers cost-saving height control unit for simple plasma cutting applications. The KHC1 system provides all the essential functions that are needed for good cuts and optimum utilization of work-piece.
PRODUCTS SHOWCASE www.mtwmag.com
The new Gast 86/87R Series of oil-less rocking piston compressors and vacuum pumps While other manufacturers have been busy selling rocking piston compressors that produce a lot of noise and less-than-ideal pressure, Gast has been quietly setting the new standard by re-engineering our oil-less rocking piston from the ground up. The result is a unit that delivers quieter performance, higher pressure, a longer life and greater application flexibility. The sleek, new 86/87R Series is not just another pretty product. It’s beauty runs deep as it performs in ways not yet seen in the industry. The patented crossover chamber design regulates and controls airflow to dampen sound and optimize performance, while delivering a wide range of pressure level options. Because the 86/87R Series can easily retrofit into an existing footprint, it’s also a smart, flexible solution for a wide range of markets and applications, viz. Environmental, General industrial, medical, printing & packaging, food and beverage, transportation, laboratory, and material handling.
Designed to performs
For Product Enquiry Contact Shavo Technologies Pvt. Ltd. Shavo House, S.No.21A/10B, Plot No,394 South Main Road, Hotel Cozy Inn Chowk Koregaon Park, Pune - 4112 001 Phoned: 020-2615 9641 Email: shavogroup@vsnl.com
“When we set out to re-engineer our rocking piston compressor, we aimed to do more than just increase pressure. We set out to dramatically reduce sound, enhance flow, create a standard footprint for easy retrofit anywhere in the world and improve the compressor’s aesthetics,” says Gast. The inherent design of rocking piston technology makes it the optimal choice for applications requiring high pressure or vacuum and air flow in a small package. The flexible cup is made with superior materials and mounted on top of the connecting rod, creating vacuum or pressure while maintaining a tight seal against the cylinder walls in a rocking motion. The forgiving design has fewer components, causes less friction and has a low exhaust temperature, for greater reliability and durability for the life of the product. Despite it’s small size, the versatility of 86/87R means this is the right product to deliver quality air solutions.
Super compact safety module More safety in a space-saving 17.5 mm
For Product Enquiry Contact DOLD Electric India Pvt Ltd (100% Subsidiary of E.DOLD & Sohne Kg - Germany)
B – 3 Vishranti Heritage, Gotri Road, Vadodara – 390 021 Call: +91 990 9001585 Website: www.dold.in
The 17.5 mm wide e-stop module UF 6925 of the SAFEMASTER series offers the highest safety in the narrowest spaces. The device is well-suited to monitor emergency stop buttons and safety gates in almost any application. Its broad voltage range from DC 8 to 36 V makes it impervious to voltage fluctuations, such as those that occur when activating battery-fed devices. This predestines the safety module for a great variety of applications in machine and plant engineering and in mobile applications. The emergency stop module fulfils the highest safety requirements, up to PL e / Cat. 4 or SIL 3. In comparison to other safety modules available on the market, the device saves over 20% of space in the switch cabinet. Besides its low space requirements, the safety module also stands out for its time-saving wiring, which requires no tools. The push-in cage clamp terminals on the front side ensure fast and easy device connections. Switches on the back of the device provide a temper-proof setting. This allows the operator to select the start type and cross fault detection. LED displays facilitate fast diagnostics. It can be used in battery-operated systems, driverless transportation systems, construction vehicles, and crane equipment. In addition, the safety module is permitted for use in furnaces pursuant to EN 50156-1 and for safety related systems for the process industry pursuant to IEC/EN 61511.
JANUARY 2018
MACHINE TOOLS WORLD
121
PRODUCT INDEX A AC I DC Geared Motor
81
AC Linear Servo Motor
81
Actuator Line
79
Air Compressors
25
Air Dryers
83
Alloy Wheel Machining Solutions
51
Aluminium Profiles
81
Angle Encoders
19
Automation Products
97
Flexible Couplings
81
B 75
Ball Transfer Units
81
Ballscrew
75
Ballscrew Support Units
75
Bending Machines
115
Boring Cutter
IFC
Boring Products
59
Boring Sytems
61
Brake Motors
109
Burnishing Products
59
Gas Flow Products
77
Gas Management
77
Gear Boxes
109
Gears, Racks & Pinions
81
Grinding Machines
45
Grinding Wheel
53
CAD CAM SOFTWARES
103
Cam Driven Systems Car Body Construction
77 81
Precision Locknuts
75
Press Brake Scales
71
Pressure Control Solutions
77
Project Engineering Solutions
97
R Harmonic Filters
111
High Pressure Filtration
77
Hydraulic Press
113
I Inserts
FRONT GATEFOLD
Instrumentation Fittings & Valves
77
K KM Actuator
75
Laser Tube Cutting Machine
101
Real Time Power Factor System Reamers Reaming Products
13
Rotary Encoders Rotary Tables
19, 71 87
S Sawing Machine
65
Screwiacks
81
Sensor Systems
33 91
33
Sheet Metal Punching
31
19
Slewing Ring
111
Spotting Drills
FALSE COVER
59 69
Length Gauges
Chamfers
63, FALSE COVER
Robot Systems
Laser-Line Scanner
Centre Drills
75 111
Reffnlng Furnace
73
Light Energy Management Systems
81 FALSE COVER
FALSE COVER
Linear Actuators
81
Stabilizers
Clamp Meters
95
Linear Encoders
19
Static Elimination Solutions
Clamps for Linear Guides
81
Linear Line
79
Stepper & BLDC Motor
81
CNC Grinding Machines
49
Linear Motion Guides
81
Surface Cleaning
77
CNC Horizontal Boring Machine
51 M
CNC Lathe
51
CNC Lathes
47
Machining Centers
9
CNC Machining Center
65
Magnetic Systems
71
Mass Flow Controllers
77
CNC Smart Mills
51
Metal Cutting Tools
63
CNC Solutions
17
Metal Working Fluids
11
CNC Machining Centers
BACK PAGE
CNC Tool Grinding Machine
7
Milling Cutters
IFC
Taps
79 95
Thermal Imaging Cameras
95
75
Contouring Controls
19
Moisture Meters
95
Tool Holders
Curvic Coupling
81
Monitoring Solution
39
Tool Identification
Cutting Tools Solutions
61
Motion Toolpaths
105
Multimeters
95
N
D
Non-Contact Tool Setting System
37
Digital Readouts
71
Dimensional Measurement Systems
41
Double Column Machining Centers
51
Drill Tap Center
51
Oil/ Coolant Mist Cleaner
81
Drilling Products
59
Optical Micrometers
33
Drills
63, FALSE COVER, FRONT GATEFOLD
O
Optical Scales
71
Oxy-Fuel CNC Cutting Machines
97
E End Mills End Mills Cutters
63, FRONT GATEFOLD FALSE COVER
Energy Absorption & Vibration Isolation Engraver Cutter
77
FALSE COVER
P
Flex Clamps
MACHINE TOOLS WORLD JANUARY 2018
95
59 FRONT GATEFOLD 35
Tube Bending Machine
101
Tube Cutting Machine
101
Tube End Finishing
101
Turning Machines
91
Twist Drills
23
U Ultra Isolation Transformers
111
V Value-Selling Training Solutions
107
Valve Finisher
IFC
Vertical CNC Lathes
47
Parts for Die & Mould
87
Pinion
75
Vertical Machining Centers
51
Planetary Gear Box
75
Voltage Detector
95
Planetary Gear Heads F
93 FRONT GATEFOLD
Test Instruments
Miniature Guide
Cycloidal Gear Boxes
77
Telescopic Line
97
IBC
111
T Tapping Machine
Threading Products
Consumables
122
19 111
Precision Ball Screws
Rack
L
C
Power Conditioners Precision Air Moving Products
G
H
Ball Spline
Position Displays
105
Plasma CNC Cutting Machines
97
Position Controllers
71
W Welding Equipments
97
ADVERTISERS INDEX COMPANY NAME
PG. NO.
A ACCUSHARP CUTTING TOOLS PVT. LTD.
63
ACE MANUFACTURING SYSTEMS LTD.
BACK PAGE
ACMEE - 2018
15
COMPANY NAME
PG. NO.
COMPANY NAME
PG. NO.
GODSON BENDING SYSTEMS PVT. LTD.
115
PARAGON MACHINERY CO. LTD.
49
Q
H
QVI INDIA PVT. LTD.
HEIDENHAIN OPTICS & ELECTRONICS INDIA PRAIVATE LIMITED
19
47
ADOR WELDING LIMITED
97
HOSABETTU HEAVY MACHINERY LLP
AMTEX - 2018
27
HOSHI TOOLS (P) LTD
61
ANCA MACHINE TOOLS PRIVATE LTD
7
HYUNDAI WIA INDIA PVT. LTD.
9
I APEX PRECISION MECHATRONIX PVT. LTD.
81
B BETTINELLI AUTOMATION COMPONENTS PVT. LTD. BIRLA PRECISION TECHNOLOGIES LIMITED
73
23
INSIDE BACK COVER
D DOWEL ENGINEERING WORKS
114
IMTEX FORMING - 2018
99
K KUKA
C CNC SOFTWARE, INC.
IMEX - 2018
113
E ELECTROTHERM (INDIA) LTD.
13
ELGI EQUIPMENTS LTD.
25
EPPINGER TOOLING ASIA PVT. LTD.
105
69
M MACHAUTO EXPO - 2018
116
MARPOSS INDIA PVT. LTD.
39
MEIBAN ENGINEERING TECHNOLOGIES PVT. LTD.
91
MGM-VARVEL POWER TRANSMISSION PVT LTD
109
MICRO-EPSILON INDIA PRIVATE LIMITED
33
MITSUBISHI ELECTRIC INDIA PVT. LTD.
17
MMC HARDMETAL INDIA PVT. LTD.
INSIDE FRONT COVER
F 51 NTB HITECH CERAMICS FIBRO INDIA PRECISION PRODUCTS PVT. LTD.
87
FLIR SYSTEMS INDIA PVT. LTD.
95
53
O OPEN MIND CADCAM TECHNOLOGIES INDIA PVT. LTD.
103
G P GEM EQUIPMENTS (P) LTD.
83
GIVI MISURE PVT. LTD.
71
PARADIGM TRAINERS PRIVATE LIMITED
R RAVIK ENGINEERS PVT. LTD.
65, 101
RAVISON'S CORPORATION
93
RENISHAW INDIA (PUNE)
37
ROLLON INDIA PVT. LTD. - INDIA
79
S SHAVO TECHNOLOGIES PVT. LTD.
77
SUPERSLIDES & BALLSCREWS CO. INDIA PVT LTD
75
T TRUCUT PRECISION TOOLS PVT. LTD.
FALSE COVER
U UNITED GRINDING GMBH
45
UNITY CONTROLS PVT. LTD.
111
W WALCHANDNAGAR INDUSTRIES LTD.
21
WOHLHAUPTER / ALLIED MACHINE & ENGINEERING COMPANY
59
Y
N FATTY TUNA INDIA PVT. LTD.
41
107
YG CUTTING TOOLS CORPORATION PVT. LTD.
FRONT GATEFOLD
YOUNG BUHMWOO INDIA CO. PVT. LTD.
11
Z ZEISS GROUP
31
ZOLLER INDIA PVT. LTD.
35
JANUARY 2018
MACHINE TOOLS WORLD
123
Vedant
Inside Story
Mr.
Birla
Chairman & Managing Director Birla Precision Technologies Ltd.
My Life’s Goals Aim & Ambition: To engage in “Conscious Capitalism”. Vision: To be the most reputed Engineering Company in India while contributing to the needs of the Society. Social Goal: To build a company that is engaged in the ideals of service, adding value to the country and uplifting the lives of those it serves. Business Goal: To create a business built on the foundation and morals of discipline, grit and duty to all stakeholders as well as oneself and thus result in gradually and ultimately constructing an organisation that is the best at what it does, while furthering the name and prestige of the nation and all its residents.
My Leisure Choices Favourite Tourist Spot: Rishikesh, India or London, England. Music I Like: Classic Rock like Led Zeppelin, Bhajans, Metallica, Pink Floyd. Sports I Love: Football, Swimming.
Ask my Taste Buds Favorite food: Marwari Thali, Idli, Italian Favourite Drink: Butter milk.
In Awe of I Admire: Narendra Modi, Sri Sri Ravi Shankar , Kumar Mangalam Birla.
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MACHINE TOOLS WORLD JANUARY 2018
DIFFICULT MATERIALS MADE EASY
LESS CHATTER. SHORTER CYCLES. YOU CAN HEAR THE DIFFERENCE. Mastercam’s Dynamic Toolpaths deliver a consistent chip load, making difficult material easier to cut. That means longer tool life, reduced machine wear, and shortened run times. See and hear the difference at Mastercam.com/dynamic.
For more information, visit mastercam.com/dynamic
AMS AD Jan 18.pdf 1 03-01-2018 02:35Reg. PM No. THC/173/2015-2017. Posted at Mumbai Patrika Channel Sorting Office RNI No. MAHENG/2015/64267 Postal G.P.O. Mumbai 400 001 on 15th of every month and Published on 10th of every month
C
M
AMS in the pursuit of excellence not just by Indigenous design & developments but also doubling the machine built capacity to
Y
CM
2200 MACHINES/YEAR.
MY
CY
CMY
K
•
375000 Sq. ft. Assembly area
•
Machining Centers covering 21% of the Total Market Share
•
10000+ Machines performing successfully across India
•
Jaw dropping YOY Turnover
10, 000+ MACHINING CENTERS IN THE FIELD
ACE MANUFACTURING SYSTEMS LTD. Plot No. 467 - 469, 4th Phase, Peenya Industrial Area, BANGALORE - 560 058. INDIA., T: +91-9880189832 E: helpdesk@amslindia.co.in 126