MACHINE TOOLS WORD - JANUARY 2019

Volume 04 No. 08 | January 2019 | ` 150

Pages 270 | RNI No. MAHENG/2015/64267

Whatever industry sector you’re in?

Aerospace, Automotive, Electronics, Medical or woodworking

Visit us at :

Hall No. 4, Stall No. C-109 24 - 30 January 2019 Bangalore, India

ANCA Machine Tools Private Ltd 8/1 , Dr. M H Marigowda Road, Arekempanahalli , (Wilson Garden ), Bangalore - 560027, Karnataka, India T: +91 (80) 6759 2100, M: +91 96637 6991 E: indiainfo@anca.com

anca.com

linkedin.com/company/anca

CEO CORNER

Publisher & Printer Shirish Dongre

CEO Shekhar D.

Tracking the Growth and Transformation of Machine Tools Industry

Editor Shilpa Dongre

Assistant Editor Shweta Nanda

Marketing Team

Machine tools industry in India is undergoing an interesting phase. In the last few years, the industry has been on a steady growth trajectory and has slowly made its mark in the global industry. Despite being highly fragmented with the presence of several small players, the industry has clocked impressive growth. As per industry reports, Indian machine tool industry is developing at 12% growth rate every year.

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

Digital Marketing Kailash P.

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

Online Division Ganesh Mahale

Circulation Executive Satish Kadam, Amol Ranshur Branch Offices (Zonal)

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

SOUTH

With the impetus on Make in India and manufacturing growth, machine tools industry, being the mother industry, has come to the fore. The momentum is slated to continue with the government’s push and rising demand. The opportunities for machine tools players are thus galore. To fully exploit this opportunity, the players are stepping up their game by tapping into the latest technology advancements. Trends like Industry 4.0, IoT and automation are transforming the face of the industry.

Being the premier magazine covering the industry, Machine Tools World, has been at the forefront in presenting the evolution of the industry. It has been our constant endeavor to bring in-depth coverage of the machine tools industry through technology updates, personal interface, latest product reviews and industry analysis.

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

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

In line with this, in our IMTEX special issue we bring you a 360 degree coverage of what major industry players are set to display at the event. Being South East Asia’s largest exhibition in manufacturing technology, IMTEX always attracts huge participation and response. And the excitement is higher this year with the exhibition celebrating its 50th anniversary. The expo is bigger and better than ever covering an exhibition space of around 80,000 square meters with participation from over 1,000 exhibitors from 23 countries. In our special feature, we give a peek into what to expect from this year’s mega event.

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

Also, as we start the New Year, we got in touch with the machine tool fraternity to know more about their strategy and vision for 2019 and how they are planning to keep up with the latest trends. Packed with interactions with industry leaders, our special issue gives you a complete glimpse into where the industry is headed.

We hope you will enjoy reading our special issue as much as we have enjoyed putting it together!

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

CEO 10

MACHINE TOOLS WORLD

JANUARY 2019

www.mtwmag.com

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Contents

JANUARY 2019

COVER STORY

Renishaw : Global Leadership in precision measurement arena Paul Weaver, Vice President, Renishaw Metrology Systems Ltd

46 BUSINESS NEWS

IN FOCUS

22

The CHIRON Group presents new SmartLine modules at AMB 2018

26

DEUBLIN SpindleShield™ Unions for CNC Machining Centers

50

60

62

70

74

78

28

ANCA’s iView enables single chucking manufacturing

34

JUNKER Group to make an appearance at IMTEX, Bangalore

34

STUDER sells the 1,000th S31Fritz

36

LANXESS further expands production of high performance materials in Germany

38

Additive Manufacturing Show takes centrestage in Mumbai 12

MACHINE TOOLS WORLD

JANUARY 2019

www.mtwmag.com

Tru Hold

Contents

JANUARY 2019

IN FOCUS

82

86

94

98

COMPANY PROFILE

102

104

108

110

112

118

120

128

132

136

124

238

242

FACE TO FACE

232 14

MACHINE TOOLS WORLD

JANUARY 2019

248 www.mtwmag.com

Contents INDUSTRY VIEW

JANUARY 2019

TECHNO FOCUS

Machine Tools TRENDS & VISION 2019

Stage Set for IMTEX 2019

142

150

TECH TRENDS

158 Two ways - one goal: Precise displacement measurement in the field of hydraulics

163

164

184 166

‘How lubricants can help in improving Machine Shop’s performance’

199

CASE STUDY

254 252 16

MACHINE TOOLS WORLD

EFFICIENT & ULTRA-DYNAMIC: SIMULTANEOUS MILLING & TURNING JANUARY 2019

257 www.mtwmag.com

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Editorial Board

Editorial Index A

LUBECO Green Fluids

Ador Welding 132, 174, 262

M

ANCA

Maco Corporation

28

Arhan Technology B

192

Beckhoff

190

Bettinelli Automation

128

Bharat Fritz Werner

Mr. Arun Mahajan General Manager

Mr. A.P. Jayanthram Consultant

AMT- The Association For Manufacturing Technology

Grob Machine Tools India Pvt. Ltd.

Mr. GK Pillai Managing Director & CEO Walchandnagar Industries Ltd

70

Bhavya Machine Tools

108

Biltz Cutting Tools

264

Birla Precision

102, 266

Blaser Swisslube C

50

CHIRON Group D

24

Dahanukar Machine Tools

Effica Automation Ltd.

Mr. Dinesh Khambhayta President MTMA-RAJKOT

Ms.Samina Khalid Marketing Manager Renishaw Metrology Systems Ltd.

Manjit Singh Matharoo General Secretary Association of Ludhiana Machine Tool Industries

Mr. Rupesh Paparaju Director, Bettinelli Automation Components Pvt. Ltd.

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

VBS Corporate Support

22

Fatty Tuna India Pvt. Ltd.

MACHINE TOOLS WORLD

JANUARY 2019

Mr. Jayant Vaidyanathan VP - Sales & Application

230

MasterCam

100

Mazak India

78

Micro-Epsilon

202

Midas Safety

242

Millenia Technologies

147

MotulTech India

94

Multi Axis CNC

82

Multidimensions

208

N N-GRAVETEK

104

Nicolas Correa

98 143

186

NuGEN Machineries

116

DMG MORI

158

Nynas

198

DOLD Electric E

265

P

ELGi Equipments

74

EMAG Automation ExxonMobil F

166 60, 184

Pilz India

216

Precihole

168

R Radius Engineering

120

Renishaw 46, 142, 218, 258

Faccin Group

164

Rollon India

FARO Technologies

146

S

Fatty Tuna India

144

SBS Precision Systems

Fenwick & Ravi (FAR)

143

Seven Steps Business

FIBRO India G

112

Transformation Systems 110

Galaxiee Consultancy

204

GEM Equipments

265

Givi Misure,

86

Gleason Corporation

212

Grob India

148,

H

Mr. B.P. Poddar Vice President - Sales & Marketing FEMCO

Marposs

NORD Drivesystems

254

Mr. P.K. Balasubbramaniian President

26

90 DesignTech

Mr. Arjun Prakash Managing Director

62

HEIDENHAIN I

170

Instamod Air pipe J

146

180, 248 238

Shavo Technologies 136, 263 Solitaire Machine Tools 220 Spanish Machine Tool

124

Speroni

252

Spraymet

224

STUDER

34

Superslides & Ballscrews 264 U UCAM

147

Unity Controls

263

V

JUNKER Group L

34

LANXESS

36

V M Traders

118

W Wohlhaupter India

232

Tsugami Precision Engineering India Pvt. Ltd. For editorial contribution contact E-mail: shweta@divyamediaonline.com

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BUSINESS NEWS

The CHIRON Group presents new SmartLine modules at AMB 2018

Dr Claus Eppler, Head of Research and Development at CHIRON

The CHIRON Group will present the latest modules in its SmartLine range – TouchLine, ConditionLine and ProtectLine – to an audience of experts at AMB 2018. “In so doing, we are pushing forward resolutely with our concept of modular software solutions, which are aimed at utilizing the full potential of digital manufacturing,” explained Dr Claus Eppler, Head of Research and Development at CHIRON. “Here, economic added value for our customers is our main focus.”

interactively with the same familiar motions as for smartphones and tablets: Press, drag and swipe.

The user receives further support in the form of condition messages, which display critical parameters, detect causes and suggest rectification solutions.

Visitors to the trade fair can experience and trial TouchLine on the new CHIRON FZ16 S five axis and DZ16 W, as well as the MT 733 two from STAMA, directly at the trade fair stand.

ConditionLine monitors the machine condition The ConditionLine software module monitors and analyzes all machine components that are required for reliable The SmartLine modules ensure process reliability, higher productivity and production optimization.

TouchLine offers contextsensitive information The new TouchLine operating system guides the user step by step through the use of their machine, adapting its interface depending on the task and the context. If required, the full machine documentation can also be called up on the 24” panel. TouchLine can be operated intuitively and 24

MACHINE TOOLS WORLD

JANUARY 2019

operation. This means that atypical operating behavior and signs of wear are detected early on. The advantages of this are that maintenance and repair work can be systematically planned, a preventative measure which helps to avoid costly production downtimes.

Collision prevention with ProtectLine ProtectLine employs preventative measures to protect against collisions in all types of operation. To achieve this, the new FZ16 & DZ16 machining centers have a “digital twin” which exactly replicates the real machine. During operation, the digital twin runs 0.8 seconds ahead of the real machine. Any threat of

The new “TouchLine” operating system guides the user step by step through operation, adapting its interface depending on the task and the context.

collision is detected and the machine is brought to a controlled stop, preventing any potentially significant damage.

The current modules are additions to the SmartLine range from the CHIRON Group, comprising process- and machine-oriented solutions. “In contrast to traditional software companies, we take a line of action known as the ‘relevant data’ approach,” explained Dr Claus Eppler.

“Our expertise in machine engineering and our many years of experience were key to our developing SmartLine software solutions. We are coming out with tailor-made solutions that help our customers to keep on increasing productivity and machine availability,” he added. www.mtwmag.com

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BUSINESS NEWS Edge computing supports local processing and platform connections The new machining centers come with highperformance industrial PCs as standard, meaning that data can be collected, stored and processed locally – without an external connection. In addition, customers gain further added value through an option to connect to conventional production control systems or global cloud-based platforms.

For example, a user can

create an overview of their different production sites or carry out statistical analyses, which enable them to plan systems maintenance and repairs even more effectively. In every situation, the user has complete control over the data that is generated and they can decide what data is released to whom and for which machines. The combination of these ideal SmartLine modules, plus the option of connecting to local systems or global platforms, offers the

right solution for every application.

Active player in digitalization initiatives Aside from developing inhouse software solutions, the CHIRON Group is actively engaged in digitalizing machine tool construction. This is why it is a central member of an initiative for networked production run by the German Machine Tool Builders’ Association (VDW). The objective is to achieve a standardized

connection between different machines and control units. In addition, the Group is also a founding member of a user organization initiated

by Siemens, known as “MindSphere World”, for the cloud-based open IoT operating system “MindSphere”.

For more information, Website: www.chiron.de

DEUBLIN SpindleShield™ Unions for CNC Machining Centers DEUBLIN Company announces SpindleShield™ technology for use with the most sophisticated CNC machines. DEUBLIN coolant unions with SpindleShield™ employ a unique patent-pending electronic leak detection system that detects coolant problems and allows for rapid machine shutdown.

Machining centers with through-coolant spindles require coolant unions to deliver coolant at high pressures through the cutting tool at the cutting surface. For dry running cycles or machining operations with multimedia such as air, MQL or coolant, DEUBLIN offers coolant unions with patented Pop-Off™ 26

MACHINE TOOLS WORLD

and patent-pending AutoSense™, a technology that separates the seals in the absence of coolant and allow indefinite dry run or multi-media capabilities.

During each cycle from one mode to the other, a minute amount of coolant spills out, which must be collected and drained.

Excessive leakage, if not detected, may leak past the spindle seals and

JANUARY 2019

eventually contaminate and damage the spindle bearings.

DEUBLIN introduces SpindleShield™, an industry first and revolutionary new technology for CNC machining centers.

SpindleShield™ protects the spindle and prevents replacement of spindle bearings by allowing rapid, automatic shutdown of

machines. The combination of remote diagnostics and a positive leak detection system virtually eliminate unnecessary preventative maintenance and costly spindle repair.

This technology can be easily integrated into any standard system bus.

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BUSINESS NEWS

ANCA’s iView enables single chucking manufacturing A survey by McKinsey showed that in manufacturing, approximately 749 billion hours are worked each year around the world. Of these, about 60% (478 billion hours) were automatable or at least semi-automatable with existing technology. Imagine if even a small number of those 478 billion labour hours were converted to planning, analysis and strategy hours.

Thomson Mathew, ANCA Software Product Manager said, “To remain competitive in tool manufacturing, more and more businesses are looking for automation or semi-automation. Taking the time to set up the infrastructure smartly is delivering significant business advantages such as improved productivity, better access to machine data and lower production costs.”

“ANCA has an extensive

28

MACHINE TOOLS WORLD

range of products and features that enable our customers to run Smart Factories. One of these is our iView measuring system that can measure the ground tool in its original clamping inside the grinding machine. This feature has recently been further enhanced with a new camera bracket design that allows operators to visually inspect and perform manual measuring of parameters like endface land width, lip distances, chisel angles and more,” Thomson concluded.

Tool manufacturers use iView to take an image of the ground tool using the iView camera and then compare the data with an ideal overlay profile generated by the iView software without having to take the tool out of the grinding machine. This means faster set up time and better accuracy as the ground tool

JANUARY 2019

is checked against the tool requirements in one set up. iView is accurate to 0.002mm (<0.0001”) to allow accurate comparison and measurement of the actual cutting tool against the profile. The technology automatically compensates the tool based on the overlay and profile error it is adjusted and reground. This process also eliminates any accuracy loss that can occur when tools are transferred between grinding and measuring machines.

Versatile and accurate one iView camera can be used across multiple machines in the MX, TX and GX/FastGrind range.

The new bracket assembly allows the iView camera to be mounted horizontally, inside machines. This means that operators can visually inspect the endface, as well as perform manual measuring functions on endface land widths, lip distances and chisel angles.

About ANCA ANCA is a market leading manufacturer of CNC grinding machines. It was founded in 1974 in Melbourne, Australia where the company still has its global headquarters.

ANCA has offices in the UK, Germany, China, Thailand, India, Japan, Brazil and the USA as well as a comprehensive network of representatives and agents worldwide.

ANCA CNC grinders are used for manufacturing.

ANCA CNC grinders are used for manufacturing precision cutting tools and components across a diverse range of competitive industries including cutting tool manufacture, automotive, aerospace, electronics and medical.

For more information, Website: www.anca.com www.mtwmag.com

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BUSINESS NEWS

JUNKER Group to make an appearance at IMTEX, Bangalore The JUNKER Group, which consists of JUNKER, LTA, and ZEMA will be making an appearance at the IMTEX in Bangalore, India, between January 24 – 30, 2019. Today, the JUNKER Group is the world market leader in the manufacture of CBN grinding machines and filtration solutions, with 1,500 employees across 14 locations.

Maximum precision and absolute passion for what we do make Junker a pioneering company with a mission to set ever-new standards and so justify the trust placed in us by discerning customers from

wide-ranging sectors of industry. The JUNKER Group is the ultimate partner worldwide in all questions of grinding and air filtration technology.

Not only unparalleled innovative capacity but also a continuously expanding

sales and service network makes the JUNKER Group the leader in its field. Greater customer proximity makes for greater planning reliability: JUNKER Premium Service acts swiftly and with outstanding expertise

wherever its customers are around the globe. Available round the clock, this service finds a solution for every problem. However, service means more than just quick assistance should the worst happen.

Individual consultation when making a new purchase or modernizing an existing system ensures an ideally coordinated product package, while intensive training courses guarantee efficient operation at all times.

For more information, www.junker-group.de

STUDER sells the 1,000th S31Fritz Studer AG makes history with the universal cylindrical grinding machine S31 and hands over the 1,000th machine to Wuhan Hangda Aero Science & Technology Development Co., Ltd. in China.

Wuhan Hangda Aero Science & Technology Development Co., Ltd. develops high-precision components for the aviation industry at the Dongxihu site in China. The company is experiencing steady growth and decided to invest in a new precision cylindrical grinding machine.

After careful consideration and detailed technical discussions, Fritz Studer AG was awarded the contract for the S31. A special event: Towards the end of 2018, STUDER delivered the 1 000th S31 to Wuhan Hangda.

The S31 is an all-rounder - suitable 34

MACHINE TOOLS WORLD

JANUARY 2019

for medium-sized work-pieces in single, small and large series production. It scores in its compact size and is especially popular with contract manufacturers who have very high and often complex requirements for cylindrical grinding. 2’500 tons of Granitan® , a mineral casting that provides a vibration-damping, thermostable and wear-free machine bed, are used in 1’000 machines.

At the turn of the millennium, the

first cylindrical grinding machine S31 left the halls of STUDER in Steffisburg, Switzerland, and it is still in operation today. It is installed at Shvabe Munich GmbH in Geretsried, Germany. “We are still very satisfied with our S31,” says the head of the grinding department at Shvabe.

The machine is in full operation for external and internal cylindrical grinding.

The additional functions for form and thread grinding are used for the production of prototypes. “On the S31, as on all STUDER machines that are used in our house, I appreciate the high accuracy and that the machines are universally applicable,” continues Tobias Traut. He proves that the S31 is an extremely reliable and consistent machine. www.mtwmag.com

Spain

Bangalore International Exhibition Centre

IMTEX INDIA 2019

HALL 1B Stand D101

January 24 â&#x20AC;&#x201C; 30

ekin.es B106

etxe-tar.com C106

fagorautomation.com A106

gurutzpe.com C104

ibarmia.com D105

juaristi.com A108

nicolascorrea.com C102

iazgroup.net D103

gamor.es B105

zayer.com B107

Organizers

In collaboration with

EUROPEAN UNION

European Regional Development Fund A way to make Europe

BUSINESS NEWS

LANXESS further expands production of high performance materials in Germany Bond-Laminates GmbH is increasing its production capacity for continuous fiber-reinforced thermoplastic composites of the brand Tepex. The company, a wholly owned subsidiary of specialty chemicals company LANXESS, is currently building a new, fourth production hall of around 1,500 m2 at its Brilon site.

Two additional production lines are scheduled to go into operation there in mid 2019. The company already produces innovative composites for the automotive industry and also for the electrical and sports industries on an area of around 5,000 m2. The investment, an amount in the single-digit-million-euro range, will significantly increase capacity to meet the growing demand for this forward-looking material.

With this expansion, BondLaminates will create up to 30 new jobs.

New compounding plant for high performance plastics The LANXESS High Performance Materials business unit is also investing in its global production network for high performance plastics, and is building a further compounding plant at its Krefeld-Uerdingen site for a sum within the mid-double36

MACHINE TOOLS WORLD

digit-million-euro range.

Starting in the second half of 2019, LANXESS will produce Durethan and Pocan engineering plastics, which are used primarily in the automotive, electrical, and electronics industries.

In addition, a warehouse and a silo facility will be built. Construction will start in the fourth quarter of 2018. The investment will create around 20 new jobs at the Krefeld-Uerdingen site. The new compounding plant will be designed in such a way that LANXESS will be able to expand its operations with further capacities in line with demand over the next few years.

Lightweight solutions for modern mobility High performance plastics and composite materials from LANXESS make it possible to design components that replace metal parts in vehicles and thus contribute to reducing weight, fuel consumption, and emissions. The

JANUARY 2019

innovative materials are used, for example, in engine applications, door structures, pedals, front ends, seat shells, underbody panels, and cockpit cross members. Depending on the component, the lightweight construction can achieve weight savings of up to 50 percent.

The continuous fiberreinforced thermoplastic composites of the Tepex brand are increasingly used in series applications in the automotive, consumer electronics, and sports industries. The highly resilient material is processed by injection molding without additional postprocessing steps. This makes Tepex the material of choice for high-volume mass production. In the sports industry, for example, it is used in the

manufacture of shoe soles, bicycle components, ski boots, body protectors, and helmets.

There are also many applications for LANXESS materials in hybrid and purely electric vehicles, some of which have already proven their worth in series production. These include components for charging systems, carriers, cell holders for battery systems, and sensors and housing parts for electric motors. The materials also offer great potential in electromobility infrastructure, such as for housing parts, switches, and terminals for charging stations.

LANXESS is a leading specialty chemicals company with sales of EUR 9.7 billion in 2017 and about 19,200 employees in 25 countries. The company is currently represented at 74 production sites worldwide. The core business of LANXESS is the development, manufacturing and marketing of chemical intermediates, additives, specialty chemicals and plastics. LANXESS is listed in the leading sustainability indices Dow Jones Sustainability Index (DJSI World and Europe) and FTSE4Good.

For more information, Website: www.lanxess.in www.mtwmag.com

BUSINESS NEWS

Additive Manufacturing Show takes centrestage in Mumbai The 2-day international event ‘Inside 3D Printing Expo and Business Forum’ held at the Nehru Centre, Mumbai during 19-20 Dec. provided India’s largest business networking platform for 3D printing technology. Manufacturing of components for cars, aeroplanes and medical devices, is witnessing an industrial revolution with three-dimensional printing. “Threedimensional printing is slated to become the new order by 2021 when the 3D printing, or in the correct technological parlance, Additive Manufacturing industry in India is expected to cross US$ 200 million,” said Aditya Chandavarkar, the Co-Founder of the Indian 3D Printing Network who organized this international show.

Aditya revealed that AM is bringing a constructive disruption in the Indian industry at a scorching pace. In the jewellery industry, 75% of the moulds are 3D printed.

Smart Tech’s Scot Dunham predicts that the global market for direct precious metal, 3D printed components and products will grow to $2.6 billion by 2020 and $4.1 by 2024.

Aditya underlines that Indian AM industry is constantly innovating and 38

MACHINE TOOLS WORLD

adapting this technology to newer applications.

It is witnessing a collaborative approach even amidst healthy competition and building a cohesive network. It has moved from creating prototypes to functional and useable end-products manufactured using AM. The industries that benefitted the most from this revolutionary technology are automotive, aerospace, tools, dies & moulds, jewellery, precision engineering from the manufacturing sector; healthcare, medical devices & dental applications from the medical industry; and reverse engineering, engineering inspection & tool-rooms from the 3D scanning segment; and design & packaging.

Among the quality visitors close to 2000 who came to explore the latest

JANUARY 2019

trends in this sphere included design heads, automotive professionals, healthcare professionals, academicians, tooling experts, architects, consumer goods designers, software developers, implant manufacturers and foundry owners. The 35 plus companies who participated in the show to project their capabilities, commitments and offerings included Renishaw, Imaginarium, Wipro 3D, Intech DMLS, Redington, Danfoss, Sridevi Tools, DesignTech, Autodesk, Bharat Forge, Novabeans Prototyping Labs, Rapid DMRLs, HP and Ultramax 3D Printing E-Studio, LHM- Germany, Oerlikon, Zhejiang Qidi TechnologyChina, , Guandong Shunde Ultralline 3D TechnologyChina, etc. just to mention a few.

At Bharat Forge, Additive Manufacturing

is a new activity. The Division uses AM for manufacturing critical components using aluminium alloys, cobalt chrome alloys, stainless & tool steel, inconel, titanium alloys and maraging steel. Its AM business is expected to fetch a turnover of Rs.200 crores in the next two years, it is learnt.

Imaginarium is a leader in 3D printing and advanced manufacturing technologies housing the largest set-up of 3D printers in the country.

Having pioneered gamechanging applications for various industries, Imaginarium has helped disrupt the manufacturing sector by enabling enterprises prototype faster, design better and realize products in shorter time spans. Says one of the engineers at the Imaginarium stall: “We www.mtwmag.com

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india@blaser.com

Come to see us: Hall 3A / Stand A-118

BUSINESS NEWS are in the AM business for more than 15 years, catering to 50 plus industry segments through our expertise. We are present in the exhibition more for sharing knowledge and creating awareness of the AM business”.

Indeed, AM reduces material wastage, ensures lesser weight of the end-product, and brings flexibility to designers. GE is said to have switched to AM for manufacturing jet nozzles made from 27 alloys without a single weld joint. Siemens has launched a digital factory in UK on 12th Dec. In India, Ace Manufacturing

and Hero Honda have gone in for AM to reap the benefits of this innovative technology.

AM also obviates the need to maintain inventory of old spares of models of vehicles or machines which are redundant.

The concurrent seminar

at I3DN discussed as many as 15 papers by industry experts on topics as varied as Industrializing AM, Striking the Right Balance between Buying Equipment and Using Service Providers, Increasing Productivity without Compromising

on Quality and Quality Control for Metal PBF, Use of High Performance Polymers for AM and so on. Some 150 delegates from a cross-section of the industry attended and derived benefit.

The organizers have announced the next edition to be held during 11-12 Dec. 2019 on a much larger scale at BEC, Mumbai to accommodate more participants. The event has been rechristened as AMTECH Expo - the acronym stands for Additive Manufacturing Technology.

- P.K. Balasubbramniian

INTECH and DMG MORI sign partnership At FormNext in Frankfurt, INTECH and DMG MORI seal a cooperation in the field of Additive Manufacturing. DMG MORI as a worldwide leading manufacturer of machine tools, acquired a 30% stake in INTECH, India, by integrating the SLM technology machines with the OPTOMET software from INTECH. Committed to Additive Manufacturing and related software solutions, including machine learning and artificial intelligence for the Metal Additive Manufacturing industry, INTECH will soon release numerous 40

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solutions, aiding users with ease of machine operations and process control, producing quality components at optimized costs, thereby empowering customers to adapt this technology quickly.

Christian Thönes, CEO of DMG MORI AKTIENGESELLSCHAFT, says: “With INTECH we strengthen our global footprint in India and accelerate innovative development in Additive Manufacturing. First time right – that means being fast towards the first good part. We are actively pushing ahead with integrated series solutions

JANUARY 2019

along the whole process chain for generative manufacturing.”

Commenting on the partnership, Mr. Sridhar Balaram, CEO of INTECH noted, “Leveraging synergies is key, and the collaboration is a perfect fit of hardware and software.”

He also added “OPTOMET can also be applied to other key AM technologies, such as Direct Energy Deposition and Binder Jetting. OPTOMET is a game changer for the whole AM market.”

INTECH supplies software solutions not only for the LASERTEC SLM series from DMG MORI

but also for other products and customers using powder bed technology.

The new OPTOMETsoftware automatically calculates the optimal process parameters. This simplifies programming and results in a markedly improved surface quality as well as reproducible material properties.

OPTOMET is a stepping stone towards accelerated industrialization of Additive Manufacturing.

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COVER STORY

Renishaw : Global Leadership in precision measurement arena

Paul Weaver, Vice President, Renishaw Metrology Systems Ltd

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COVER STORY Q. RENISHAW has leadership position in metrology industry, how did RENISHAW India managed this significant growth?

Renishaw is one of the world’s leading engineering and scientific technology companies, with expertise in precision measurement and healthcare The Renishaw Group currently has more than 70 offices in 35 countries, with over 4,000 employees worldwide. Around 2,800 people are employed within the UK where the company carries out the majority of its research and development and its manufacturing. Renishaw has been recognised with 18 Queen’s awards for business innovation and export showing how we continue to strive for excellence, and continue developing.

In India, Renishaw have been trading for around 36 years, and set up a local company in 2000. Since then, we have added an 80000 square foot manufacturing facility and now employ in excess of 400 people in the market. Renishaw tend towards investing in markets at the beginning of their development, and as India is the worlds’ second most populous country it was always going to be a high potential market so the decision was taken to enter the market before it was considered as a developing market by many companies. Since that time we have continued to invest as the market has begun to realise its’ potential. Having skilled and knowledgeable people continues to be the key factor in this development, and as a business we invest in our staff heavily in order to continue to offer the best support possible.

Renishaw, in 2016 opened Additive Manufacturing Solutions Centre in Pune, India. The facility is providing a secure development environment in which customers can expand their knowledge and confidence using additive manufacturing (AM) technology.

The Solutions Centre is equipped with the latest AM systems and staffed by

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knowledgeable engineers to allow fast access to deploying the technology, all at fixed predictable costs.

Q. What are the plans to promote RENISHAW brand in India? Is there any new product to be launched in IMTEX 2019 ?

The show’s 50th anniversary will be marked by the introduction of an Industry 4.0 pavilion. In line with this, Renishaw will showcase a complete automation cell, demonstrating to manufacturers how intelligent process control is key to the operation of a successful smart factory. Additionally, the company will launch several new products to address the industry’s need for automated process control.

Intelligent process control By exhibiting a high-productivity machining cell, Renishaw will demonstrate how integrating smart factory process control can transform a machine shop’s production capabilities, improving speed, ease-of-use & flexibility. The cell highlights how CNC machining operations can benefit from high levels of automation & connectivity and demonstrates process control techniques that Renishaw uses in its own factories for automated precision manufacturing.

Renishaw will demonstrate intelligent process control for larger parts, by exhibiting the Equator™ 500.

Additive manufacturing productivity Renishaw will have a separate additive manufacturing stand, where it will exhibit the four-laser RenAM 500Q. The machine significantly improves productivity, speeding up the process by up to four times in the most commonly used platform size, without any compromise on quality.

Increasing speed, without compromising on accuracy The world’s fastest workpiece set-up

cycles on CNC machines are enabled by SupaScan and the latest OSP60 scanning probe, which will be on display at IMTEX. Exclusive to SupaScan, the QuickPoint macro cycle delivers market leading measurement speed.

Visitors to Renishaw’s stand can experience the multi-sensor capability of the REVO® 5-axis measurement system on co-ordinate measuring machines (CMMs).

Q. How about RENISHAW’s initiatives in measurement technology space?

Which are your focus areas?

Renishaw PLC is founded on Research and Development, and as it has grown has continued to invest around 15% of its’ annual budget into R&D. Renishaw is not just the leader in the metrology field - it actually created many of the technologies that are in use today, beginning back in 1973 with the invention of the touch trigger CMM probe in order to measure the fuel pipes for the Concorde Supersonic Airliner. This emphasis on R&D is probably the single largest focus for the entire company – never standing still as we believe that there is always a better way.

Clearly we are placing significant emphasis on our metal additive manufacturing (3d printing) offer, with continual developments taking place as the market develops in maturity.

Outside of that we are focused on developing techniques and products that will improve accuracy and throughput such as the Revo 5 axis CMM scanning system, Sprint Analog Machine tool scanning probes, Equator 500 Gauging solutions and the revolutionary XM-60 calibration system able to calibrate all 6 degrees of freedom in a single setup.

I think the best way I can sum up our approach is that our focus areas are to continually seek technology innovations across our product ranges, from machine calibration, in process measurement & gauging up to post

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COVER STORY process inspection. If we develop a process that we feel advances measurement technology then we will try to commercialise it into a product, as the ethos of Renishaw is a genuine desire to help global industry become increasingly productive & less wasteful.

Q. What are the market opportunities for RENISHAW products in India?

How do you plan to position these products?

It is clear that the market in India is already sizeable, and growing – and the government initiatives around ‘Make in India’ are further fueling the interest and growth in the manufacturing sector. As India moves away from being a sub-contract supplier base in the lower tiers of the manufacturing pyramid towards having an entire domestic supply chain, the complexity of components and requirement for process control accuracy greatly increases. This is where Renishaw can really add the most value to the market. We have a unique offer in that we can add significant value to the machining process from ensuring that machines are capable of manufacturing to required tolerances and standards (through our Calibration offer), ensuring tool integrity and condition & in cycle metrology (through our Machine Tool offer), and then post process measurements (through our Gauging and CMM offers).

Add to this our offer in the technology of the future in Additive Manufacturing then Renishaw is extremely well positioned to assist Indian manufacturing in the leap from a high potential market into an advanced manufacturing economy. In summary, the application of Renishaw technology in a manufacturing process can ensure increases in productivity, scrap reduction, increasing production utilization and ultimately increase profitability. Our positioning of the offer is based around the points above – that process control pays for

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itself and can significantly improve production processes.

Q. Can you brief us more about RENISHAW’s top line product range?

Renishaw is one of the world’s leading engineering and scientific technology companies, with expertise in precision measurement and healthcare.

The company supplies products and services used in applications as diverse as jet engine and wind turbine manufacture, through to dentistry and brain surgery. It is also a world leader in the field of additive manufacturing (also referred to as metal 3D printing), where it is the only UK business that designs and makes industrial machines which ‘print’ parts from metal powder.

Q. What are the key technological trends that are driving metrology industry?

Globally, a shift towards smarter, leaner & efficient manufacturing is taking place through data-driven manufacturing and automation. Technology has changed the nature of manufacturing, with robotics, process and measurement machinery & IT systems now an integral part of the factory floor. Sensor technology is developing rapidly and becoming more integral. Metal cutting tools equipped with a range of new generation sensors that enable extensive monitoring of equipment and process attributes (spindle health, tool wear, coolant temperature, power usage etc) will become commonplace. Therefore, machine tool connectivity is becoming easier & seamless. Combined with developments in cloud computing & big data analytics this will provide users with the ability to make informed decisions. Cost Management, productivity gains, decreased downtime and improved quality will be the result of this.

We will also see an increased range of automation solutions. Robot technology will increase, however automation will not be only limited to robots.

Automation extends beyond robots and there will be increases in integration of simpler automation solutions with metal cutting machines too. This will make a big impact in productivity, quality & safety. These simpler solutions will include tool pre-setters, pallet changers, machine tool probes, inventory management systems, tool condition monitoring systems etc.

All of these advances are ultimately being driven by the Global requirement for increasingly complex products with ever increasing capabilities. This increases the need for more efficient manufacturing, tighter tolerances and improved production repeatability and accuracy.

Q. What is your vision for RENISHAW India for 2020?

Renishaw see India as a growth market.

With the current rate of change, India will be classed as a high tech, advanced economy in the near future & the Make in India Strategy will drive this through the domestic production of increasingly more complex and critical systems for Aerospace, Space, Defence and Automotive projects. Our metal additive manufacturing (3d printing) offer means we are well placed to move forward as this technology moves from disruptive into the mainstream – this is already happening in certain segments such as Aerospace where production parts are now being printed.

Renishaw has always heavily invested in Research and Development this continues at pace. With the market conditions, our leading edge technology & a strong local team, my vision is to continue to lead the market in metrology and further strengthen this position through education. Educating customers of the massive benefits that process control brings to them in productivity & quality gains. This ultimately leads to increased profitability, which makes Indian industry more competitive in a Global marketplace.

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IN FOCUS

Liquid Tool – Helping customers win !

Punit Gupta – Managing Director, Blaser Swisslube India

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Vision of Blaser Swisslube Liquid Tool – Our way of life!

India is a growing economy and manufacturing has been growing well with good prospects over a long term. It looks bright, however there is a challenge of competitiveness in the market. Low cost competitiveness is eroding. The Manufacturing Industry is realising that investment in technology is required to succeed and to keep the winning edge.

The Team of Blaser India is passionately driving with a committed approach to help our customers in building sustainable business. This means increasing the competitiveness in manufacturing through many different dimensions like Productivity, Machining Expertise and Serving with tailored on-site customer service.

The Leverage effect - It is

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IN FOCUS

fascinating to see the positive impact, which can be brought by little investment in the area of metalworking fluids. Blaser Swisslube has been able to demonstrate this dimension very well over the years.

Liquid Tool gives us a chance to grow with customers who have a holistic approach to production & manufacturing process and recognise the true value of cutting fluid. We want our customers to be more successful with our Liquid Tool and we would like to commit ourselves to do everything possible in this journey.

Our company has been fully committed to provide customers with comprehensive solutions rather than merely products.

Providing added-value through our Liquid Tool has become our way of life!

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Q. Can you tell us more about the Liquid Tool concept ?

Liquid Tool is our value proposition, which helps in increasing competitiveness of our customers.

Doing it by driving their productivity has been a key success element of our company globally. It brings transparency and a holistic view on overall returns on their investments.

Productivity, cost-effectiveness and process quality are factors that critically depend on the selection of metal working fluid and the competence of the partner. Our extensive machining know-how & high expertise, customised services and high technology formulations allows us to work with customers in a deep basis. An area of metal working fluid which was considered as a necessary evil has been completely turned around

with Liquid Tool concept. It helps customers to exploit the potential of machines and tools to a larger basis and win.

Q. What are the benefits a customer can get from Liquid Tool ?

Consistently high work piece quality, minimal reworking times, longer tool life for greater machine availability, lower cycle times, increased process reliability etc are few vital elements in machining. With state-of-art technology center at our global head quarter in Switzerland, we are constantly trying to explore the higher possibilities by carrying out stringent tests. It includes surface quality of components, tool wear patterns and higher cutting parameters.

Hundreds of cases studies have been conducted in India to witness

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IN FOCUS bacteria by consuming the available nutrition, which limits their own growth as well. The result is long term emulsion stability, process stability and one of safest formulation in the world for human health and environment. It is a big benefit to the customers and users.

In addition to successful technical performance, one of the top priority at Blaser Swisslube has been to set high standards towards human and environmental. Metalworking fluids that last for years without bactericides have been a Blaser Swisslube strength for more than 40 years.

these improvements at customers’ places wherein investment by customers in our Liquid Tool generated substantial returns on their investments. Many customers have witnessed 8% to 15% range in cut time reduction and 20% to 40% improvement in tool life. However, it all depends upon the individual machine setup. Each one is unique.

Q. What are the Technology solutions for upholding environmental sustainability?

It is a global requirement for all the manufacturing companies to contribute towards a greener planet, either due to regulations or self-consciousness towards the environment and health. Blaser Swisslube designed Blasocut – Bio Concept, a water-miscible metal working fluid, which works in harmony with nature. It allows the colonisation by specific, water borne bacteria (termed as “primary bacteria”) that push back all other

Q. How does product development activity take into account the latest technologies to cope with the market demands?

We invest in our Research and Development (R&D) significantly, because that is the best way to keep our new and existing products on the cutting edge of technology. More than 70 specialists in our R&D and

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Blasocut – 100% bactericide free

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customer service laboratory spend every day working together in various disciplines: analysis, chemistry, microbiology, metallurgy, physics, and manufacturing technology.

Because of trying to provide our customers with technological benefits, our R&D has grown to one of the biggest in its field. Research and Development is very important to Blaser Swisslube to uphold our benchmarking lead. For Blasocut customers who rely on Blaser Bio concept – not only we continually check the overall germ count in their test sample, as micro biologist we take a much closer look: exactly which bacteria are present, how many of them ? We not only use the classical test methods, but also latest molecular biology detection techniques.

Technology centre with the latest CNC machines as well as stateof-the-art CAD/CAM systems, for optimally simulating and thoroughly understanding our customers’ production situations. Thanks to this technology centre, we gain a better understanding of their highly complex manufacturing processes and the interaction of chemistry, microbiology and mechanics, so that we can continuously improve our cutting fluid developments.

Individual criteria like high-pressure stability, tool wear protection and additives durability are systematically tested. There is a dedicated expert team, which is constantly looking in machining of different materials at Technology center, which helps to judge the impact on productivity.

New materials, technological innovations and ever-improving machine performance constantly challenge our metalworking fluid development and we are happy to bring out innovation for our customers.

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IN FOCUS

“Mobil’s perfect formula for Machine Tool industry” ExxonMobil Lubricants Private Limited reveals how the right lubricant can improve productivity and increase profits for a manufacturing business Imtiaz Ahmed, General Manager - Marketing Deployment (Commercial) ExxonMobil Lubricants Private Limited

Q. ExxonMobil is a lubrication expert. What are the Lubrication Solutions the company offers to a machine shop?

The machine shop industry is core to the manufacturing sector. The Indian manufacturing sector is turning a curve - we are witnessing a focused and continuous effort on part of manufacturers to not just increase productivity and cut costs, but also adopt sustainable processes and technologies for a greener business. As newer technologies in the machine shops gain momentum, the lubricant industry is also gearing up to meet the need for customised specialty products. Industry leaders like ExxonMobil™ are powering this transformation, bringing technologically superior world-class lubricants developed through global expertise of decades that deliver significantly improved productivity and cost savings.

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Q. In terms of lubricant selection and usage, what are the specific challenges that a machine shops/ manufacturing sector face?

For the manufacturing sector, a key operational challenge is to strike an optimum balance between throughput and maintenance. A direct fallout of this imbalance can be a breakdown of operations, which can severely derail deadlines and hamper production.

Sometimes manufacturers are tempted to postpone or delay preventive maintenance or they replace original components with lower-quality items.

This practice may create unsafe conditions in harsh manufacturing environments if these low quality components – including lubricants - can’t stand the up to operating conditions. Poor maintenance can also cause health and safety issues, as well as lead to unplanned or excessive downtime. Manufacturers need to perform preventive

maintenance on recommended schedules to keep operating costs low and throughput high, while ensuring worker safety.

Q. How important is oil analysis as part of the lubrication program?

Technologically-advanced lubrication practice is one of the key factors for preventive maintenance. Lubricant is the lifeblood of machines and oil analysis is akin to a doctor testing a blood sample to assess one’s health and detect ailments that require treatment. A sample of oil provides crucial information that can help increase productivity, reduce unscheduled downtime, improve equipment durability and lessen lubricant consumption. Mobil ServSM Lubricant Analysis, bringing its thorough knowledge of applications and equipment built by working closely with original equipment manufacturers, delivers precise

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IN FOCUS analysis and detailed, actionable recommendations, resulting in cost savings, strong productivity and peace of mind.

We also bring expertise through our Mobil ServSM Engineering Services to help plants optimize their lubrication programs, troubleshoot equipment issues and proactively inspect and monitor equipment for more efficient and profitable operations.

the oil life of regular synthetic oils, even in continuous high operating temperatures and under extreme operating conditions.

In addition to our high performance lubricants and fluids, we provide a range of technical services to help keep the machine running at peak efficiency while also extending machine & oil life, reducing downtime and lowering operating costs.

Q. Incorrect lubricant usage often hampers productivity in a machine shop. How do ExxonMobil’s products and solutions address these challenges?

Incorrect lubricant usage – even over usage of lubricants - can severely hamper productivity. For instance, disregarding the manufacturer’s recommendations for any piece of equipment or component could potentially lead to failure of the equipment or affect the machine’s warranty. With usage of lubricant closely linked to varying factors like environmental conditions, speed, load and temperature, getting the usage right is imperative for manufacturers.

Using the appropriate grade and type of lubricant is essential for proper bearing performance. Failure to choose the right lubricant can lead to shortened bearing life.

After many decades of serving the industry, we have the proven lubricants and expertise to help manufacturers at every stage of the manufacturing process. Our lubricants are designed to work together and minimize the impact of cross-contamination. For instance, our recent launch, the Mobil SHC™ Elite, is a breakthrough synthetic gear and bearing circulating oil that has been specifically engineered to deliver long-lasting protection for machines, delivering 12 times the oil life of mineral oils and double

Q. What are Mobil’s key products for the Indian manufacturing sector?

Mobil offers a complete range of lubricants for the Manufacturing sector, including OEM-approved products with years of proven performance, as well as advanced problem-solving synthetic oils, industrial oils and greases. Our range for the Manufacturing sector includes Mobil DTE 10 Excel™ Series, our high performance anti-wear hydraulic oils specifically designed to meet the needs of modern, high pressure, industrial and mobile equipment hydraulic systems; Mobilcut™ series – the aqueous metal working fluids that deliver a dependable performance in a wide array of metal removal processes; Mobil Vactra™ Oil Numbered Series – the premium-quality slideway lubricants specifically designed to meet the requirements for accuracy, aqueous coolant separability, and equipment protection of precision machine tools; Mobil SHC™ 600 – the exceptional performance gear and bearing oils designed to provide outstanding service in terms of equipment protection, oil life and problem-free operations; Mobil SHC Gear™ – the synthetic industrial gear oils designed to provide outstanding protection of gears and bearings; Mobil SHC Rarus™ – the supreme-performance air compressor lubricants; Mobil SHC Polyrex™ - the specifically designed

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greases to improve productivity in high temperature conditions; Mobilith SHC™- the superior performance greases designed for a wide variety of applications; Mobilgrease XHP™ - the extended-service lithium complex greases designed for a wide variety of heavy duty applications and operating conditions and Mobilgear™ 600 XP – the extra high-performance gear oils having outstanding extreme-pressure characteristics and load-carrying properties.

Q. ExxonMobil is known for its cutting-edge innovations and customisations. Can you share an example of how Mobil Serv created a solution for an Indian manufacturer?

In terms of customization, let me share an example of a recent engagement with Modern Mould Limited, a leading organization in the plastics industry. The injection moulding major charged a new hydraulic oil in their machine and a heat exchanger malfunction resulted in water entering the oil. To manage the high production demand, the machine could not be stopped for oil replacement and running with contaminated oil would damage the pump and machine components.

Offering a solution to Modern Mould Limited, Mobil’s Field Engineering team proposed to opt for online water removal with a low vacuum dehydrator. After completing the water removal procedure, the oil’s suitability for use was tested under Mobil Serv Lubricant Analysis program and it was found fit for further use. Thanks to Mobil Serv’s predictive maintenance and corrective action, the damage to the machine components was averted, the oil disposal was avoided and the high productivity was maintained, potentially saving 36 hours, 2200 litre of oil & revenue of INR 670,800!

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IN FOCUS

Eyeing the

BRIGHTER future

Kunal Marathe - Marketing Director LUBECO Green Fluids

Q. Being the key player in the industry, Please brief us companyâ&#x20AC;&#x2122;s journey from inception & share some of the milestones achieved?

We switched from textile chemicals to industrial lubricants following closure of mills in and around Mumbai region.

The transition was far from smooth but we held onto it nevertheless.

Since Pune was a automobile hub, we shifted base from Mumbai to Pune and became Pvt. Ltd. in 1998. We started with 2-3 products like EDM Fluid, Washing Chemical & Synthetic Coolant but developed & increased our product range year after year and we now have around 80 odd products. We made technology and additive partners from Germany & UK along the way to speed up our R & D and upgrade our technology. Because of these alliances almost all our products are RoHS (EU Compliance) certified. We recently entered into the field of fluid management and developed a tube type skimmer which performs at least 40 times better on speed, efficiency and cost counts. We developed a wide network of distributors in North, West and South India as well as in country like UAE. Q. Please brief us about companyâ&#x20AC;&#x2122;s infrastructure & what are the technology alliances that has been made in order to out-front the competition?

The company was started in a mere

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1500 sq feet make shift plant in 1998, which now is spread across 30000 sq ft in an industrial area and we are still expanding. Investment in plant and machinery has been growing every year and we now have a storage capacity of more than 3.5 Lakh Ltrs. Focus was given on laboratory infrastructure and along with R & D and QC labs we now have our own Microbiology lab as well. The workforce too grew by about 10 times during this period. We joined hands with two technology partners from Germany and UK and created our brand Lubeco and launched the same in 2015. We also created a separate brand Fluidmate, which literally means-A friend of the fluid! Fluidmate will have equipment and machinery used in fluid management systems.

Together the Boron, Chlorine, Sulphur, Phosphorus, Formaldehyde free technology of Lubeco and power saving, fluid life enhancing, ETP cost reducing technology of Fluidmate will be a game changer for the company.

Q. What are the products manufactured by your company?

Our company has two brands Lubeco and Fluidmate. Under Lubeco we have all types of fluids & lubricants like Metalworking fluids, Hydraulic and Lubricant oils, Rust preventives, Cleaners, Mist lubricants, EDM Fluids, Speciality lubricants for drawing, punching,

rolling, etc, Carbide grinding coolants, Paint strippers, Rust removers and so on. In Fluidmate we have products like skimmers for small machine tanks, medium size washing machine tanks and large size ETP and central coolant tanks. We also have fluid suckers to remove huge volume of fluids from large tanks within minutes. Coolant mixers for forming exact cutting oil emulsions eliminating manual errors. We also have refractometers, pH meters, TDS meters under Fluidmate series.

Q. What is your marketing strategy for India?

We first focused on creating a brand appeal and now our marketing strategy is simple-promote this brand in the nooks and corners of the country. To reach out to such a large population spread across such a huge country, we will participate in various exhibitions in Tier 2 and Tier 3 cities along with the biggest of them in BangaloreIMTEX. We also plan to expand our dealer-distributor network in the country and appoint marketing managers in various regions. Apart from this, we also plan to conduct seminars and training sessions in various parts of the country with the help of our distributors and area marketing managers. We have been pushing and encouraging students to develop products by using renewable energy and sponsor their

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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?

Everyone knows that the technology changes with time but the speed at which it is changing these days is astonishing. So to keep pace with these technological changes and not only sustain but race ahead in the competition, we have to constantly upgrade ourselves by developing existing products and innovating new ones. On top of this, the environmental impact of the old technology is also one of the reasons to look for eco-friendly and environmentally safer options.

New technology has to be more user friendly and cost effective too in order to make it implementable. Unless we are a step ahead than the competition we will not move ahead, we will remain stagnant and Ultimately phase out. Simply put, if the world needs a certain technology and nobody has it and if you are able to develop that technology, then sky is the limit.

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?

The most important aspect of benchmarking a product is customer satisfaction. Customer satisfaction involves all the aspects. To know what will satisfy the customer, we have to collect a lot of data related to his processes, machines, users, current problems, expectation from new product etc. This data is formalised into a document which is used as a base for developing a product. At every stage of product development this data is referred and once all the aspects are matched by the

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product, it is put on trial-first in a lab and then in the field. When the lab trials and field trials go as per customer requirement, then only the product is tested for itâ&#x20AC;&#x2122;s environmental impact and then once it passes all of these tests, it is launched in the market. Now comes the hardest part, to maintain the same quality batch after batch. For that again a process chart is prepared which is locked into a software and connected to RM stock and QC lab.

So the RM stock confirms the correct dosage of raw materials and QC testing confirms batch conformity. Unless QC passes the batch, it is not made available for the billing. In short, a nonconformed batch will never go into the market. Apart from this we also maintain ISO standards in procurement, production, quality control & sales.

Q. According you what are the factors affecting to your business?

Quality manpower and availability of space is what bothers us. In todayâ&#x20AC;&#x2122;s scenario, even though technology is advance, it comes at a cost which needs to be passed onto the customer and with cost cutting becoming a vital norm in business development, it is not feasible to implement cutting edge technology horizontally. So we need to strike a balance between use of technology and quality manpower.

Because the available manpower not is well trained, the time taken to spread the technology increases extraordinarily. Secondly, getting space for expansion is also very important in order to maintain stock and standards and serve increasing number of customers without affecting the existing ones. But due to unavailability of space and that too at an affordable price creates obstacles in our growth and development.

Q. What are the key technological trends that are driving the industry?

More and more eco-friendly tech-

nologies are being invented and implemented. Environmental impact generates desires to develop new technologies. Because the carbon footprint generated by old technology needs to be curtailed or may I say stopped completely. So that alone drives current technological trends.

Apart from that, saving cost remains the second most driving force for new technologies. Industry and government are working together in driving the industry towards a greener future. E.G. Government has made ETPs mandatory to stop effluent into the ground. So industry wants to generate less effluent in order to reduce cost of effluent treatment. So suppliers need to provide that technology which will reduce the cost of effluent than the last day.

Q. How do you perceive the future of the industry?

The future of the industry looks promising with better taxation policy (GST), easier business norms, more foreign investment coming into India by way of Make In India projects, growing new industry like Aerospace along with the existing Automobile industry, more focus and spending on research and development in all fields. Overall the future looks good and stable.

Q. What is your vision for your company for near future?

Our vision is and has always been sustainable growth in terms of volume and technology. As I have already mentioned earlier that technology is the catalyst for success and without success there would be no investment in newer technology, both go hand in hand. So our vision is to develop new technology, market it and sell it! We also plan to expand and upgrade our manufacturing facility, participate in exhibitions, appoint new distributors and marketing personnel in untapped region!

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‘We focus on technology & platform developments not product development’

Mr. Praful Shende, Chief Sales & Marketing Officer, Bharat Fritz Werner

Our aim is to enable progress of the customer’s manufacturing. To that end, we are focused on providing machines, and ensuring that our manufacturing competitiveness is enhanced, says Praful Shende, Chief Sales & Marketing Officer, Bharat Fritz Werner (BFW). In an exclusive interview with Shweta Nanda of MTW, he talks about the company’s thrust on innovation, its strategy to ensure customer satisfaction and environmental conservation efforts. Excerpts: Q. With IMTEX round the corner, what are your expectations from the mega event being held in Bengaluru from January 24 to 30?

What opportunities is BFW seeing by participating at IMTEX 2019?

IMTEX, being the flagship event, is a great platform to network, meet our existing and potential clients and of course showcase our new products.

That said, we at BFW first and foremost view it as an opportunity to know and engage with clients from a wide range of segments, understand their requirements and current challenges. We then use these key points to design our future products and services.

At IMTEX 2019, we are set to

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display a wide array of new and exciting technologies, including advanced multi-process technology, high speed machining technology.

We are also showcasing IRIS, our Industry 4.0 platform, and innovative products from our Kalam Center of Innovation.

Q. According to you, which factors are leading to the growth in Indian machine tools industry? Which industries are leading in terms of demand?

Indian manufacturing is growing and will continue to grow. There will be a few glitches here and there in the short term but by and large the outlook looks positive.

The government also continues to provide major impetus on manufacturing to enhance its share in GDP to rise to 20% from current 16%. Consequently, machine tools being the mother industry is also growing.

Automotive /auto components sector has been at the forefront of growth and will continue to hold a major share, especially due to shift from BS-IV to BS VI norms by 2020. Commercial vehicle segment will continue to grow on account of thrust on infrastructure. Apart from automotive, infrastructure, railways, MSME job shops, die and mold, and electronics are other significant segments driving the growth.

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Q. How well is India positioned in the global machine tools market?

Comment on the major challenges for the machine tools industry in India.

As per the latest Gardner Business Media survey, India is within top 10 machine tools consuming nations globally. Although there is a jump in ranking from the previous years, in absolute terms, machine tools market is still a 2 billion dollar industry with equal share of imported and Indian machines. That said, there is a lot of opportunity for the industry to grow and scale.

The challenge for the Indian machine tools industry is two-fold.

Firstly, in bringing new technology and scaling up for existing product lines. For instance, new technology, such as multi-processed technology is not readily available. Secondly, the Indian machine tool players are primarily busy meeting the demand of local market, while exports are a bit on backburner. I believe, that for the next level of growth, the focus on exports needs to be enhanced.

The industry needs to access markets outside India and establish the ‘Make in India’ brand. We, at BFW are focused on both these issues.

Q. Industry 4.0 is a buzzword that is bringing a shift in the industry. Tell us about BFW’s focus on Industry 4.0. In your observation, how ready are Indian manufacturing companies for these technologies vis-à-vis global peers?

Industry 4.0 is a broad term. In Indian environment, it signifies evolution of an ecosystem where the customer, manufacturing, organization, supply chain—all these elements will have to stay connected to respond to the needs of the shop floor in real time. The top

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expectation and priority of Indian companies from Industry 4.0 is increasing productivity of their asset.

So, in India the focus on Industry 4.0 is essentially asset productivity driven, while the Western world continues to put big thrust on technology.

We at BFW aim to keep things simple, because a large section of Indian manufacturing industry consists of MSMEs. We are focusing on helping our clients increase productivity without making the whole subject complex. IRIS, our platform for Industry 4.0, is a simple solution that enables our clients to know why their machine is not producing to its optimal level and provides them ability to act in real time to see it work. It attempts to make the machine more and more intelligent.

In terms of readiness, Indian companies are not totally ready for Industry 4.0. Tier I large organizations have understood the subject—some of them are putting plans in place and some of them have taken the steps ahead. However, a large part of MSMEs are not yet on board. I believe the real game will change once the MSMEs get ready to join the movement and that is where IRIS will play an enabling role.

Q. In your observation, what are the expectations and demands of Indian buyers? How does BFW facilitate the customers and ensure that their demands are met?

Customers are demanding costeffective automation, increased production and multi-operations in a single machine. They are expecting fusion of technologies and also customized products.

At BFW, we are co-developing products along with the customers,

by understanding their needs and replacing expensive import substitutes. Our thrust is to give them appropriate solutions and our wide product portfolio in terms of turning, milling and special machines allows us to customize the products and meet their unique requirements.

Q. Please update us about your achievements on the R&D side.

We at BFW strongly feel that innovation is critical to growth.

To fuel innovation we have a dedicated center named after visionary Dr. A.P.J. Abdul Kalam.

Our Kalam Center of Innovation is committed towards doing meaningful development on the technologies related to the machines of the future.

For us, the focus of R&D is not on product development but technology development. We are exploring the usage of alternative material for the making of the machine structures and improving its performance. We are also working on technologies that will ensure stable performance of a machine in tropical environment.

Due to our efforts in R&D and some breakthrough innovations, the Confederation of Indian Industry (CII) recently recognized BFW as one of the top 25 most innovative companies in India. We are the first one from the Indian machine tools fraternity to be featured in the prestigious group. It is very motivativating for us to grow the culture of innovation within BFW. Q. Tell us more about your environment friendly measures.

BFW has always been a leader in undertaking environment friendly initiatives. At the product side, we ensure that our products are greener by adhering to the standard norms for new product development. We

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In addition, we follow environment friendly practices at our plants. We do rain water harvesting and horticulture at both our plants in Peenya, Bangalore and Hosur, Tamil Nadu.

We have setup a solar power project that supplies power to the entire facility in Peenya. The 980 kWp solar project generates 15 lakh units of energy which helps us in meeting our power requirements.

This plant has helped us offset 1,350 tons of carbon emission every year.

Based on this experience, we are

exploring similar deployment at our Hosur Plant.

Q. What is your future vision and growth plans for the company?

Our direction, since inception, has been to enable progress of the customerâ&#x20AC;&#x2122;s manufacturing. We strive to provide optimum technology solutions to our customers be it process solution or product solution.

We are not just focused on providing machines, we are focused on making sure that cost-per-piece becomes more effective for the customer once he uses a BFW solution.

Looking ahead, we are planning to grow ahead of market growth by few percentage points and aim to double

our manufacturing capacity. We have recently opened a new manufacturing plant at Hosur, which is spread across 35,000 sq. ft. and includes significant numbers of modern machines to enable integration of existing foundry facility with machining capability. The Industry 4.0 compliant factory and all the manufacturing processes here are designed to take it to next level through digitalisation and superior engineering to ensure cost efficiency, increased productivity and shortened manufacturing time. Further, we are exploring our next expansion with a new plant about 18 to 24 months down the line, depending on how the market continues to grow.

Saving trees each day and every day, BFW way. Solar-powered Peenya Plant

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Mr. Ramesh Ponnuswami Executive Director ELGi Equipments Limited

ELGi: Marching towards Global Leadership in AIR COMPRESSOR Technology ELGi Equipments Limited, headquartered in Coimbatore, is the 7th largest manufacturer of air compressors in the world. The company with a comprehensive range of innovative compressed air systems, has earned the worldwide distinction of having designed sustainable solutions that help companies achieve their productivity goals. The Indian MNC’s goal is to become the No.2 air compressor manufacturer in the world by 2027. P.K. Balasubbramaniian converses with Ramesh Ponnuswamy, Executive Director, ELGi Equipments Limited, to understand the dynamics of the air compressor industry vis-à-vis ELGi’s thrusts to achieve the ambitious goal it has set for itself. Excerpts: 74

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Q. What’s the standing of ELGi in the global arena?

ELGi is the 7th largest air compressor manufacturer by revenue terms.

ELGi sells its products in over 100 countries. In the fiscal 2017-18, our revenues crossed USD 230Mn. Q. What’s your range of manufacture today? Is it comprehensive enough to meet the requirements of all major industry segments?

ELGi has the complete range of air compressors across reciprocating and screw types; for both portable and stationary applications. It’s quite a comprehensive range.

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Inside out: ELGi’s production facility spells world-class

Q. What are the dynamics of the Indian air compressor industry & what measures do you take to stay ahead?

The Indian air compressor industry is about USD 600 Mn and growing at 5-7% annually. While international players have been active in the Indian market for many years, in recent years there has been an increase in the number of foreign players / brands, especially for screw air compressors. This is for both oilflooded and oil-free segments.

ELGi’s products are benchmarked for performance and quality with the best in the world and we strive to be better than the best. ELGi’s products operate at the lowest life-cycle cost giving our customers the best value for money. We strive to keep abreast of industry trends and introduce products in line with emerging customer requirements, this helps us to stay ahead in the market place.

Q. There was a lull in the textile industry recently. The automobile sector is just picking up. How do you do the balancing act?

ELGi’s products are present in several industry segments. Adverse

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business cycles in one or two segments, while impacting our performance in those segments, do not therefore affect us significantly in an overall context.

Q. What is your brand promise and differentiated offer to the customer?

Our brand promise is “Always Better”. This is reflected not only in the performance of our products but the way our customers experience it in every possible touch point. Our products have the lowest total cost of ownership and we offer warranty programs that are the best in the industry. This differentiates us in the market.

Q. How are you heading with your global aspirations, also considering your recent strategic moves?

Our presence in key global markets such as US, EU, Australia, etc. is growing at a healthy pace year after year. We are considering both organic and inorganic growth options.

Q. You recently launched your oilfree compressors in the US market.

What’s its significance?

Oil-free compressors are among the fastest growing segments of air compressors, considering increasing

regulations in many industries that use compressed air. This has resulted in a shift in buying decision by customers from oil lubricated to oilfree compressors. The US market is a very attractive market given its size and the market dynamics offer good prospects for our products. We had to expand our product range in the US market and introducing our oilfree range in that market is a natural progression.

Q. How are you geared to meet the challenges posed by the market which is highly discerning & demanding?

We are focused on innovating continuously to stay ahead of the competition. This is both on the product side and market side. Our approach to product management and work in the front end are geared to respond effectively to meet emerging challenges in the marketplace.

Q. What’s your success rate in educating the customer on energy saving in compressor usage?

We actively engage with our customers in selecting the right compressor - the power rating of compressor selected has to be matched to their compressed air

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Where appropriate, we actively educate and promote customers to use products with VFD to save energy cost. We also offer VFD retrofits post-installation and establishment of actual air demand.

We conduct air audits to check compressed air distribution, usage and performance of compressors in customer’s facilities. These audits are focused on providing value added inputs to our customers to minimize energy losses and improve overall efficiency. The audits also help in planning for capacity enhancement if appropriate.

Q. You claim to design sustainable solutions to help companies achieve their productivity goals and keep the ownership cost low. Could you elaborate this?

Our machines have the least oil discharge into the atmosphere thus, reducing the impurities.

We also take pride in designing the machines for reducing wasteful use of energy or systemic leakages of energy. This ensures that the energy cost, which is the largest component of the Life Cycle Cost of a

ELGi is one of the five companies in the world to design & manufacture oil-free air ends

compressor, is kept at the minimum.

Q. How would you summarize your major strengths and capabilities?

• 50+ years of manufacturing air compressors, since 1960 • Full-fledged R&D facilities to ensure continuous innovation • We are one of five companies in the world to design and manufacture proprietary oil-free air ends • We offer end-to-end compressed air

solutions with 400+ compressed air systems • Presence in more than 100 countries • Best-in-class Lifecycle Cost (LCC) • Cost leadership Q. What’s your vision for ELGi? Our vision is “Always be the choice everywhere“ & our aspiration is to become the No.2 air compressor manufacturer in the world by 2027.

ELGi’s sprawling manufacturing facilities in Coimbatore

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VERTICAL VERTICALTURNING TURNINGMACHINE MACHINEVT VT22 SETTING SETTINGTHE THEPACE PACEFOR FORSHAFT SHAFTPRODUCTION PRODUCTION SHORT SHORTIDLE IDLE TIMES TIMES

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MAXIMUM: MAXIMUM:4-AXIS 4-AXISTURNING TURNING WITH WITH22XX1111TOOLS TOOLSENSURES ENSURES MAXIMUM MAXIMUMPRODUCTIVITY PRODUCTIVITY

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Technical TechnicalData: Data:Chuck Chuckdiameter, diameter,max. max.160 160mm, mm,Main Mainspindle spindlePower Powerrating rating/ Torque / Torqueatat4040%%EDED17.9 17.9kW kW/ 142 / 142Nm, Nm,Workpiece Workpiecegripper gripper diameter, diameter,max. max.6363mm, mm,Workpiece Workpiecediameter, diameter,max. max.100 100mm, mm,Workpiece Workpiecelength, length,max. max.400 400mm, mm,Turret Turrettool toolstations stations2 x2 11, x 11,Turning Turningtools tools and anddriven driventools toolsapplicable. applicable.

EMAG EMAG India India Private Private Limited Limited “Technology “Technology Centre” Centre” I No. I No. 17/G/46-3 17/G/46-3 · Industrial · Industrial Suburb Suburb I 2nd I 2nd Stage Stage · Yeshwanthpur · Yeshwanthpur I Bangalore I Bangalore · 560022 · 560022 I Karnataka I Karnataka · India · India Phone Phone Sale: Sale: +91+91 80500 80500 50163 50163 I Phone I Phone Service: Service: +91+91 80500 80500 50165 50165 I E-mail: I E-mail: sales.India@emag.com sales.India@emag.com I www.emag.com I www.emag.com

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Mazak’s Global Leadership in Machine Tools & Metalworking

Mr. Anil Bhardwaj, Managing Director, Mazak India

Mazak is undoubtedly the world’s largest machine tool builder.

The conglomerate with a strength of 8,331 employees on its roll, operations in 26 countries worldwide and a product portfolio covering some 260 types of systems encompassing the entire gamut of sophisticated machine tools designed to enhance flexibility, productivity and automation in the manufacturing arena, is indeed flexing its muscle and proving its mettle in spearheading technological innovations, discovers P.K. Balasubbramaniian in a one to one with Mazak India’s Managing Director, Anil Bharadwaj. Excerpts: Q. You are a world leader in machine tools. Could you brief us on your history and present standing?

Yamazaki Mazak was established in 1919 and has been contributing to the development of the machine tool industry as the global company.

Mazak manufactures not only advanced machine tools such as multi-tasking centers, CNC turning

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centers, machining centers and laser processing machines, but also automation systems with the concept of ‘all in one’ to support global manufacturing by providing exceptional productivity and versatility. We use contemporary technologies and are committed to develop advanced machine tools and provide cutting-edge solutions for the

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IN FOCUS progress of manufacturing as well as society.

Q. What’s your range of manufacture today?

As I said, we manufacture a range of advanced machine tools such as multi-tasking centers, CNC turning centers, vertical machining centers, double column machining centers, horizontal machining centers, CNC laser processing machines, flexible manufacturing systems, CNC systems, CAD/CAM systems and production support software, besides automation systems. In our standard range, we have something like 260 types of machines. We also make customized systems to meet specific customer needs.

Q. What’s Multi-Tasking?

Multi-tasking is when you combine several cutting processes, including turning, milling, drilling, tapping and deep-hole boring on one machine as opposed to having those same

processes handled by multiple machines. When you can process an entire workpiece from raw material input to final machining in one single set-up, we refer to it as ‘done in one’ operation.

Q. Could you elaborate 5-Axis Machining?

5-Axis Machining provides infinite possibilities as to the part sizes and shapes you can effectively process.

The term ‘5-axis’ refers to the number of directions in which the cutting tool can move. On a 5-axis machining center the cutting tool moves across the X, Y and Z linear axes as well as rotates on the A and B axes to approach the workpiece from any direction. In other words, you can process five sides of a part in a single setup.

Palletech System is exclusive to Mazak. It brings advanced, preengineered automation to today’s machining environments. It is a multi-tasking solution for any manufacturing or volume reqirement, and is compatible with all our horizontal machining centers as well as most of our vertical and 5-axis machining centers. With our Palletech Manufacturing Cell controller software over standard PCs and networks, shop management can monitor operations, view and change schedules on-the-fly, manage part program files from anywhere on the network, track tool life / breakage and issue instructions to the shop floor.

With this system users are able to interrupt a planned machining queue and produce an emergency part with no cost penalty. That is the advantage.

Q. What’s special about your automation systems?

By automation, we refer to our so-called Palletech System. The

Q. Could you give some idea of your production facilities and support bases network wordwide?

We have five production facilities

Mazak’s Multi-Tasking Equipment - An engineering marvel

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in Japan alone. We also have manufacturing facilities in US, UK, Singapore, and China. In China itself we have two plants. Worldwide we have 83 support bases. These comprise 38 Technology Centers and 45 Technical Centers in 26 countries.

Our Group companies are spread across Japan, North America, Central & South America, Europe, as well as Asia which includes Malaysia, Taiwan, Korea, Thailand, Indonesia and Vietnam.

Q. Could you throw some light on your operations in India?

Mazak India with National Head Office at Pune has its network spread all over India to cater to the customer needs. A strong workforce, especially trained in Japan helps to provide total solutions to the customer. Mazak India Head Office is spread across a 5-acre land with a built up area of 1,75,000 sq. ft. The Technology Centre showcases a spread of Multi-Tasking Machines, Horizontal and Vertical Machining Centers, Lathes and Laser Cutting Machines. The Technology Center showcases the latest and proven solutions to demonstrate the technical capabilities of Mazak India.

Q. What are the support services you offer?

If you are referring to Mazak India, we

have our pan-India presence to stay closer to our customers at large. We provide online service support to our customers. Be it trouble-shooting or quick delivery of machines or spares, we are only a phone call away to reach out to the customer. In order to maintain efficient service support, the regional part center stores up to a variety of 8,000 spare parts with a total quantity of 4,50,000 items.

In addition, it is connected to our Japan Global Part Center for fast and efficient response to customer requirements.

This apart, we provide extensive training in operation, programming and maintenance of our machines to all our customers. Our Technology Center is equipped with all our state-of-the-art machines and we can arrange demo of all our typical systems there.

Q. We understand you have a Spindle Rebuild Unit too. Please tell us more about this facility.

Spindle is the heart of any machine and is easily susceptible to damage due to accidents. Repair / replacement of the spindle can be

expensive and time consuming. In order to support customers, Mazak India has installed a spindle cartridge repair facility with advanced testing and condition monitoring equipment such as dynamic balancing machine, test jig with simulators, vibration, temperature and lubrication monitoring devices. With the new facility, spindle repairs can be carried out quickly and at affordable costs.

Mazak India also offers spindle exchange program which cuts downtime and provides the highest levels of quality and reduces costs.

Q. So what’s your differentiated offer to the Indian customer?

In today’s competitive manufacturing world where demands are high and enhanced quality, efficiency and productivity are cirtical for success, manufacturers need a machine tool partner with proven competence and who can deliver what they need and when they need it the most.

And that’s exactly what they can expect from Mazak. By virtue of our technology base, global presence and wherewithal of high order, we are eminently placed to provide cutting-edge solutions, while further solidifying our position as a leader capable of providing innovative, productive and futuristic products and solutions to the end user.

Mazak’s world-class Technology Center in Pune

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“Make in India”campaign will definitely boost manufacturing sector of India

Mr. Rajesh Kushwaha, Managing Director, Multi Axis CNC

Q. Please brief us about recent initiatives undertaken in machine tools space? Which are your focus areas?

We are very fast growing organization in field of manufacturing CNC Milling Machines, we are only Manufacturers in North india doing customization in Milling area. we are catering to almost all area`s like Dies & mould, Shoe Mould, Pattern Making, Engraving, Dental, Jewellary, Titenium machining for Defence, Press tools, Ceremic Industry etc.

We are catering SME`s includes various field to provide machine tools with latest Technology. We Participate IMTMA/others seminars and training programs at regular intervals through out the year. We found really very fantastic results

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from our staff by showing keen interest and attending seminars and acquire lots of information on related subject from experts.

Q. What are the market opportunities for your products in India? How do you plan to position these products?

Prime minister of India have announced “Make in India” campaign will definitely boost manufacturing sector of India. For any manufacturing unit machines are the prime requirement and hence we believe that there are lots of potential in the sector of Machine Manufacturing. Now a days buyer are become more and more demanding, price sensitive, focusing more on performance and after sales service

of machines. In this circumstances as a manuafcturers, we are continuously puts our efforts and emphasis to create awareness among our staff to focus on customer’s expectation to cope up market demand. India is very demanding country after China, there are huge potential for domestic market if surplus can export to neighboring country like SriLanka, Bangladesh, Myanmar, Thailand Vietnam, combodia Philippine etc. our products are economical with latest technology with 100% service backup make our customer trust upon us.

Q. What is your marketing strategy for India?

A good marketing team represents the face of the company as it

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needs to project the brand, its key strengths, products and services in order to convince the customers.

Being capital equipment, effective marketing assumes far greater significance, specifically in case of machine tools and accessories.

Indian machine tool industry greatly requires systematically trained sales and marketing engineers who are able to effectively differentiate the products’ strengths across to the customer and win more business.

To provide an in-depth understanding of the technological aspects as well as the best practices of sales and marketing strategies, we consider the following aspects for sales & marketing Strategies.

• Customers’ requirements today in CNC machine tools? cost per component (CPC), cycle time, and quality requirements.

• Calculating ROI and Revenue amortization.

• Process based approach of sales challenges and solutions.

• Major roles of sales engineer Market Management, Customer engagement, Need analysis, Contract proposal, customer acceptance, order management and post installation management.

• Need Analysis - customer interviews to understand project scope, current business conditions, method of accounting costs, etc.

• Contract proposal - preparing proposal covering present problem, proposed solution, value with ROI analysis, choices of financing relevant with industry trends.

• Sales process - chart preparation, sales techniques, negotiation with decision makers, etc. Customer acceptance and order management.

• Marketing strategies for high value

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products.

• Case Studies in machine tool sales & marketing.

• Commercial aspects and taxation norms.

• Soft skills needed for sales and marketing professionals.

• Group exercises and discussion.

Q. According you what are the factors affecting to your business?

North India little far away from majority of machine tool manufactures mostly in field of CNC machine tools, Punjab dedicatly pioneer in manufacturing conventional machines but significantly in recent years there are many CNC machines manufactures come in picture for producing CNC Turning centers, CNC Routers, VMC`s CNC Grinding Machines.

Delhi NCR now becoming hub for CNC grinding machines, many machine manufactures in Ghaziabad producing good quality CNC grinding machines.

Though we are Considering SMEs and Customization according to customer need, we are alone in region to understand customer pain point and deliver right solution in terms of Price, Size, Power Option, Spindle Power option, local service, Assistance in CAD-CAM, Tooling, Operation, maintenance along with optimization.

It is necessary to exhibit our product in market. Visiting and participation in machine tools exhibition provides best platform and play roll of catalyst. As a manufacture we are providing necessary help and creates platform for our Engineers to arrange group visit in Exhibition. I am regularly visiting in International exhibition

held in south east asia..

Q. What are the key technological trends that are driving machine tools industry?

Indian Machines have create good repo in global market. We have to work hard for getting order from export market and prove our product better in quality, Technology, delivery, and price compare to other global players to grab export markets.

Now a days customers expect less dependability of human skill, fatigueless operation, trouble free performance in machines. Various latest technology like atomization in loading / unloading of components, robotics solution, in process measuring sensors, high tech safety features etc are available and it create good value of product.

Q. What is your vision for your company?

“We the Multi Axis CNC Machine Tools Manufacturers shall achieve Higher position in north India Machine Tools Industries by delivering wide range of cutting edge products through professional management, frugal engineering value chain, partnering suppliers driven by customer satisfaction.”

Though we are Considering SMEs and Customization according to customer need, we are alone in region to understand customer pain point and deliver right solution in terms of Price, Size, Power Option, Spindle Power option, local service, Assist in CAD-CAM, Tooling.

For more information, Website: www.multiaxiscnc.in

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IN FOCUS

Givi Misure: Excellence in Measurement Technology

Mr. Pierluigi Guerra, Chairman Givi Misure, India

Q. Please take us through Givi Misure’s journey in India. How far along has the company come since initial days? What are some of the milestones you have achieved in the journey?

Givi Misure was established in the year 1979, to design, develop and manufacture Optical Steel Scales.

During 1991, the company acquired Sipe Automation and Metromii to expand product range of Encoders and Digital Readouts. Since 1997, Givi Misure is certified to ISO 9001, which is a sign of attention paid by company to the quality of its products and processes. After having consolidated its know-how in measuring system based on Optical principle, Givi Misure, invested in the development of Magnetic Technology, these investments led to the introduction in 2002, of first magnetic sensor model MTS. In 2008, Givi

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Established in 1979, Givi Misure is in the business of position measurements. In an interaction with Machine Tools World, Mr. Pierluigi Guerra, Chairman of Givi Misure, India tells us about the key solutions of the company, its expectations from the upcoming IMTEX exhibition and the company’s focus on R&D. Excerpts:

Misure completed its product portfolio, starting the production of position controller model THESI. In last few years Givi Misure with its objective of continuous development, introduced scales for Absolute Measurements. In the year 2014, the company developed new series of scale s for CNC Synchronized Pres brakes. During 2018, the company introduced absolute scales and also released models for Fanuc and Siemens system, on the principle of PLUG AND PLAY. Q. With IMTEX round the corner, what are your expectations from the mega event, which is also celebrating its 50th anniversary this year? What opportunities are you seeing from the event IMTEX is my favorite event and I always wait for it. The event

attracts a large participation from manufacturers, from all over the world. All manufacturers of Machine Tools and allied products wish to participate in the event, because key persons and decision makers from all over India, visit IMTEX. This year, we are extremely excited about the event as this is the 50th year of IMTEX. I feel our products get exposure to a wide base of users across India through this exhibition. Givi Misure use IMTEX as the platform to build brand image for our products.

Q. Tell us about some of your key solutions. Please elaborate on how your technologies help in enhancing customer’s productivity and efficiency.

Givi Misure is in the

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IN FOCUS

business of position measurements.

Hence, quality of our products reflects directly on quality of components manufactured by Machine Tools. The accuracies and repeatability of machined components depend on our products and other allied products such as ball screws, LM guide ways etc.

The reliability of our product will reduce set up time, correction time and down time of the machine. The introduction of Absolute Scales will further reduce set up time after frequent power failures. Eliminating homing sequence after each power failure enhances productivity of the machine tools.

Q. Please elaborate on how expectations and demands of Indian machine tools companies are evolving with time? How do you meet these requirements and ensure customer satisfaction?

Indian Machine Tool builders have shown excellent improvements in machine tool design which in turn reflect in operations, such as reduction in cycle time, achieving high accuracies, safety, and

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aesthetics. As Indian users demand for best technology, with minimum cost and highest reliability, naturally, machine tool builders, demand similar factors from sub system suppliers such as our product range.

Our inventions and developments always keep above factors in mind.

With constant feedback from our customer and implementing the feedback in our products, we achieve customer satisfaction.

Q. What would you describe as your niche? How do you stand out from the competition?

Presently our niche is CNC Press brake scales. We hold major market share in this area. We are able to hold the market share, due to quality, accuracies and reliability of scales.

We offer solutions to customer, considering value for the money.

How do you perceive India as a market? Comment on the opportunities and challenges that you see in the country in your segment

Indian market is growing. There is high demand for all the products including Auto/Consumer/ Health etc. Naturally, this overall demand puts demand on mother machine tools. Therefore there will be continuous growth in demand of Machine Tools for at least for the next five years. Givi Misure has strengthened its manufacturing and R&D activities, keeping this type of growth of next five years.

Q. Tell us about your focus on R&D and quality?

Our R&D team always innovates based upon latest technology and customer demand. Therefore, we are little ahead of competition. Being ISO Certified Company, quality checks are conducted and recorded, at every level.

Q. What is your future vision and growth plan for the company?

Our vision is to make Givi Misure among top three companies in the world for measurement technology. Accordingly, we are formulating our development and growth plan.

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IN FOCUS

Opportunity for India are immense, Machine Tools Industry is turning a new leaf

Santosh Dahanukar, Partner Dahanukar Machine Tools

Q. How well is India positioned in the global machine tools market?

Comment on the major challenges and opportunities for machine tools industry in India.

Globally India is positioned somewhere around 30th Position in manufacturing Index. But itâ&#x20AC;&#x2122;s the fastest growing economies in the world. With huge manufacturing base, the demand for Indian Products globally is increasing. India has huge scope for improvement across all drivers of production.

Opportunity for India are immense, Machine Tools Industry, in India is turning a new leaf, Manufacturers are renewing their focus now on increasing productivity through use of combination of automation and improving their in house processes.

Two key challenges for India is to manage it rather young work force

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and providing them with sustainable resources. With governments now putting their full might behind the manufactures with Schemes like MAKE IN INDIA to make India a manufacturing hub. India is bound to improve on all parameters.

Q. Please update us on the recent developments and trends in the grinding tool segment?

With the increasing demand from the end-use industry coupled with the growth in the automotive industry, the India market is set to boom. Companies are now focusing on evolving grinding machinery market by developing technologically advanced machines which comprise automated equipment which eliminates the scope of human error and impacts the overall quality of the

product. This has led to the evolution of innovative machines which helps in manufacturing accurate and precise products at lower cost and less time.

Such factors are considered to impact the market positively. Moreover, owing to the requirement for precise finishing across several applications, grinding machinery has found penetration across all industry verticals.

Q. How are the disruptive technologies like automation, Industry 4.0, 3D printing, IoT bringing the shift in the industry? In your observation, are Indian companies showing readiness and inclination to adopt these technologies?

India has a huge work force, hence there has to be a balance between use of man power and automation.

Although Industry 4.0, 3d printing, Iot

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IN FOCUS etc are bringing huge changes across the world, itâ&#x20AC;&#x2122;s still in its nascent stages in India. Our Msme sector has a huge potential for automation, but its very price sensitive, hence it will still take time for such systems to become industry norms. High cost associated with adopting such systems are a huge barriers in adoption of automation in large scale. Indian companies barring a few big players are still to look at these technologies as a viable alternative to the traditional way of manufacturing.

Q. Tell us about some of your key solutions. Please elaborate on how your technologies help in enhancing customerâ&#x20AC;&#x2122;s productivity and efficiency?

Dahanukar Machine Tools since its inception in 1983, has always manufactured machine which offer huge value to the customers, the machine manufactured by us are in tune with the customer needs and requirements. Company has recently launched many new surface grinding machine models for catering to varied customerâ&#x20AC;&#x2122;s needs. Machine ranging from job sizes as small as 100 mm X 150 mm to job sizes 1500 mm X 600 mm are introduced in the market.

Many new industry first grinding

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machine features are introduced with the launches of Linear Motion Series, Vfd Series, Adf series to suit customers requirement. Simple NC controlled machines and programmes are developed after long research keeping in mind ease of use for operators.

Machines are sold as ready to use grinding machine, helping customers use the machine right away without losing valuable time of the shop floor.

Time study of components, making of jigs and fixtures and other background leg work is carried out on behalf of customer for giving them the best possible solution and helping them making an informed decision by our team. Company is recently renewed its focus on appointing Dealer network for sales & servicing of machine, across India for supporting past and new customers. Adding value to our customers through lowering the cost manufacturing and thus helping them achieve profitability.

Q. With IMTEX round the corner, what are your expectations from the mega event being held in Bengaluru from January 24 to 30? Tell us about the products you are showcasing and are there any new launches?

IMTEX is one of the best machine tools

exhibition to showcase products. It has many visitors across all categories and an excellent opportunity to compare oneself with the peers. We expect to strengthen our customer base and improve on our dealer network during this exhibition.

Major advantage of participating in India premier exhibition is the face to face interaction with prospective & informed clients, where we get to understand the needs and requirements and try and fill those gap to create products which positively help in productivity increase for end users. We are showcasing our two new machine models in this edition of IMTEX. Specifically targeting two sectors, one is mould manufacturing and other being small tool rooms across India. We have designed the machine to be very precise and accurate at a very reasonable price.

Q. What would you describe as your niche? How do you stand out from the competition?

Niches are created by providing much needed value to the customers so that they think of us as their partners.

Niches are also created by identifying gaps where products are introduced to improve productivity for users.

Dahanukar Machine Tools is known by its customer as providers of quality grinding machine at a reasonable rates.

Our Manually operated machines are used by a large number of users pan India. We are providing semiautomatic machines to large numbers of players from automobile sectors.

Our machine are known for their reliability and accuracies. We have a very loyal base of customer who in turn are recommending our machine to their manufacturing circle. We have created a place in our market as providers of customised solutions to our customer and this in turn makes us stand out from our completion.

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IN FOCUS

We need to innovate continuously to make our customer successful Yatendra Kumar, Business Head MotulTech India

Q. How far along has MotulTech India come since inception? What are some of the milestones you have achieved in the journey ?

We are just stand up on our feet & now started running. Last year was very good for our company, we have grown 40% plus and plan to repeat the same in this year as well. We have launched many new products like SAFKOOL 6220 a high performance semi synthetic water soluble MWF for aerospace components (aluminium as well as titanium) machining. It can handle very high pressure in demineralised water without any foaming issue. Apart from this we have also launched Special Chuck grease which can not only sustain the water but also all type of coolants and provide long term lubrication to the chuck.

Q. With IMTEX around the corner, what are your expectations from the mega event being held in Bengaluru from January 24 to 30 ?

IMTEX is platform to show the latest

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technology products for metal working industry. Our focus is show two different products ranges: Minimum Quantity Lubricants (MQL): In todayâ&#x20AC;&#x2122;s highly competitive world, where technologies are changing very fast and we are finding the competition not only from known competitors but also from unheard competitors. Hence we need to work for the development of sustainable products, which are not only required for us to survive in the market but also for the sustainable for the environment.

Our SUPRACO 13XX series MQL came to existence serving both of these purposes. These are futuristic products, since they offer heavy

reduction in over all consumption of metal working fluid/cutting oil and also bio- degradable. SUPRACO 13XX MQLs not only save the direct cost of cutting oil but also help in reduction in carbon foot print, energy cost, disposal cost (as there is no disposal), cleaning cost and rust preventive cost. Inspite of the huge benefits these products are not very common not only in India but also in the world, as these products require specialised chemistry to manufacture and also specialised machines (on which they can be used). There are very few companies who are using this technology in their machine shop today. Today all metal

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IMTEX 2019 // HALL 2B BOOTH F107 // 24TH–30TH JANUARY 2019

PRECISION, FOCUSED ON WHAT MATTERS MOST: THE NEW VOLLMER VGrind 360E

Efficient grinding for carbide tools Greater efficiency for service and small series production: The VGrind 360E with kinematically optimal multilevel machining, 5 CNC axles, innovative operating concept and lots more. See for yourself!

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IN FOCUS cutting operations (except grinding & deformation) can be done with MQLs. Clean Hydraulic oil: According to OEMs and industry research the following facts lead to more frequent problems in high performance systems: • Hydraulic systems are getting smaller • Fluid residence times in reservoirs can be as short as 30 seconds • Oil reservoirs often not optimum in shape or size • Oil flow rates are very high relative to oil volumes • Hydraulic systems are designed to have higher power densities • Hydraulic oil temperatures are higher (> 130°C transients seen) • Hydraulic oil pressures have generally increased With all of these tougher conditions, oil is being pushed to its limits on a daily basis hence they can finally lead to: • Increased oil temperature • Oil degradation • Varnish and sludge buildup • Valve sticking

• Excessive filter clogging • Machinery downtime and excessive maintenance costs • Varnish removal problems, HS&E issues with solvents, etc.

RUBRIC CLEAN, premium hydraulic oils, which are not just filtered to get the right cleanliness level as per ISO 4406:1999 (upgraded version of NAS 1638) and claimed as clean oils, but prevents varnish build-up and keeps your hydraulic systems running at peak efficiency. More importantly, RUBRIC CLEAN will extend the life of your system by: • A fluid solution to keeping a hydraulic system free of varnish • High oxidation life to protect components • Excellent wear protection to extend equipment life

• Outstanding filtration performance in presence of water • Excellent rust and corrosion protection • Separates water quickly MotulTech also offer RUBRIC R-CLEAN, a non-solvent industrial system cleaner that removes existing varnish and contamination from hydraulic fluids. RUBRIC R-CLEAN is added to existing equipment and Machine continues to operate and produces parts while equipment is being cleaned (maximum cleaning time recommended is 48 hours).

At end of cleaning, cleaner / hydraulic fluid is drained* and equipment is filled with our hydraulic oil RUBRIC CLEAN HM which keeps the system clean and avoids further downtime. varnish surface

residual bit of oil

Figure 1with regular HLP hydraulic oil

MOTUL GROUP EXPERTISE

Figure 2with Motultech Rubric Clean

1

CASTED CASTED

FROM MELTED METAL TO DIE CASTED METAL BODIES

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DRILLED

TRANSFORMING RAW METAL INTO FINISHED PARTS

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3

FILLED

GETTING THE BEST FROM ALL TYPES OF ENGINES WITH HIGH PERFORMANCE LUBRICANTS

Q. What are your expectations from 2019?

We are starting year 2019 with a positive note and have 10 products lined up for launch in metal working basket. We always believe that we need to innovate continuously to make our customer successful and all these successful customers will keep us in the business and make us successful.

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Automation for a Changing World

Smarter Solution, Better Tomorrow Delta Industrial Automation offers comprehensive green manufacturing solutions for smart machines, production lines and factories to meet the rapid market changes and ensure our customers an outstanding future together.

Find out more at IMTEX 2019 and get an overview of Delta India Industrial Automation business in specific and discuss in detail about its CNC, AC Drives, Servo Motors & Drives, PLC, HMI, SMPS, Power Quality, Smart Sensors, Temperature Controllers, Energy Management and Robotics Solution offerings complimenting the machine tool applications.

Meet us at Imtex 2019 Venue: Bangalore International Exhibition Centre (BIEC) Hall no. 4, Stall No. H4 B141 Date: 24th to 30th Jan 2019

www.deltaelectronicsindia.com automation@deltaww.com

#DeltaPoweringGreenAutomation

IN FOCUS

‘Indian customers are looking for Complete Solutions’ One of Europe’s leading companies in the field of milling solutions, Nicolas Correa is eyeing huge opportunities in India. Started as a representative office in India in 2006, it began its full-fledged office in 2008 and today has more than 75 machines installed. In an interview with MTW, Parag Alekar, CEO, Nicolas Correa S.A. India Branch says demands and expectations of Indian customers are evolving rapidly and they are looking for complete solutions rather than standalone machines. He shares how the company is meeting these changing demands, its focus on quality and future growth plans. Excerpts: Parag Alekar, CEO, Nicolas Correa S.A. India Branch

Q. With IMTEX round the corner, what are your expectations from the mega event being held in Bengaluru from January 24 to 30? Tell us about the products you are showcasing and are there any new launches?

Through IMTEX we usually showcase our existence in India.

We feel this IMTEX will get us lot of serious enquiries which can be materialized. We will not be displaying any new products of ours, but would be showcasing enhancement in our existing product range, our present and future investments in India, etc.

Q. Please update us on the recent developments and trends in the milling sector?

In the present trend of multi-tasking & 5 axis machines, customers are looking at better machining parameters on universal heads,

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especially aerospace Industry. We have developed our new universal head with higher rpm with high torque to cater to both Titanium as well as Aluminium machining on one head. We have catered to these requirements with our latest machines which are with higher rpms, high rapids and higher acceleration.

Q. How do you perceive India as a market? Comment on the opportunities and challenges that you see in the country in your segment?

Presently, India is the most preferable market globally after Brazil for investment. There are lot of investments in infrastructure and energy. Since our segment is into medium & large size machines, we have major customers who are into these sectors. Obviously for

us presently Indian market is the most preferred destination for both Investment as well as business.

The only challenge in Indian market is timely implementation.

Since we are into capital investment, decisions are not taken faster and opportunities are missed by customers. We need to put in extra efforts to push customers to invest and encash the present opportunity.

With 2019 Elections round the corner; political conditions will also affect market scenario. Continuation of current policies will further boost the present economy.

Q. Which sectors do you primarily cater to? Tell us about your key clients.

Presently, we are catering to the infrastructure industry. Our key clients are equipment manufacturers for these Industries.

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IN FOCUS Q. Please elaborate on how expectations and demands of Indian buyers is evolving with time? How do you meet these requirements and ensure customer satisfaction?

We have seen considerable change in Indian buyers. There are two categories of customers, new entrepreneurs are quite aggressive and decisions are taken within a month from demand by them. For some customers decision making process is very long. As time element is very important, sometimes they miss the opportunity because of delayed decisions. But change is happening at a rapid rate. Secondly, major customers are looking for complete solutions rather than standalone machines. We are catering to this

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requirement by providing solutions locally (Made in India). This strategy has worked out well for us and our major customers are looking us as a Complete Solution Provider.

Q. Please elaborate on Nicolas Correaâ&#x20AC;&#x2122;s focus on quality and innovation.

We manufacture machines under EFQM (European Federation Quality manufacturing System). 5.1% of our turnover is being used for upgradation of our existing product range & adapting new technology. Nicolas Correa is the leader for machine tool innovation segment under European Machine Tool Manufactures Program (CECIMO). Our machines are already equipped with Industry 4.0 norms.

Q. What is your future vision & growth plan for the company in India?

In a view of good response from customers to our product range, we are looking forward for good growth in business in 2019.

We are investing in skilled engineers and recently we have started universal head repairing centre. Majority job shops are showing interest in our machines; and after sales service is major aspect for these customers. Our complete focus is continuous improvement in service with reliable product and offering complete turnkey solution to customers. Overall, we are happy with our progress and very optimistic about year 2019.

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IN FOCUS

Cognitive heritage of three decades for excellence & innovation

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Q. Please brief us about recent initiatives undertaken in the CAD/CAM space? What are your focus areas?

The main focus is always to make the software easier and more intelligent, and the machining faster and more efficient with less wear and tear on machines and tools. Mastercam has introduced several pieces of technology in the last few years that assist with this need. The most game changing has been Dynamic Motion technology to create material-aware toolpaths where the angle of the tool engagement is constantly changing to keep a more consistent chip load on the tool and use more flute length.

The result is a faster machine time, for example, when roughing for 2D parts, the cutting time can be cut by 75%.

It’s much easier on the tools, because the entire cutting surface is being used, and it’s much safer. Our shop at CNC Software headquarters uses Dynamic Motion technology exclusively, instead of conventional cutting.

Another exciting advancement in CAD/CAM is Accelerated Finishing.

This technique delivers better finishes in a much shorter time on a variety of complex surfaces. With new classes of shaped tools being introduced, we work closely with tool manufacturers to develop toolpath motion that takes the most advantage of what can be done with these emerging tool shapes.

sector in 2019 followed by an even stronger 2020. Automotive, aviation, and electronics are just a few of the sectors that we are looking at to deliver steady, sustained growth.

As the world’s most widely-used CAM software, we’re fortunate to have an enormous pool of practical shop experience in a variety of industries on which to draw. This is is invaluable in determining the changing needs of specific industries. We use this collaboration with our user community, combined with our internal expertise, to provide the tools that those industries need to thrive.

Q. What are the market opportunities for your products in India? How do you plan to position these products?

The indicators for Indian manufacturing under the Make in India initiative are encouraging for Mastercam. We expect an expanding manufacturing

Q. What are key technological trends that are driving your industry?

The primary driver has been – and remains – increasing productivity through faster and more flexible manufacturing output. This remains a common trend among all shops regard-

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Q. What is your strategy for India?

We have a three-part strategy for serving the needs of Indian manufacturing.

1. Forge a strong and wide-reaching sales and support partnership in India to ensure Mastercam users will have the technical backing they need to succeed.

2. Carefully watch the evolving Indian manufacturing sectors, evaluate what specific applications they need to reach their goals, and provide focus in those areas.

3. Work with our Indian users as partners to gain insight into both what they need to expand their current business, enter into new sectors of manufacturing, and improve their day-to-day operation.

Mr. Brian Summers, Executive Vice President, CNC Software, Inc.

less of industry.

But another rapidly growing trend that is being embraced by Make in India is connectivity, or Industry 4.0.

We address this by focusing on how many places Mastercam can touch to ensure that information can be brought in, used and coordinated elsewhere in a shop’s process as needed. Mastercam powers the machine tools, but that is just one part of what a shop needs to do. Mastercam also provides a platform for the shop to do a variety of things like metrology, robotics or digital tool management—all of these pieces roll up into the growing connectivity of Industry 4.0.

Q. What is your vision for Mastercam in India?

In India, our goal is to empower manufacturing with superior products and support. No matter the industry, shop size, or manufacturing challenge, some things are consistent in every shop across the globe. Our vision for Mastercam in India is the same as it is anywhere people need to make parts – to create software and services that solve the world’s manufacturing challenges.

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COMPANY PROFILE

Vedant Birla Chairman and Managing Director Birla Precision Technologies

Birla Precision Technologies: A Legacy of Excellence Backed by the legacy and heritage of one of Indiaâ&#x20AC;&#x2122;s most prestigious business families coupled with its firm focus on market demands and innovation, Birla Precision Technologies has maintained its growth trajectory over the last three decades. The companyâ&#x20AC;&#x2122;s Chairman and Managing Director Vedant Birla shares what makes the company tick and shares future plans 102

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COMPANY PROFILE

A

leader in high speed and high performance machining, Birla Precision Technologies (BPT) was established in 1937. In over three decades of its existence, BPT has grown from strength to strength and has established itself as a prominent name in the manufacturing of high quality Cutting Tools, Iron Castings, Tool Holders, Engine Components, Hydraulics Valves and Precision Components.

The company today has five divisions, four state-of-the-art factories and 12 branch offices across India. It exports to major customers in the US, Europe and to the Far East including China and its client list includes major global giants, including Cummins, Honeywell, Husco International, to name a few.

Besides, BPT also sells in domestic market in a large way to all major domestic customers and Government Organisations.

With Chairman and Managing Director Vedant Birla at the helm, the company has achieved several milestones and clocked steady growth in domestic and international markets.

Birla says that at the core of the company’s continued success is the fact that it has kept pace and evolved with the changing market requirements. “We have been manufacturing in India since 1937 and have developed a strong supply chain. We keep a close eye on changing customer demands and strive to ensure that our products factor in those changes,” asserts Birla.

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Another key factor that has enabled the company to remain ahead of the pack and continue its good run is its capability to customize the products and solutions as per the unique customer requirements. “We are focused on Value Selling, not product selling. Customers looking for high technology and innovation come to us as we have the capacity to customize the products as per their requirements,” elaborates Birla.

The company has a firm focus on R&D to provide Value-Added products to customers. It believes that R&D helps in pushing the limits of the products and creating better solutions to meet evergrowing customer demands of high productivity and quality. BPT invests heavily on R&D and believes it is critical to business growth.

BPT keeps its eyes set on the changing technology and feels that technology will drive the industry in future and will hold the key in the long run. One trend that BPT is betting big on is Industry 4.0-automation and data exchange in manufacturing technologies. “In our automotive division, we are geared up with all our customers for Euro 6 norms which come into India in 2020, requiring a 10 year jump to be done in 5 years for India,” shares Birla.

Taking the next leap BPT has a strong presence in the automotive sector and is planning to grow it further in the coming years.

“We have plans to make significant

investments in our Auto Components division over the next three years.

There is a strong demand for parts and we are looking to expand our capacity to cash in on this Industry boom,” says Birla.

Concurrently, BPT is also planning to diversify its offering in the automotive segment by strengthening its presence in Hydraulic Components. This strategic move is to gear up for the rising popularity of electric vehicles. “While move towards electric vehicles is good, once they become mainstream, many of the components we make now will be rendered obsolete. Right now, we can’t foresee whether it will take five, 10 or even 20 years for the entire market to make that transition.

However, we need to be prepared,” Birla asserts.

Apart from considering other car components that the company can build, it is also looking at supplying to the Defence sector. Further, the company is looking at growing its flagship division, Tooling. “Our brand is best known for our drilling solutions and we are looking at further strengthening our position by investing in quality and consistency.

We have expanded our capacity in Tooling by 15–20%,” Birla shares.

Looking ahead, as the automobile and manufacturing segments continue to gain momentum, BPT’s growth outlook looks positive.

Given the company’s firm focus on innovation, customer service and diversification, it is all set to scale greater heights.

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COMPANY PROFILE

Tushar Tambat, Partner, N-GRAVETEK

Umed Tambat, Partner, N-GRAVETEK

N-GRAVETEK: Adopting Customer-First Approach for Growth Tracing its origins to a small rented apartment of 700 sq. ft. in heart of Nashik city, N-Gravetek has traversed a long way since it humble beginnings in 2008. Today, the company has marked its name as a reputed manufacturer of CNC engraving and micro-milling machines, with more than 180 installations across India. Shweta Nanda of MACHINE TOOLS WORLD takes a look at N-Gravetek’s growth trajectory, its focus on identifying and meeting customer needs and future plans

B

ack in 2004, refurbished 3-axis CNC engraving machines were typically being used for job work services. The market demand and potential opportunity due to scarcity of engraving machine manufacturers in India led to the conception of N-GRAVETEK. With the idea of manufacturing low budget 3-axis CNC engraving machines to cater to Indian 2D & 3D CNC engraving market, N-GRAVETEK started its journey from a small rented apartment in Nashik. In a decade of its existence, the company has climbed the success ladder and established itself as a prominent player providing one-stop-solution for all engraving applications. Today, the company has grown to 10,000 sq. ft. premises located in Satpur MIDC and has over 180 installations pan-India to its credit.

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At the core of the company’s success lies its deep focus on understanding and fulfilling market demands and customer needs. With brothers Tushar and Umed Tambat at the helm, the company over the years has launched several products to enable customers to meet their challenges in 3-axis, 4-axis and 5-axis applications. “Since our establishment we have been manufacturing products as per Indian market demand and feedback from our existing customers. All our product range is developed keeping in mind quality, durability and consistency.

We believe in developing technology that increases the profitability for each customer’s business and providing true value for their investment,” asserts Tushar.

Keeping Pace with Evolving Needs In the past few years, the demands

and expectations of Indian buyers has been evolving rapidly. While price continues to be a dominant factor, machine productivity, accuracy and performance also features high on their radar. “Indian buyers now have broadened their horizon and are ready to shell out money if they get all the above benefits from the product.

Indian buyers expect end-to-end solution when investing in a product,” affirms Umed. He further says that the Indian market has accepted the trade-off between high initial cost and good quality. The fact that good quality machines can reduce your production set-up, lead time and trim material preparation has widened the perspective of the buyers.

To meet these needs of Indian customers, N-Gravetek aims to manufacture CNC machines that involves exact, high-speed movements

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COMPANY PROFILE enabling expedited production and customization. “We have a dedicated demonstration center where every client is given customized training by our expert engineers according to their application. Along with this N-Gravetek has partnered with world-class Engraving / Engineering CAD-CAM software solution providers like Type3 and SprutCAM to fulfill our customer’s requirement,” Tushar shares. To suit customer’s budget and job requirement, N-GRAVETEK’s products are available in four different categories. DESKTOP SERIES includes budget friendly table top light weight 2D & 3D CNC engravers; ECO SERIES includes economical yet highly powerful 3-axis CNC engraving machines with optional 4th-axis attachment; PRO SERIES comprises professional 3-axis micromilling & engraving machine which are suitable for customers who require good precision and surface finish; and PRECISION SERIES includes highly precise micro-milling & engraving machines with very rigid foundation.

PRECISION SERIES products are suitable for customers who are looking for production machine with high precision and rigidity.

With its extensive product portfolio, N-GRAVETEK provides complete end-to-end solutions for a wide range of industries such as automobile, forging, signage, plastic, jewelry, garment, leather, printing & packaging, biscuit, chocolate & confectionery, pharmaceutical, toys, textile, watch, electronic & electrical, footwear, to name a few.The company bets big on the latest technologies to improve the quality of the products and increase the profitability of customer’s business to ensure true value for their investment. It adheres to the phrase “innovation is key to success!”

“Our R&D team is on a continuous ride so as to make our products more

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and more beneficial for our customers.

We always try to introduce new features to our products increasing flexibility for attendants and reducing the need for manpower at shop floor.

We also try to provide best technology in most compact design to meet our customers’ needs,” says Umed.

The industry is currently noticing a demand for 5-axis machines and application specific machines. Smart machines and automation are other technology trends that are seeing an uptick. Shedding more light on the technologies that are transforming the engraving machines, Umed says, “Empowered by features like automatic tool changer, auto-Z toolpresetter engraving and micro-milling machines can incorporate a string of tasks and processes into a single more efficient process. The CAD/ CAM software too have a great role in rising the innovation bar in our micromilling and engraving machines.”

Indian market has accepted the trade-off between high initial cost and good quality. The fact that good quality machines can reduce your production set-up, lead time and trim material preparation has widened the perspective of the buyers Umed Tambat, Partner, N-GRAVETEK Commitment towards Quality With its motto, “Quality, Durability, Consistency,” the company has a firm focus on quality. N-GRAVETEK’s entire manufacturing process is scrutinized and goes under inspection by its quality control department. “We

calibrate our products to get precise results with high accuracy. Each and every machine manufactured goes under quality tests wherein various standard programs along with customer application specific tests are realized on the machine. The products are delivered to the customers only after they have cleared all the quality tests and customer is satisfied with the results of jobs realized for their application,” informs Tushar. The company is eyeing further growth in the coming years in India due to increased impetus on manufacturing.

As high end machines are mostly imported in India, there is a huge potential to cut costs with similar machines being manufactured locally in the country. Local manufacturers are thus sitting on a cusp of a major opportunity.

“Figuratively speaking more than 50% of the Indian market depends on these imported machines from the global market. If manufactured in India, the cost of these CNC machines can be cut down by about 25% than the similar machines manufactured in Japan, Germany and other countries.

Considering the opportunities, the last few years has seen a dramatic affirmative change in the Machine Tool Business. India’s policy environment is also becoming much more supportive of manufacturing, which is fueled by launch of the “Make in India” campaign in 2014,” elaborates Umed. The company is gearing up to tap into this growing market demand.

It has been consistently manufacturing and delivering 25+ machines per year since the last five years.

Looking ahead, it is aiming to double its production capacity and is exploring options to export its products as well as introduce CNC micro-milling and engraving machines for specific industrial application like tire side-wall engraving.

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COMPANY PROFILE

Rohit Shah, Director Bhavya Machine Tools

Jatin Shah, Director Bhavya Machine Tools

Bhavya - The

B

havya Machine Tools is an inspiring tale of two brothers- Jatin Shah, 48, and Rohit Shah, 46. They started their journey from an ordinary shop on the streets of the Old City of Ahmedabad. Today, they operate from a scintillating corporate office and have their presence as one of the leading business of industrial machinery not only in India but all over the globe. Bhavya owes its magnificent presence in the market to the brothers who complement each other and work in tandem to

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Unstoppable take their company to newer heights.

Their togetherness is the company’s strength.

Being constantly innovative is Bhavya’s strategy and that is what keeps them ahead of their opponents.

Global contenders are their inspiration. They want to bring in India the best of the technology and export best local products worldwide.

Customers’ requirement is of utmost importance to Bhavya

Machine Tools. If a customer approaches them with a requirement which they don’t currently cater to, they immediately set up a team to study if that specific type of tool can be designed or procured.

This approach has earned Bhavya Machine Tools its name in the market.

For more information, www.bhavyamachinetools.com

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COMPANY PROFILE

Our vision is to enable Excellence through Total Employee Involvement P R Ramesh Co-founder & Vice President Seven Steps Business Transformation Systems, Bangalore

T

he billion dollar question in Business Excellence Journey is, “is it sustainable”?. The next question that follows is, which is the best methodology? TQM, TPM, LEAN, SIX SIGMA, TOC, AGILE, BPM?. After years of practical exposure of working with various organisation, we found the answer. We decided to share it with rest of the organizations.

Seven Steps Business Transformation Systems was founded about a decade ago with the mission of Making Excellence a Culture. We have developed a Seven Step methodology to achieve and sustain Excellence.

Two major factors that play important role in sustaining Business Excellence Journey and its results are : Leadership and Culture. One of the great Business Gurus, Dr Edward Deming said “The secret of success is constancy of purpose”. If the Leadership believe in long term and aligns & integrates all Business strategies under a single umbrella, the success can be assured.

Otherwise all tools becomes Flavour of the Month.

Over the years, we have transformed several organizations in adapting best class practices and moving towards World Class Levels. The great news is most of them are sustaining the results and continuing the journey for years. The mantra is very simple but

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it requires great commitment from the Leadership Team. That is the reason, we work only with those organizations where leadership demonstrates commitment and believes in Cultural transformation. It is a bit longer process like practicing Yoga without side effects!

We tell this fact upfront and only after the acceptance and understanding about the way Excellence work, we proceed to the next step. Each organization is different; so our roadmap also is customized based on the challenges faced by the organization. For Example if the overall Lead-time to delivery is too high, Lean methods will help and if the consistency process or results is a problem, six sigma tools will help.

Most importantly, if organization has no set vision, mission and strategies, Hoshin Kanri is the best tool. So a combination of several methodologies blended and a customized business excellence model is created for each aspiring organisation. Our first step before accepting any assignment is “Initial diagnostics (in the form of assessment) and feedback”. We suggest certain principles to be embraced and strictly followed based on our initial study. Once Leadership agrees to the Principles and recommended model, the journey begins Seven Steps Business Transformation Systems Established

in 2012 provides Business Excellence Solutions in the areas of Manufacturing, Service, Construction, Education, Infrastructure, IT, Governance and Healthcare. The Company is managed by professionals who have vast industry experience and passionate about Business Excellence.

Expertise includes Business transformation Strategies, Balanced Score-card, Policy Deployment (Hoshin Kanri), TQM, TPM, Lean, Six Sigma, Quality Management Systems, Business Process improvement and Environment & Safety Management Systems. It has other verticals to complement its vision. Seven Steps Academy of Excellence provides world Class trainings and certifications.

Bexsolutionz division supports Visual Workplace standards. SME division provides world class services for excellence for aspiring and committed small and medium businesses. Seven Steps developed unique Standard for 5S called SSAOE-A5S-10 and certifications awarded to organizations after stringent assessment .

Seven Steps offers special packages to Micro. Small Scale Industries as a part of its CSR initiative. A 100 crore club is created with a vision of transforming 100 Micro and Small Scale Industries to 100 Crore companies by 2025.

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COMPANY PROFILE

FIBRO : German Precision Crafted in India

Mr. Vivek Nanivadekar Executive Director, FIBRO India Precision Products Pvt Ltd

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Q. What are the milestones your company has achieved till date ?

FIBRO India is a 100% subsidiary of FIBRO GmbH and was established in 2008 and started manufacturing in a small way in rented place. But within couple of years it became difficult to meet the market demand from that small rented place. As such FIBRO India bought the plot of 4000 sq. m. in MIDC Phase II, Chakan and started the construction in 2011.

Finally, FIBRO India shifted to its own plant in March 2013 and in 2017 we started the construction of our 2nd plant adjacent to the existing one.

We started manufacturing guide pillars for domestic as well as export market. But then as market expectations increased, we kept on adding new products every year in our manufacturing range.

Subsequently in 2015 our Rotary Table division in Germany also decided to join FIBRO India to manufacture the Rotary Tables of ‘FIBROTOR’ series for automation industry. Our new plant is now ready for production. We have successfully commenced the assembly of FIBROTOR Rotary Table in 2018.

The journey in Indian market so far has been quite interesting with ups & downs but every team member enjoyed it. We have been growing at an average CAGR 30%. Our strategy has been ‘working closely with the customer to understand the problems/difficulties and offer them the right solutions. Based on the market feedback we keep on adding new products every year.

We are positively responding to the government initiative of ‘Make in India’.

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COMPANY PROFILE Q. What product technology you represent?

FIBRO has two distinct operationsStandard parts also known as Die components, and Rotary Tables.

FIBRO GmbH has been closely working with Mercedes Benz, AUDI, Volkswagen etc for pressed components. In India, we are manufacturing fast moving standard parts like oil less guide elements, spring plungers, cam slide units etc. catering to domestic as well as

international markets.

We have been adding new products and their variants every year catering to the Global market requirements.

Also, FIBRO are the pioneers in the Rotary Table. There are basically two types of applications for Rotary Tables one in the Automation and second in the Metal cutting, for which FIBRO has the largest range in both segments Rotomotion and Rotocutting respectively.

Q. What is the future of your products in India?

As per the TAGMA survey report the Tooling industry is expected to grow at CAGR 11% in next three years. Besides, India is considered

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as developing economy. Due to initiatives taken by the government like ‘start up India’ ‘Make in India’ it has opened the doors in IT as well as manufacturing sector. I firmly believe India can become Global manufacturing hub sooner than later.

As a result of above initiative, the Sheet metal forming industry is also on the rise in India and thus the Tooling industry. Secondly there is tremendous pressure on lead time as well as on the cost at every stage of new product development. This will drive the local manufacturing of tooling with reduced lead time and cost competitive.

The use of cost competitive quality standard parts will help the Tool makers to deliver the results.

That is where FIBRO India has a role to play. At FIBRO India we are manufacturing standard parts and keeping the stock of fast-moving items to support the local Tooling industry to reduce their lead time.

Similarly, there is the substantial growth anticipated in automation sector. Therefore, it was decided to manufacture the Rotary/ Indexing tables in India to cater to this sector.

FIBRO India will be making these tables for the world market soon.

We are “Expanding our Horizons” to meet the market demand.

Q. What is your vision for forthcoming years ?

To put it in simple words ‘Working closely with the customers, understanding their problems/ difficulties/challenges, FIBRO India will provide precision technical solutions thru. Standard parts and Rotary Tables to the toolmakers, Automation and general manufacturing industry by adapting innovative, cost competitive manufacturing methods.

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COMPANY PROFILE

NuGEN Machineries & Metalworking

The mark of excellence

N

uGEN Machineries Ltd. specializes in the manufacture of â&#x20AC;&#x2DC;Trimansâ&#x20AC;&#x2122; Conventional, NC and CNC Hydraulic Press Brakes, Shears and other sheet metal working machines for more than three and half decades in India. The manufacturing facility is based near Ahmedabad. The company is run by technocrats and professional directors who work full time in various work areas such as Product Design & Improvements, Marketing, Contracts Execution, After Sales Service, Quality

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Control, Finance and Customer Supports according to their area of specialization and core competence.

Nugen, an ISO 900-2015 certified company, has introduced and pioneered the Rear Cylinder Hydraulic Press Brake in India. It has also designed and manufactured variable Rake Hydraulic Shear with in-house R & D effort and has installed nearly 2000 Press Brakes and Shears in India and abroad.

NuGEN has also successfully designed and manufactured Special Purpose Presses and plants for

manufacturing SAW pipes (Press Cap. 1500MT X 6000MM), Hydraulic Tube Tester, Extrusion Presses (500MT), Electrical cable drum making plants and Welding Electrode Plants.

The Machines have been exported to Malaysia, Turkmenistan, Kuwait, Tanzania, Bahrain, Dubai, Sharjah, Abu Dhabi, South Africa, Sultanate of Oman, Ethiopia, Jordan, Ghana, Zimbabwe and USA. For more information, Website: www.nugenindia.com

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FOR A COMPLETE HEALTH CHECK-UP OF YOUR ELECTRICAL EQUIPMENT

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Just like the human body, electrical equipment require a complete examination to identify any glitches. Whether the process is of installation, maintenance or repair, Extech’s testers and meters are always up for the task. To ensure smooth operation of your electrical equipment, Extech offers a wide range of test instruments that help you identify a problem before it occurs.

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FLIR Systems India Pvt. Ltd. 1111, D Mall, Netaji Subhash Place, Pitampura, New Delhi – 110034 Fax: +91-11-4721 2006 | Webiste: www.extech.com

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COMPANY PROFILE

Insist on Quality Bearings Insist on V M Traders (L to R) Mr. Dagdu Jadhav - Sr. Manager Marketing, Mr. Maruti Padwal - CEO, Mr. Vinod Padwal - Head - Business Co-ordination

V

.M. Traders established by Mr. Maruti Padwal in the year 1982 is one of the largest importer & stockist of bearings.

Situated in the business capital of India, Mumbai it carries very good name & goodwill in the market.

V.M.Traders primarily deals in bearings of INA, FAG, TSUBAKI, OZAK, ABBA, IKO. We keep bearings in wide range useful for various industries & market. We also have a showroom to facilitates prompt service & to fulfill the requirements of the masses.

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Over the years, we at, V.M.Traders have maintained our leadership position in the trading industry of bearings, cam clutches & rod-ends adhering to the highest quality standards.

Our superior, state of the art customer service ensures that all your requirements are met immediately.

Our position of consistent excellence is maintained through continuous developments, streamlining of work operations & improvements to the line.

V.M. Traders works closely with its

customers to serve the holistic needs of the industry with a complete series of roller bearing, linear bearings, precision bearings, cam clutches & rod-ends.

Please contact us for the requirements of bearings such as needle roller bearings, linear bearings, rod end bearings, spherical bearings, cylindrical bearings, clutch bearings, ballbearings and many more.

For more information, Website: www.vmtraders.com

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COMPANY PROFILE

Radius: Marching on Growth Path

Gurushree Prasad K R

Girish kumar S

Nagaraj C

Radius Engineering Solutions Pvt Ltd

T

he company has achieved a number of milestones over the period of 10 years. Among the major milestone is the establishment of the factory by newly constructing a 7000 square feet shop in the industrial area of Bidadi. The infrastructure with the overhead crane and other facilities make it the ideal place to build state of the art technology machines. The second milestone that the company has achieved slowly but surely is the development of the line of world-class machines for making stator coils and pellet dies. The products have gone through the evolution process and now are the best machines available anywhere in the world with a lot of proud customers. The other milestone that the company has carried forward is leveraging the skill and expertise in the hole making to subcontract shops with the company setting up shops in different cities offering gun drilling services for a variety of components from orthopaedic, die & mould, auto, aerospace etc. Now we have our Gun drilling Job shops at Bangalore, Delhi, Pune and in a monthâ&#x20AC;&#x2122;s time in Chennai.

Our vision for the future years is to see that we reach different markets for our entire range of machines. With food for poultry, cattle, fisheries all becoming a well-organised industry the requirement of pellet dies is also going to increase and Radius has wonderful value for money machines with

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necessary automation to cater to this segment. Our vision is therefore to be the best machine manufacturer in the world for these pellets die machines and cater to the global market and give excellent value for money solutions.

With demand for energy always on the rise whether it be the conventional like hydro, fossil fuel, nuclear or renewable like the wind the requirements for big generators will be the order of the day.

Also with increasing impetus on rail transport worldwide the requirement of traction motors also are going up.

Radius with its wide range of machines for stator coil making will be well leveraged to play a major role in this segment.

The product technology the company represents is offering customized cutting edge solutions for the problems faced by the customer.

With the increasing thrust on automating the process which can give consistent quality the challenge is to meet the customers ever-growing expectations at a lesser cost. The product technology that Radius represents is using CNC with remote diagnostics, Scada and developing necessary software and tools to get the manufacturing done in an easy and consistent manner. In the pellet die gun drilling machine we have 10 axis machine which can run uninterrupted for shifts and offer high productivity.

Our coil making press with all the

pressure and temperature sensors have the best process monitoring done on SCADA and made available to the customer for traceability and quality control. Our taping machines have intelligence built in to tape the coils accurately. Thus Radius represents adopting latest technology but utilising the same optimally to give the customer excellent value for money proposition The future for products in India looks great with the make in India thrust and lots of manufacturing happening in India, Radius has offerings in the machines front catering to the energy, food processing, transport industries with its staple of products in pellet die making machines and stator coil making machines. Also with the expertise that the company has in gun drilling and deephole drilling the company can handle a wide range of diameter from 1 Dia to 30 Dia in gun drilling and dia 30 to 200 in BTA deep hole drilling machines and for length up to 3 metres and cater to some of the most critical applications spread across various industry segments like orthopaedic, fuel injection system, auto, aerospace, die and mould, Petroleum etc. Radius with its enormous expertise in gun drilling, tooling, machine, fixturing & entire application will offer subcontract and job work solutions at different locations all over the country.

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C E L E B R AT I N G

Y E A R S

Tel: +91 3174 222 852/3 | Email: sales@dutchtechtools.com | www.dutchtechtools.com |

/DTTIndia |

/dutchtechtools

COUNTRY PROFILE

BILATERAL RELATIONS SPAIN-INDIA

I

n 2017, Spain ranked 22nd in the importing countries from India and 33th in the exporting countries to India. The bilateral trade relations between both countries reached almost 5,000 million euros, which placed Spain as the seventh largest trading partner of India in the European Union.

From January to September 2018, exports from Spain to India have reached 987 million euros (4.9% more than in the same period of the previous year). Imports were 3,116 million euros (3.2% more than the same period of the previous year).

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In 2017, exports were 1,276 million euros and imports were 3,877 million euros, which resulted in a negative commercial balance of 2,600 million euros, worsening by 18% compared to the previous year. The export figure is the highest since 2013 and represents a growth of 1.46% more than in 2016.

On the other hand, imports continued their upward trend and grew by almost 12% in the last year.

SPAIN Machine Tools and Manufacturing Technologies Industry Spain is the European Unionâ&#x20AC;&#x2122;s third most important producer and exporter

of machine tools and is ranked ninth in the world.

This position has been achieved thanks to the commitment of manufacturers of machine tools, accessories, parts and tools to technological innovation, internationalisation and labour skills improvement.

Production in the advanced manufacturing and machine tool sector increased by 13% in 2017, exceeding the growth forecasts and reaching a record for the sector with 1,690 million euros.

Employment, one of the main factors

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COUNTRY PROFILE Spanish Machine Tools Industry in India Spanish exports of machine tools to India during 2017 remained stable at around â&#x201A;Ź26 million, placing India in the 10th position of Spanish exports with a share of only 2.9%. Considering that Spain is the ninth world exporter (third in Europe) and that 73% of the machine tools produced in Spain are exported, Spanish companies can still further progress in this market.

However, these figures do not include the sales made by Spanish companies that are already established in India and producing machine tools here, the number of which is increasing steadily. The Spanish machine tool supply in India also targets client sectors such as aerospace, energy or defence, usually through specific and tailormade projects, in which Spanish companies are highly specialized.

behind the stability of the sector, continues to rise with a 4.1% growth during 2017.

The solid results of exports in previous years have been followed by a more moderate growth (4.1%) but have reached a record 1,233 million euros. In 2017, the sector exported 73% of its production, with the following being the main receiving countries: Germany (represents 14.4% of all exports), China (9.9%), Mexico (9.8%), USA (8.4%) and Italy (6.4%). These are followed by France, Portugal, the United Kingdom, Poland and India (2,9%).

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Spanish Companies in India Over 200 Spanish companies have subsidiaries, joint ventures, projects or liaison and purchasing offices in India.

Investments are mainly concentrated in infrastructure (Abertis and Grupo San JosĂŠ), renewable energies (Gamesa), automotive components (Antolin, Gestamp), water desalination (Abengoa) and single brand retail (Inditex - Zara / Mango).

A wide number of companies in the machine tools sector have their own representatives in India: Danobat, Ekin, Fagor Automation, Juaristi, Nicolas Correa, Gamor, Zayer, Goratu, Pinacho, GH Electrotermia SA and many others are present in the market through their distributors or agents.

SPAIN AT IMTEX 2019 This is the ninth time that Spain participates in IMTEX with an official pavilion, which means that the commitment of Spanish companies

to both the Indian market and the fair is solid and long-term. Another proof of the importance of this market for our companies is the presence of almost all of them with permanent office in India. The fair is the perfect platform to show new technological developments and a meeting point with operators and professionals of the machine tool sector to get the pulse of the Indian market.

The 9 Spanish companies that will be showing their novelties in HALL 1B at IMTEX 2019 are: EKIN, S. COOP. (B106). www.ekin.es Design and manufacturing Of Broaching And Spline Rolling Tools And Machines ETXE-TAR GROUP (C106). www.etxe-tar.com Flexible Machining Systems for Crankshaft, Flexible Machining Systems for Con-rod, Deep Hole Drilling Machines with MQL or Oil, Special Purpose Machines, Transfer Machines and Machining Centers, Turnkey Machining Solutions , Laser hardening machines for crankshaft Automation Systems Leak Test Machines FAGOR AUTOMATION (A106). www.fagorautomation.com FAGOR AUTOMATION is a company with great experience in the development and manufacturing of products for machine automation and control. It excels by its capability to develop software and the versatility of its productive process to offer solutions tailored to the needs of their customers. Historically FAGOR AUTOMATION has focused his efforts on the machine-tool sector where they are one of the world leaders. Its wide technical and sales network spread out in more than 50 countries through its own branch offices and distributors.

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COUNTRY PROFILE GURUTZPE Turning Solutions S.L. (C104). www.gurutzpe.com GURUTZPE manufactures multifunction heavy duty lathes and provide high value turning solutions.

Their machines cover a machining range for workpieces between 1 and 200 t in weight and swing between 200 mm and 4000 mm in Ø.

IBARMIA INNOVATEK (D105). www.ibarmia.com 5 AXIS MACHINING CENTRES; Moving column machining centres with fixed table, of 3, 4 & 5 axis (continuous & simultaneous). Multiprocess (Milling+ Turning) moving column machining centres. Universal moving column 5 axis machining centres Machining solutions for big circular pieces.

JUARISTI BORING & MILLING MACHINES (A108). www.juaristi.com Manufacturers of Planer Type Horizontal Boring & Milling machines // Medium & Big Sizes Machining & Turning Centers // Floor Type Boring Milling machines with RAM // Hydrostatic Horizontal Floor Borers // Floor Type Milling machines // Rotary Tables // After Sales Service in India.

NICOLAS CORREA (C102). www.nicolascorrea.com NICOLÁS CORREA is one of Europe’s

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leading companies in the field of milling solutions for the most demanding production environments.

NICOLÁS CORREA offers the widest range of milling solutions on the market, including bed machines, gantry machines and floor type machine.

SHUTONIPIRANGA (D103). www.iazgroup.net Shuton and Husillos Ipiranga have integrated into IAZ Group, creating a leading group in the design and manufacture of high-performance ball screws for the sectors of machine tool, injection moulding, press and other applications. Dia 16-160mm, length up to 15m.

GAMOR (B105). www.gamor.es Gamor manufactures Tapping Machines, Tool Grinding machines, Chuck jaws and other machine tool accessories with almost 50 years of experience in the metal working sector. The Indian sales and service office GA-MOR Machines Tools Pvt. Ltd. opened in 2007 and besides Gamor products also distributes and services drilling machines from Erlo and Profile formers, Hydraulic Punching machines, Forging Machines; Hydraulic Press brakes, Shears, Broaching machines from Nargesa.

ZAYER (B107). www.zayer.com Zayer has an experience for more than 60 years manufacturing Bed type milling machines and machining centres, Moving column milling machines and machining centres, Bridge type milling machines and machining centres, Gantry type milling machines and machining centres.

Zayer offers a wide range of milling machines and machining centres with the latest technology, especially for die and moulds manufacturer as well as for the aerospace, wind power and railway industries and for general machining.

Manufacturing range: Our global presence is based on an extensive and professional sales network, with company branches in Italy, Brazil & China.

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ENDLESS POSSIBILITIES

VISIT US

Hall 3A | Stand B111

Hall 6

| Stand B109

24-30 January 2019 Bangalore, India

MARPOSS FLE XIBLE SOLUTIONS OPTOQUICK is the latest generation Marposs flexible solution, for high precision gauging controls on shafts, as for instance cam, crank or gear shafts, gear shafts or electric motor shafts. Optoquick helps operators with fast and precise quality controls while located directly at the side of the manufacturing machines. The combination of optical and tactile sensing technologies - complete MARPOSS design - allows the Optoquick to deliver extended gauging capabilities and flexibility, at the highest level of its category.

OPTOQUICK, NO MATTER WHAT THE GAUGING CHALLANGE IS.

M A R P O S S I N D I A P v t . L t d . 1 4 7 , S e c t o r 7 , I M T M a n e s a r 1 2 2 0 5 0 - Te l . + 9 1 1 2 4 4 7 3 5 7 0 0 | s a l e s @ i n . m a r p o s s . c o m

COMPANY PROFILE

The Bettinelli

advantage Over the years, Bettinelli Group and CDS Indexers have become synonymous with high quality automation products and technologies.

Rupesh Paparaju, Director, Bettinelli Automation Components, India

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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 broad product spectrum covers IP parallel shaft indexers, IT roller dial indexing tables, TR roller dial indexing tables, HP roller dial indexing tables, IG/IGA roller gear indexer, TL precision link conveyors, MHP/LHP part handlers, FT-HT open center ring tables and packages of rotary indexing tables. Bettinelli has a wide range of standard products.

These are delivered in 3 weeks.

Parallel Shaft Indexer

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JAN 24 - 30

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COMPANY PROFILE

Rotary Indexing Tables, TR Series

When it comes to customized products, these are designed, manufactured and shipped in 6-8 weeks.

The manufacturing takes place centrally in Italy. The regimen starts with design & engineering, CNC induction hardening, CNC milling, grinding, quality check and then assembly, painting and shipment.

In order to ensure quality, all components are machined internally, including the cam hardening by a proprietary CNC controlled induction hardening equipment.

For better finish, the products are also subjected to chemical nickel plating, blasting and painting.

The manufacturing process is constantly controlled to conform to international standards. The company’s quality systems are ISO9001-2008 certified.

Strategic advantages Over the years, Bettinelli Group and CDS Indexers have become synonymous with high quality automation products and technologies. “Our design and

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manufacturing systems have furnished competitive and strategic advantages to numerous industries in pharmaceutical, automobile, manufacturing, packaging and a plethora of other sectors. And for automation functions, our solutions are invariably preferred by companies,” says Rupesh Paparaju, Director, Bettinelli Automation Components, India.

The Indian subsidiary, headquartered in Pune, serves its customers in India by providing installation, commissioning, and after-sales support. It also offers technical consultation. In the pharmaceutical industry cam driven systems are used in filling, blister pack, tablet making and packaging machines. In automobile industry, they are used in pallet transfer tables, assembly machines, painting applications and test rigs, just to mention a few. In machining industry, they are used with advantage in deburring, lapping and pressing machines and in transfer lines. In SPM & robotics, they find applications in transfer lines, station

loading, sequential operations and so on. Inwelding, these indexers are inevitable in positioners, synchronous welding, robotic welding and component transfer.

Packaging too is a major application area. Cam systems are used in box filling machines, wrapping machines, cartoning and capping machines. Indexers are also used in casting, printing and cosmetics industries.

Closer to the customer The Indian arm of Bettinelli, based in Pune, Bettinelli Automation Components Pvt. Ltd., is highly customer-centric. “Our presence in India means quite something in fostering a symbiotic relationship with our customers. It helps us to match our world-class products with our eminent customer support,” underlines Paparaju, Director, who has built up a team to improve Bettinelli’s response time. “CDS are high-tech products which lend themselves to enhance the operational efficiency and productivity at the customer’s end.

We stay close to the customer to understand his needs and offer customized solutions within the shortest possible time to ensure peak uptime of his equipment and operations”, he adds.

- P.K. Balasubbramaniian

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COMPANY PROFILE

Ador : Playing a pivotal role in Nation Building

Mr. Satish Bhat, Managing Director, Ador Welding Ltd.

S

ince its inception on 22nd October 1951, Ador Welding Limited (formerly known as Advani-Oerlikon), has traversed a long journey and has served as a prime source of employment for thousands. This Mumbaibasedcompany is nothing short of a national heritage due to its premier welding and associated services. It would not be an exaggeration to call it one of the main architects to lay the foundation stone for the postindependence industrialization in our country in which welding plays a pivotal role. Since its establishment, it has been the foremost choice for the finest Welding Consumables & Equipment, Welding Automation Products & Systems, CNC Cutting Systems, PPE & Gas Cutting Products

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and Accessories and so on, catering to numerous sectors of our economy.

Ador’s contribution is not limited to any particular industry. It serves across varied domains that include Automobile, Wind Energy, Thermal & Nuclear Power, Heavy Engineering, Mining, Chemical & Fertilizer, Oil & Gas, Project Engineering Business, Railways, Defence, Infrastructure and a plethora of others. It makes sure to deliver the optimum level of perfection in welding & fabrication.

Known for its pursuit of excellence in every sphere of its activities, the company shares the benefit of its philosophy of sharing its scholarly know-how of the domain to the burgeoning manufacturers, industrialists and students. It came up with a separate skill development

institute ‘Ador Welding Academy’ to polish the skillset of Students, Professionals and Trainers.

The company is professionally managed to the core. You name any problem pertaining to welding and it will hardly take any time to come up with the right solution. Ador has been working very closely with the industry to meet its welding needs, be it making consumables to meet sub-zero or high temperature service conditions, developing low power consuming high weld quality welding inverters or customized automated solutions.

Several Firsts Ador’s PEB Business has the distinction of having developed the first-ever Mobile Flare system of

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COMPANY PROFILE

an innovative design. Apart from this, it is the only company in this field to have a ‘Clean room’ for the manufacture of inverter welding equipment in India. It is also the only Indian welding company to have an NABL accredited testing laboratory.

Its Pulse-MIG welder, Champ Pulse 500 is India’s first indigenously manufactured welding inverter which is an engineering marvel and is at par with the best in the world. The company has a unique customercentric behaviour inculcated in its ethos and it consciously works towards developing solutions.

Ador manufactures welding products at four strategically located plants across the country. It sells them to customers through a wide network of distributors and channel partners by means of a brigade of sales and service engineers. The company has been exporting its products since 1968 to its distributors and end-users located in more than forty countries. It also has a Project Engineering Business that undertakes EPC contracts and fabricates process equipment for various industries in India and abroad.

Technology Driven The technology development center located in Pune has state-of-theart equipment like XRF analyzers, Creep testing equipment, Carbon, Sulphur & Oxygen Nitrogen Analyzers, Optical spectrometer, Strip cladding equipment and many more. Digitalization of its systems and processes has led to a discernible improvement in timely delivery and product life cycle management.

The exclusively designed Apps for business intelligence,customer order processing & sales management have enhanced efficiencies greatly. The clean room ensures that it makes the

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most trouble-free inverters available and is able to offer a three-year warranty. It has a team of 50 plus research engineers working tirelessly towards updating existing products and adding new ones to its product portfolio to meet the customer’s ever-changing needs.

The company is working with top government establishments to develop special welding consumables for highly critical welding applicatiosas import substitutes. Its welding academy, AWAPL is working closely with NSDC for Skill India towards imparting knowledge and skill in the welding field, more so as the country looks to become a manufacturing hub for the world.

The company has delivered its services to clients who are considered elites in the industry. Companies like L&T, Reliance, Maruti Suzuki, BEML, TATA, Godrej, Yamaha, Ford, Hyundai, Alfa Laval, Royal Enfield, Bajaj, ONGC, HMEL, BPCL, SKF, FLSmidth, SAIL, Aditya Birla Group, Coal India, MRPL, Cochin Shipyard, BHEL, Railways, and Defence Establishments are a few of the hundreds of names on the domestic scene. In the International markets, it has prominent names like ASRY, NPCC, Dangote, Petrofac, KOC, KNPC, QP and Eversendai to name a few.

Glittering Milestones By the late 1960s the company had four manufacturing plants. The Technology Development Centre for R&D was set up in 1967 and the company started exporting to the Middle East, Africa and South East Asia by 1968. In1986, the company went public.

The last decade (2009 till now) has seen a series of path-breaking performances in values and volumes and Ador Welding, with its passion for welding, is growing from strength to strength as India’s welding powerhouse.

Looking Ahead The company has grown significantly in both values and volumes in the first two quarters of the current financial year and is looking to grow by 10-12% in the current fiscal.

The industry is moving towards automation and robotics and eventually towards industry 4.0 and Ador Welding is geared up to meet these challenges.

Investments in infrastructure, Railways, Automobile and the Defence sectors will enable the company to maintain its momentum in the coming years as well.

“Our vision is to cross INR600 Cr by 2020-21 and to continue to enhance the operational efficiencies of our customers across the globe by offering best-in-class products and services,” says managing director Satish Bhat who is a veteran with long stints with market leaders like Ador Welding, Schuler, and Mahindra Group in a career spanning over 32 years. With proven skills in managing medium and large companies in the capacity of MD/CEO, he has led business teams in areas like business strategy, sales & marketing,product technology and development, financing and operations.

He is also known for his deep insights in to the intricacies of Global markets– the US, Middle East, Europe and Africa both in short and long cycles.

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COMPANY PROFILE

We always seek out new technologies & applications to provide tailor-made solutions to the customer : Rushil Shah

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

Shavo Technologies Pvt. Ltd., a part of the Shavo Group with a standing and reputation spanning over five decades, is in the frontiers of niche high technologies cutting across diverse disciplines.

The company represents some of the world leaders in their respective fields for technology solutions like static elimination, precision air movement, high quality instrumentation, high purity gas delivery, corrosive gas handling, energy absorption and so on. With a vast product portfolio, the company serves over a thousand customers from diverse key sectors including semiconductor, aerospace, defense, chemical, oil & gas, automobile and so on. In an interview with Mr. P.K. Balasubbramaniian, Mr. Rushil Shah, Managing Director, Shavo Technologies gives a vivid account of his company’s capabilities and commitments to give better value to the discerning customer by leveraging the technologies from the world over.

Excerpts: Q. From static elimination solutions to precision air moving products to instrumentation fittings and high purity gas delivery systems, you are dealing in a wide spectrum of products and technologies. What is the common thread in all these?

Our endeavour has always been to work in niche high technology areas across industries where we can offer significant value for a variety of problems. Our products and their applications find solutions in a diverse range of industries such as Semiconductor, Aerospace and Defense, Converting, Automotive, Chemical and many more.

Q. What are the pioneering efforts you have taken in concept selling?

Our core selling concept, which we believe differentiates us, would have to be our deep application knowledge

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and command over the technologies we sell. For any solution oriented company, this is critical. We have gone from selling component to systems and solutions and turnkey capability in an effort to keep offering better value by leveraging the technologies we provide.

Q. Across the board, which are the technologies you would call as cutting edge?

All our Principals have specific technologies that would be classified ‘cutting edge’ considering that almost all our principals are world leaders in their fields. For Static Elimination, we have ‘cutting edge’ integrated power supply ionising bars with full feedback control ( a first in the industry), for Gas Delivery, we have some of the most sophisticated fully automated systems capable of dealing

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COMPANY PROFILE with the most dangerous gases, we offer from HORIBA a multi gas, multi range Mass Flow controller again a first in the industry and many more such products across our range.

Q. Your principals, Gast has been a leader in air moving products. What are the technological innovations they have displayed in recent years?

Our journey of working with High Technology Industries has started with Gast which today remains one of the world leaders in Air Motors and Fractional horsepower. Over the years, we have released many new pumps that have extended typical service life to new frontiers especially with the new rocking piston technology pioneered by Gast.

Our latest 87 R series offers industry leading pressure performance at lowest noise levels.

Q. What’s the challenge in designing and offering high pressure regulators for corrosive fluids? Which are the industries that benefit from these?

Corrosive gases are used in a wide range of industries from Chemical, Tooling and the new areas of Nanotechnology, Photovoltaics, etc.

Handling corrosive gases requires deep application knowledge, understanding of the materials to be used especially soft goods. Many corrosive gases are also liquefied which need special

Applied gas delivery systems

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considerations, from heating to weight measurement, etc.

first such unit to have PESO / CCOE Approval from Nagpur.

Q. What’s the level of awareness of the ill-effects of static electricity in the industry and the need for neutralization?

I can say that the awareness on the causes and cures for static electricity are low in industry but steadily growing. A lot of problems of contamination, material misbehavior, etc., are often attributed to other causes when they really are static related issues. We continue to publish articles and bring awareness to the industry by working with a number of industrial associations.

Q. Which are the applications where energy absorption is crucial – I mean where you recommend your Enidine products?

Generally of course ‘Energy Absorption’ has applications wherever we need to decelerate motion, in the Industrial space.

Factory Automation especially with Pneumatics is the key application, but we also find safety applications such as end stops for large cranes like those found in steel and ports as an important area. Lately our focus has been vibration isolation with special attention to strategic electronics in the Defense Sector which has some of the most stringent requirements for G force transmissibility.

Q. What’s special about the instrumentation valves you offer to say petrochemical industries? Do they require any approvals here from labs like NABL or FCRI? The valves and regulators we supply to the Chemical Industry in general have a wide range of certifications.

For valves, we have course type approvals from various third parties like Llyod’s, TUV, DNV, etc. and the products meet all industrial standards and wherever required such as ASTM F-1387, for Oil & Gas, ECR 110 for Automotive NACE, for Sour Service and many more. In fact our Tescom vaporizing regulators, in addition to having ATEX Approval, is the

Static measurement for effective static neutralization

Q. Where do your fluid control products go?

Our Fluid Control products once again find applications in a very diverse range of industries, but the main would have to be Oil & Gas, Chemical, Analytical and general manufacturing.

Q. What’s the significance of ultra high purity gas delivery systems and what are their applications in Indian industry?

I believe the growth areas in the Fluid

High quality instrumentation valves

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COMPANY PROFILE

Rocking piston compressor

Control Industry lie in Semiconductor manufacturing and Photovoltaics which demand ultra high purity gas delivery systems. Equipment to service these industries is typically made to the exacting specifications of the SEMI code which controls all processes from raw material to manufacturing, testing and even packaging. The surface finish and cleanliness requirements for these industries are extremely demanding often requiring products to be assembled in Class 100 environments.

Q. If you take one industry, for instance, you must be offering several products from your basket.

As a test case, which are the products you offer to the automotive industry?

Our supplies to the Automotive Industry almost cover the entire breath of our product lines e.g. all engine testing for the now EURO IV and Euro VI norms use our Tescom Central Gas Supply Systems for calibration gases. We supply Gast Air Motors almost extensively to all automotive paint kitchens. You will find our Enidine shock absorbers at the end of travel on many assembly lines. Our Meech Jet Stream Ionizing Systems clean & neutralize car bodies and plastic parts prior to painting and our other Fluid Control products find extensive applications in the

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Shock absorption products

CNG space and the automotive testing area such as car air bag testing for example.

Q. What must be the head count of your customers today? Can you mention some prominent ones?

We are fortunate to be working with some of India’s Top Companies such as Reliance, Tata’s, Biocon, GE, Department of Space, Ministry of Defense and many more. I believe we have in excess of 1000 live accounts.

Q. These products are highly serviceoriented. What’s your service set-up?

Our service set-up / service team has been growing from strength to strength. We have full service capability at our Pune office and are in the process of building a world class center in our Bangalore Factory.

Our service support is a key pillar of the value we provide.

Q. How wide is the technology gap that you find in India as a provider of overseas products and technologies?

Being in niche areas, I find the technology gap to be considerable but I believe this is largely related to fewer players in this kind of area.

But as we all know over the last decade, the technology gap has been fast shrinking and will continue to do so as we see more FDI in Indian Industry.

High pressure regulators

Q. Addition of any more agency lines in the anvil?

We have generally been extremely selective and have refrained from having a long line card, preferring a deeper involvement with our current partners to fully exploit their potential, but we have recently signed with Horiba to introduce flow control solutions and we would probably close with 2 more agencies in the Fluid Control area over the course of the next year.

Q. What’s your greatest contribution to Indian industry?

It would not be correct to say that I have made a contribution to indian industry but the Shavo Group started by my Father, Mr. H.K. Shah is widely recognized as the Indian pioneer in Industrial Pneumatics and we can safely say that we continue to provide new solutions and contribute to the growth of our customers.

Q. What are the challenges ahead for you?

The economic situation continues to remain strained and we, as an importer, remain under pressure due to exchange rate fluctuations. Also as we offer customized solutions, it is a constant challenge to seek out new areas and new applications to provide our solutions.

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INDUSTRY VIEW

Machine Tools TRENDS & VISION 2019 It’s truly an exciting time for Machine Tools Industry in India. With the government’s emphasis on manufacturing, machine tools being the mother industry is standing on the threshold of a major opportunity.

The industry has been witnessing a steady growth and shows no signs of slowing down in the coming future.

As per industry reports, Indian machine tools industry is projected to grow at 5.5% annually through 2019.

Given the positive market forecast and outlook, machine tools players are gearing up to cash in on the tremendous opportunity. As we kick-start the New Year, MTW spoke to industry leaders to know about the prime trends that will rule 2019 and their strategy and vision for the year to stay ahead of the pack. Excerpts: Renishaw Metrology Systems Ltd.: Innovation at the Core Trends: Intelligent machining processes (Smart Manufacturing) is the latest trend in our industry. Widely publicized trends such as Industry 4.0, the Industrial Internet of Things, cloud computing and data mobility provide manufacturers with an unparalleled opportunity to develop processes which deliver improved productivity and process capability. Automation, measurement and feedback can deliver process control throughout the stages of manufacturing. Optimised processes monitor not only the condition of parts, but also the performance of machines, process trends, interventions and environmental effects.

Mr. Paul Weaver Vice President, Renishaw Metrology Systems Ltd

Key Products: Renishaw provides the technologies required to measure and control many of the key process variables in CNC machining and other forms of manufacturing. A combination of preventative, pro-active, reactive & tailgate measurements for process control has been used in Renishaw’s machining facilities very successfully over the past 25 years. This approach has enabled highly automated manufacturing with low overall labour costs to be realised. Automation + Accuracy + Data capture + Integration + Intelligence = Productivity + Capability. In fact at IMTEX, we are showcasing a Smart Factory set up, demonstrating to manufacturers how intelligent process control is key to the operation of a successful smart factory and to address the industry’s need for automated process control.

Strategy: Our tagline: Apply innovation says it all. And every year we say – applied innovation when we launch products in market.

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INDUSTRY VIEW Fenwick & Ravi (FAR): Focusing on Exports Trends: Machine Tools Industry is very energetic and wondered that the domestic industry has clawed back well in the last 10 to 12 years to regain 50% of the consumption in an evergreen market. Today Japanese or, European firms based in India, do have Indian made machines, which was not the case some time back.

It is the clear positive sign of growing market. In machine tools industry, several technologies are coming up as the manufacturing sector growing with modern metal cutting machines either with compact CNC or, VMC machines.

Mr. R Ravi, Director, Fenwick & Ravi (FAR)

Key Products: We have also developed so many new technology in the areas of clamping systems for machining center and some equips with industry 4.0 and IoT features. We have our own separate design department, which is doing all the research and innovating new products with latest technologies. Our mission is to provide “German Quality Machine Tools at Indian prices” to support Indian manufacturing sector.

Strategy: For financial year 2019-20 and 2020-21, we are hoping to reach the total turnover of Rs 23 crore and Rs 30 Crore respectively with the investment in high capacity machines and new technology. We are a growing company. Every year, we are implementing some new changes in our manufacturing plant with some new technology. Our key products are well known in India as well as few foreign countries. For achieving these higher figures we are more focusing on export market for our key products and in the last two financial year we have achieve above our targeted turnover. In future too we are hoping for the same.

NORD Drivesystems Pvt. Ltd.: Products meeting the latest energy efficiency norms Trends: Automation, Industry 4.0 is the latest trends in our Industry and our products are ready for IoT-Industry 4.0 can communicate with one another and apply suitable for automation, post parcel, logistics, material handling, packaging, etc. They are highly energy efficient and virtually maintenance free and suitable for any harsh ambient and operating conditions. Also, Premium Energy efficiency motors, we are having the complete portfolio up to IE4 and with BIS Mark.

Mr. Muthusekkar, Managing Director, NORD Drivesystems Pvt. Ltd.

Key Products: Our products meet the latest energy efficiency norms and BIS (Bureau of Indian Standards) optimized drives and offer total solution and total cost of ownership. They are suitable for today’s digital world. We have IE4 and IE5 Motors on the way and meanwhile we have products such as FDS- Field distribution systems and Decentralized Drives with the largest capacity – which no competition has, smooth surface motors etc. and all equipped with latest technology to meet the energy norms.

Strategy: We optically canvass ourselves and our products and keep improving upon. That is the ways to stay ahead not just focus the competition and put ourselves forward. As we have many patents to our credit- This clearly shows how we are ahead of the competition. For us every day is an incipient day and every year is an incipient year and fixates on product efficiency improvement, innovation, etc. To keep ahead of ourselves against the antecedent day and year.

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INDUSTRY VIEW Fatty Tuna India Pvt. Ltd.: Offering Complete Solutions Trends: The manufacturing sector is changing at a meteoric pace and much of this change is due to innovation and progression in technology. Let’s a look at the tech solutions having the greatest impact on the industry.

Additive Manufacturing (3D Printing): One of the biggest news in the manufacturing technology sector in the last few years is the proliferation and applications of 3-D Printing. It has caught the imagination of the general public and the manufacturing fraternity. It gives you a lot more possibilities for how you design a part.

B P Poddar Sr. Vice President, Fatty Tuna India Pvt. Ltd.

The Internet of Things (IoT): IoT is a revolutionary manufacturing technology that allows electronic devices connected to each other, within the existing Internet infrastructure, to communicate with one another without human intervention.

Artificial Intelligence: The Science & Engineering of making intelligent machines, especially intelligent computer programs. While exploiting the power of computer systems, the curiosity of human lead him to wonder –“Can a machine think and behave like humans do..??” AI has been dominant in various fields.

Nanotechnology: Nanotechnology is the technology of the future, it involves the manipulation of matter on atomic, molecular and supramolecular scales. It is going to play an indispensable role in every manufacturing industry in the future.

Robots on the rise-managed by humans: Building a better manufacturing sector with augmented and virtual reality, robotics and data analysis using smart equipment naturally raises an important question: What will the Industry 4.0 workforce look like? We will still need people who can manage new operations, manage the robotics, program them and maintain them. New jobs will be created over the next decade as a direct result of automation and artificial intelligence - although technology will cause job losses too.

Key Products: We are not only offering standalone machines but complete solutions, which includes pre-sales, application engineering support, installation & commissioning through well qualified and factory trained engineers, support through warrantee and after warrantee, timely spare parts availability. To meet various requirements of market and various industrial segments , we have joined hands with few other Taiwanese Machine Tool Makers and started marketing different machines such as : - VTL, Double Column Machining Centers, Grinding Machines, EDM .

Strategy: We have different technologies to stay ahead of competition. FEMCO is one of the largest machine tool makers for offering solutions to “Alloy Wheel Manufacturing Industry Segment” – passenger cars and motorcycles. Until now we have supplied more than 2,500 machines all over the world.

We offer complete solutions – machines, clamping systems, engineering, automation, measuring, cleaning, laser marking- ready for integration in Industry 4.0.

FEMCO understood requirement of Valve Industry and developed HBM (Horizontal Boring Machine) with integrated Facing Head (U-Axis). This configuration have 6-axes movements i.e. X,Y,Z, B, W & U. This combination offers process flexibility of VTL & HMC on a single machine.

This is the most appropriate solution for boring, milling turing, internal & external taper turing, sphere turning ,ID & OD Grooving, Facing etc. Our vision is to be a partner of Various Industry Segments where we and our customers arrive on most appropriate technological solutions in order to meet global market requirements efficiently.

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INDUSTRY VIEW FARO Technologies: Committed to Offer Innovative Solutions Leveraging Advanced Technologies Trends: As the digital transformation of the manufacturing industry continues to gain prominence, manufacturers will continue to look for solutions that allow them to digitize information and digitalize processes to reduce their response times to market changes.

Key Products: The 8-Axis Quantum FaroArm® is the world’s only eight-axis portable metrology arm solution that enables operators to rotate a part in realtime, relative to the arm. When paired with the FAROBlu™ LLP and integrated with the CAM2 2018 software, the end-user experience is elevated through an advanced user interface and reporting dashboards — streamlining inspection activities and facilitating shorter cycle times.

Mr. QUAH Beng Chieh, Head of Marketing (Asia Pacific), FARO Technologies

Strategy: FARO endeavors to offer its customers more innovative and effective solutions with its advanced technologies. We expect a rise in demand for sophisticated metrology solutions, and we’re fully committed to supporting the machine tools industry through its evolving precision measurement needs.

Instamod Air pipe: Focus on Gaining Market Leadership in Compressed Air Piping Solutions Trends: In light of present global scarcity of power and ever increasing cost of generation of electric power be it conventional or non-conventional the whole manufacturing sectors started looking aggressively either for low cost power generation or energy saving technology. In Industry, there are three main utilities – Electricity, Water & Compressed air. It is estimated that around 10% of industrial electricity is utilize to produce compressed air. So considering the importance of input cost of industrial products manufacturing sector is giving more & more focus on efficient way of compressed air generation as well as transmission of compressed air. The whole spectrum of industry is started adapting energy saving methods and technology to make their products technically more superior & commercially competitive.

Mr. Santosh Kumar Managing Director Instamod Air pipe Pvt Ltd

Key Products: AIRpipe has a great role to play towards the contribution of energy saving compressed air piping system. We offer wide range of compressed air transmission network size starts from 20 mm to 200 mm to cater all diversified requirements of different industries. As per British Compressed Air Society to generate 1 Bar pressure compressor motor capacity needs to be increased by 7-10 % for the same volume of air. AIRpipe designs the piping network in such an optimal way that the pressure drop doesn’t go beyond 2-3% of set pressure.

Unlike the traditional airpiping system AIRpipe, which is absolutely rust free, provides zero leakage piping system. Usually energy lost through leakage & pressure drop in 10 years old traditional piping could be recovered in 1.5 -2 years by adapting energy efficient AIRpipe compressed piping network.

Strategy: AIRpipe is thriving hard to be the market leader in compressed air piping solutions through its continuous product modification and bringing the customer service closer to customers than ever. We have placed 40-strong distributors with close proximity to industrial hubs & equipping them with all technical knowhow to understand the exact requirement of clients & satisfy their need. Keeping adequate stock in our primary & secondary warehouse to swiftly ship the materials down to the customer is another step to keep ourselves ahead of the market.

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INDUSTRY VIEW UCAM Private Limited: Focus on R&D and Improving Efficiency Trends: The Buzz today is all about Industry 4.0/IIOT and what it can mean to different sections of Machine Tool Professionals. Smart users of Machine Tools can surely benefit from improved productivity & cost savings when applied well.

Machine Tool Builders are utilizing these enablers to differentiate from competitors and go into business. The other most important trend is the Additive Manufacturing and it is here to stay and grow. This has now given a new dimension to the already colourful spectrum of manufacturing technologies.

Beyond that from the machining perspective, Users want to be more and more productive and save on costs and lead times. With this the consumption of 3 plus 2 axis solutions are steadily growing. Utilization of full 5 axis machines too are slowly showing upward trend.

Mr. Indradev Babu Managing Director UCAM Private Limited

Key Products: Of the three product verticals, the flagship Rotary Tables you will see this IMTEX a slew of new products, including a Turn Mill Table 5 axis solution for Machine Tool Builders. We are happy to receive orders for such units from our European Customers. Our new URX and URXH series have high performance specifications meeting or beating global bench marks. Nimble Machines is launching 4 new models with several variants and is already making waves. We expect very strong traction for the new range. Nimble Electric is showcasing new generation of torque motors with improved and reliable performance.

Strategy: The mantra comes with different flavors and hues. Improve efficiency, differentiate, invest on R&D. We need to get more nimble in our actions. Industry 4.0 gives much opportunity also to contribute for Customerâ&#x20AC;&#x2122;s benefit. But of course at UCAM the search for new avenues to better our products and services is always on. You will always see UCAM comes out with something new during every edition of IMTEX.

MILLENIA TECHNOLOGIES: Customer Satisfaction with Advanced Products and Latest Technologies Trends: Right now the industry is looking forward for atomization and quality in all processes of manufacturing. As MILLENIA TECHNOLOGIES, we are on path of supporting this trend by supplying the best European Technologies from our principals like OTEC Prazisionsfinish GmbH & ELMA Schmidbauer GmbH from Germany, ALICONA from Graz, AUSTRIA & IHI IONBOND GROUP AG, from Switzerland. Our machines help to reduce the human error, increase the production with high-quality product delivery to the industry.

Mr. Gautam Tiwari, CEO, Millenia Technologies

Key Products: Our products are used in different industries like Aerospace, Cutting Tools, Medical Implants, Automobile & Engineering etc., for Surface Finishing by OTEC ,Ultrasonic & Steam Cleaning by ELMA, Form & Roughness Measuring BY ALICONA & CVD, CVA & CVI COATING by IONABOND, so we always keep our product more advanced with latest technology which is compatible for Industry 4.0 & our principals are on regular basis investing in R&D to come up with latest features in our machines to increase the productivity.

Strategy: Our vision is to satisfy the customer with our high quality latest technologies, know-how & professional after-sales services. We want to increase our market share and become the reliable partner for all the above manufacturing industries. So we are focused on bring technologies your way to your doorstep.

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Grob India: Focus on Futuristic Technology Trends: For the Global Machine Tool Industry, multiple trends that necessitate extreme agility on the part of Machine builders are occurring everywhere. As Automotive Industry continues to be the main driver for the Machine Tool Industry, the enhanced attention towards electro mobility is a reality, globally. However, Chinese and Asian markets, continue to have substantial requirements for machinery and systems for conventional combustion engines, which is expected to remain for long. As a strong company which has proven capabilities in both conventional engine manufacturing technologies as well as electromobility related automated design and production capabilities, GROB is one important company which

Mr. L.J. Naidu, Managing Director Grob India

is well poised to help our customers to manage this unique technology transition.

Key Products: As a Leader in the Machine Tool segment, we are also catering more and more to the unique production challenges offered by industries like Aerospace, Die Mould and Medical, as they all need special capabilities for machining that involves multi axes interpolation and multi-face machining in single set up, apart from unprecedented accuracy levels and machine repeatability GROB has mastered technologies in all the above old and new fields and hence qualified to manage these multiple technologies for our customers. As automation is attracting huge attention when compared to basic machines, our developments such as Rotary palette storage systems and Robotic loading systems enable unmanned operation in shifts. Our universal Machine series G350, G550, G750, and G 1050 are continuously expanded and modified, driven by evolving customer requirements and technical developments.

As GROB is already working with several global auto majors in the fields of automated stator, rotor production, electric motor and battery & fuel cell assembly for electric cars and related technologies, we are very sure that as and when India takes a serious plunge with rational production volumes of electric vehicles, we would be in a position to offer tried and tested latest technology solutions to our Indian customers as well.

Strategy: GROB has always been a company that invested in futuristic technologies and built a ring of professional reliability. In India, our biggest strength is our huge team of trained service and application support engineers equipped with state-of-art remote tele diagnostic facility. To be closer to our customers, enhance our facilities and to provide turnkey solutions to our customers in India and countries nearby, we have just acquired 20 acres of land near Bangalore, located in the State of Andhra Pradesh. We will endeavor to remain true to our global leadership in India as well with global quality professional support for our system machines as well as universal machines.

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INTEGRATED SINGLE SOURCE PRODUCTION INTEGRATED SOLUTIONS SINGLE SOURCE

PRODUCTION SOLUTIONS TURNING TURNING

FLEXIBLE SHAFT MACHINING GEAR HONING

POWER SKIVING POWER SKIVING

GRINDING TOOLS FLEXIBLE SHAFT MACHINING

I.D. & O.D. GRINDING I.D. & O.D. GRINDING

COMPLETE MACHINING GRINDING TOOLS

SURFACE THREAD GRINDING GRINDING SURFACE GRINDING

AUTOMATION SYSTEMS HONING TOOLS

HONING TOOLS

GEAR HONING THREAD GRINDING

PRODUCTION

PRODUCTION

DVS will be at the IMTEX at booth A107 in hall 4 The DVS TECHNOLOGY GROUP is made up of Germany-based companies focusing on turning, gear cutting, grinding and gear honing technologies. Besides engineering and manufacturing machine tools, automation systems as well as grinding and gearhoning tools, DVS operates two production sites where transmission parts are machined in series production exclusively on DVS machines. This adds a high degree of production know-how to the experience of the DVS machine tool and tooling manufacturers.

With a unique combination of machining technologies, tooling innovation and production experience for the machining of vehicle The powertrain componentsGROUP DVS isis one ofup theofleading system DVS TECHNOLOGY made Germany-based suppliers in the industry. companies focusing on turning, gear cutting, grinding and gear honing technologies. Besides engineering and manufacturing

machine tools as well GROUP as grinding honing tools, DVSemployoperates The DVS TECHNOLOGY hasand more than 1,300 two production sites where like transmission parts and are machined in ees worldwide.

On key markets China, India the United on DVS adds a and high Statesseries DVS production supports itsexclusively clients with theirmachines. own staffThis in service sales. degree of production know-how to the experience of the DVS machine tool and tooling manufacturers.

www.dvs-technology.com

With a unique combination of machining technologies, tooling innovation and production experience for the machining of vehicle leading system suppliers Your powertrain local DVS components contact: DVS is one of thePhone: +91-20-679-20500 in theENGINEERS industry.

Email: mail@nemade.in NEMADE PVT. LTD.

Plot 16, Gat 605/2, Mukaiwadi Road, The DVS TECHNOLOGY GROUP has more than 1,300 employees Pirangut, PUNEOn - 412115 worldwide. key markets like China, India and the United States INDIADVS supports its clients with their own staff in service and sales.

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TECHNO FOCUS

Stage Set for

IMTEX 2019 A

s IMTEX, the flagship event of Indian Machine Tool Manufacturers’ Association, draws closer, machine tools industry is gearing up to put its best foot forward.

Also, this year’s event is special with IMTEX celebrating its 50th anniversary. Over the timeframe of 50 years, the event has emerged as a one-stop-shop for cutting-edge and futuristic manufacturing technologies from India and other global players.

The event showcases latest

innovations in metal forming technologies, robotics and automation, welding and joining, wire-forming and drawing, presses, die casting, hydro forming, sheet metal forming machines, hydraulic and pneumatic systems and elements, testing machines, and more.

Being South East Asia’s apex exhibition, it attracts huge footfall every year with visitors from a wide spectrum of manufacturing and ancillary industries. This year, the

event is being held from January 24 to 30 at Bangalore International Exhibition Centre.

For machine tool players, IMTEX serves as a great platform to not only showcase their products but also to network with peers and interact with customers but to understand their key requirements and pain points. With IMTEX 2019 just around the corner, MTW spoke to industry players to get a glimpse into what to expect from the event and new product launches:

DesignTech Systems: Showcasing Latest Technologies for Engineering Excellence

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Vikas Khanvelkar, Managing Director, DesignTech Systems Ltd.

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ince its inception in 1998, DesignTech has been working closely with the Mechanical Engineering industry in India, helping them make a transition from traditional processes of yesterday to adopting the latest technologies to match the global standards of engineering excellence. In continuation this year too, the company would be showcasing some of the advanced CAE solutions, 3D Printing or Additive Manufacturing Technologies, latest CAD and PLM solutions from global leaders.

“Our focus is to help our customers attain their goals of product design and manufacturing excellence through efficient processes and systems that augment productivity, generate greater ROI and enable them achieve higher cost effectiveness. These technologies would help them remain competitive and relevant in the fast changing market space,” asserts Vikas Khanvelkar, Managing Director, DesignTech Systems Ltd. What’s new: DesignTech Systems Ltd. has newly tied up with PTC as their Value Added Reseller to promote and sale their IoT (Internet of Things), Virtual Reality (VR) and Augmented Reality (AR) solutions, ThingWorx in India. “We would be showcasing this entire range of product portfolio at IMTEX 2019,” says Khanvelkar.

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TECHNO FOCUS Hurco India Pvt Ltd.: Displaying Latest Generation High Performance Machineries

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urco India Pvt Ltd is a subsidiary of Hurco Companies Inc. USA, a Nasdaq listed company. The company is showcasing latest generation high performance machineries. “Hurco is celebrating 50 years of innovation in 2018.

Hence IMTEX 2019 is very significant event for Hurco India,” says Managing Director, Sanjib Chakraborty.

The company is displaying the following machine models to suit the requirements of different industry segments: X40i : This is high speed and high performance 3 axis VMC with Bridge type structure suitable for precision components from industry segments like die mould, medical implant, aerospace etc.

Sanjib Chakraborty, Managing Director, Hurco India Private Limited

HM1700Ri : This is high performance 4 axis HMC suitable for oil & gas sector, die mould, aerospace. This is a newly launched machine.

VMX42SRTi : This is high performance 5 axis VMC suitable for tool room, die mould, aerospace. This machine is designed as highly flexible to help customer to use machine more efficiently and effectively as 3 axis, 4 -axis and 5 - axis application.

VM10Ui : This is one of the world’s smallest 5 axis machine with compact design suitable for medical, aerospace, cutting tool etc. This machine will be showcased at our partner Solid Cam’s stall.

VM20i : The is general purpose 3 axis VMC suitable for tool room, auto components. This machine will be showcased at our partner Sarda Magnet’s stall.

What’s New: The company is showcasing Hurco HM1700Ri horizontal machining center for the first time in India at IMTEX 2019.

AXIS Tools: Showcasing NexGen Cutting Tools

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Sunil Taneja, Managing Director, AXIS Tools

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XIS Tools for MICRO MACHINING are renowned for High Precision Ultra Micro, Micro and Macro Tools. The company offers tooling solutions for a wide range of industry segments including electronics, micro mechanical, aerospace, automotive, die and mold, jewelery, horology, writing instruments digital dentistry and medical sectors. “Tools manufactured by us are designed and customized for the most demanding applications and emerging materials,” says Managing Director Sunil Taneja.

AXIS Tool designs encompass balanced Micro Geometries, Precise Edge preparation, Super-finishing and High Performance NexGen Coatings. The company exports to more than 30 countries worldwide, including advanced economies such as Germany, Switzerland, Japan, USA and South Korea.

At IMTEX 2019, AXIS will present 0.015mm (15 Microns) Ultra micro Drill.

“This has been achieved after an extensive technology deployment, skills and expertise in tool making,” says Taneja. Highlights being showcased are NexGen Cutting Tools with unique Geometries, AXIS+ Cutting Tools with Super-finishing and CVD Diamond Coated Tools.

Other attractions will include application specific tools to make it simpler for customers. “Team AXIS understands evolving customer needs to offer solutions in most demanding applications,” asserts Taneja.

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TECHNO FOCUS Dutch Tech Tools: Launching New Series of Drills and Endmills

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utch Tech Tools offers premium drills and endmills made from solid carbide to machine a wide range of materials.

Abhijit Nag, Executive Director, Dutch Tech Tools Private Limited

What’s New: In addition to displaying its standard products, the company is launching two new series: Duronto FX Drills and XNOX Range of Endmills.

“Duronto FX Drills are high performance premium solid carbide drills. The premium drill is 3xd up to 30xd in lengths with internal coolant holes. It has advanced new coatings and application range from universal- Steels, stainless steels to special alloys,” shares Abhijit Nag, Executive Director, Dutch Tech Tools Private Limited.

Sharing details about XNOX Range of Endmills, Nag says, “Our XNOX Range of Endmills are premium high performance endmills that feature 4 Flutes & 5 Flutes for various applications. These endmills are capable of slotting, side milling, trochoidal milling, plunging and ramping- all with one tool.”

Grind Master Group: Launching Breakthrough Technologies

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t IMTEX 2019, Grind Master Group is going to display Flexible Microfinishing Machine and a robotic cell for foundry automation.

What’s new: The company is launching two breakthrough technologies. “One will be our Next Generation Microfinishing Machine, which is highly flexible for finishing automotive powertrain components. This will have ultra-user friendly NANOFINISH Control System which is IoT and Industry 4.0 enabled.

NANOFINISH range of machines built by us are being sold worldwide and we are proud to be the Global Technology Leaders in this segment,” informs Sameer Kelkar, CEO and R&D Head, Grind Master Group.

Second technology Grind Master Group is displaying is Robotic Automation for Foundry, particularly for aluminum, cast iron, steel casting foundries.

“There are several advances in this technology like adaptive grinding, automatic path correction, IoT and Industry 4.0 enabled NANOSMART Controller and compact design on this Robotic Cell,” says Kelkar.

Sameer Kelkar, CEO and R&D Head, Grind Master Group

TOYODA Micromatic Machinery India: Introducing IoE with Smart Factory Concept

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OYODA, supplies supreme quality of grinders (camshaft, crankshaft & cylindrical), cutting machines (HMC/VMC/SPM/Gear Skiving) & ‘Internet of Everything (IoE)’ module.

Mamoru Nagasawa, Managing Director, TOYODA Micromatic Machinery India

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What’s New: At IMTEX 2019, it is launching High Precision CNC Cylindrical Grinder GL4P-32E. “Made in India by Micromatic Grinding Technologies (MGT), this machine has been made in a technical collaboration with JTEKT Corporation-Japan. The machine is designed as per ‘JTEKT-Japan’ standards with the manufacturing expertise of MGT. The USP of the machine is that it includes Hydrostatic Wheel Spindle for machine longevity, rigidity and precision results. The machine has application in automotive transmission and all cylindrical shafts (up to 320 mm long),” says Mamoru Nagasawa, Managing Director, TOYODA Micromatic Machinery India. In addition to machine, the company will be introducing ‘IoE with smart factory concept’.

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TECHNO FOCUS Hoffmann Group: Focusing on Products that Maximize Productivity

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Pinaki Banerjee, Managing Director, APAC, Hoffmann Group

offmann Group, Europe’s leading system partner for quality tools, is deeply committed towards India market. At IMTEX 2019, the company is showcasing products that will help its customers enhance their productivity.

However, Hoffmann’s approach to productivity enhancement does not follow the conventional offerings of the majority suppliers. In line with its global philosophy, ‘System Partner of the customer,’ it takes a holistic approach of the total production process.

“Conventional offerings for productivity improvement focus only on metal cutting, which is just 15 - 20% of the total production cycle. With our wide range of products in metal cutting, clamping technology, metrology, grinding, hand tools, workstations, storage systems etc., we offer the customers the best solutions to enhance productivity in the cycle of “raw materials in” to “finished materials out,” elaborates Pinaki Banerjee, MD, APAC, Hoffmann Group What’s New: The company’s GARANT Master tool family is enriched with new innovative additions of Master Tap, Master TM and Master Titan.

“Master Tap and Master TM are high performing solutions for threading (tapping & thread milling). With these two warhorses, we offer the customer very versatile threading tools which are universally suitable for most of the materials.” shares Banerjee.

Shedding light on Master Titan, Banerjee says that it is best suited for milling in Titanium. “With a solid carbide tool for every milling application, Master Titan is the ultimate choice for highest cutting parameters with excellent tool life,” he says.

PolyWorks India: Opening the “Collaborative Suite” line of products

A

t this year’s show, the company is showcasing its flagship product PolyWorks Universal 3D Metrology Software. Specifically under this, it will be showcasing live demonstrations of Metrology Suite products used for Metrology/Inspection and Reverse Engineering applications. “The main attraction will be our ability to use a single software for 3D scanning, portable Arm CMMs and also Fixed type CNC CMMs of any brand,” shares Amar Kulkarni, Vice President, Sales, PolyWorks India.

What’s New: The company is opening the “Collaborative Suite” line of products and will be showing it for the first time to Indian customers. “This is a natural progression of our already successful Metrology Suite but promoted as an entirely new solution designed to assist our customers in their transition to modern digital collaboration workflows, in line with Industry 4.0 best practices,” says Kulkarni. According to the company, it is a product line that will help customers manage all their 3D inspection devices from a single platform and manage data/inspection results in a single interface.

To solve data-management issues and digitally interconnect all users of 3D measurement data, the company is offering the PolyWorks|DataLoop digital data storage solution. “It stores, manages, and shares PolyWorks inspection and reverse-engineering projects using a customer’s existing PLM solution. It also offers a universal Web interface to monitor, visualize, and analyze the 3D metrology results stored on the PLM from any PC or mobile device,” updates Kulkarni.

Amar Kulkarni, Vice President, Sales, PolyWorks India

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TECHNO FOCUS Elesa and Ganter India Pvt. Ltd.: Displaying Enhancements to Existing Product Lines

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lesa+Ganter is an innovative global leader in the design, manufacture and distribution of 60,000 standard machine elements. At IMTEX 2019, the company is displaying operating elements, machine elements, indexing elements; clamping knobs, clamping levers; U-handles, fixed, revolving, foldaway handles; control elements, rotary controls, levelling elements; joints, hinges, latches, hook, toggle and power clamps; tube clamp connectors, castors and wheels, retaining magnets; and accessories for hydraulic systems.

Ram Grover, Managing Director, Elesa and Ganter India Pvt. Ltd.

What’s new: Elesa+Ganter has a firm focus and is constantly engaged in the development of new and innovative solutions. At IMTEX 2019, the company will be showcasing many new additions in our existing product lines, i.e. castor wheels, sheet metal hinges, safety hinges, column level indicators, electronic position indicators, U-handles, indexing elements, telescopic slides, latches with safety functions, load rings, vertical toggle clamps, safety retractable handles, etc.

“We have products with specific properties for every application and our standard machine elements are designed to meet the needs of several industrial sectors like catering & food industry machines, printing & packaging machines, construction & material handling equipment, medical, chemical and pharmaceutical industries, textile machinery, and many more,” says Ram Grover, Managing Director, Elesa and Ganter India Pvt. Ltd.

Osborn Lippert (India) Pvt. Ltd: Showcasing Premium Polishing Products

O

Shirish Tambe, General Manager, Osborn Lippert (India) Pvt. Ltd

SBORN Lippert India Pvt. Ltd., established in 2002, develops, manufactures and markets polishing wheels, compositions and industrial power brushes, both standard and custom-designed equipment for grinding, deburring, surface finishing and polishing. Osborn products and solutions are used in more than 500 different industries, such as cookware, cutlery, heavy fabrication and engineering, automotive, aerospace, jewellery, metallurgy, oil & gas, retail & distribution, PCB, wood, shipyard, medical, construction, lockware.

At IMTEX 2019, the company is displaying premium polishing products.

“We are showcasing buffing wheels, polishing compounds, accessories for high gloss finishing; advanced products for weld cleaning & pipelines: knotted wire brushes & special brushes; premium solutions for deburring: Osborn Top Brushes; innovative solutions for flexible honing & internal deburring: Novoflex & tube brushes; and high performance rollers for metal processing,” informs Shirish Tambe, General Manager, Osborn Lippert (India) Pvt. Ltd What’s New: The company is especially focusing on showcasing its expert abrasive range, i.e. DRONCO. “We shall launch this new segment on the platform of IMTEX. Dronco currently owns the most advanced manufacturing technology for cutting & grinding discs. Our range of cutting & grinding discs, diamond tools, ceramic abrasives and technical brushes for professional craftsmen is produced in globally recognized high quality,” says Tambe.

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TECH TRENDS

DMG MORI combines

LASERTEC 3D &

LASERTEC SLM models with conventional CNC machines

As a full-liner for the additive manufacturing of metal parts DMG MORI combines its LASERTEC 3D and LASERTEC SLM models with conventional CNC machines

A

s a global full-liner with over 20 years of experience in the ADDITIVE MANUFACTURING of metal parts, DMG MORI represents innovative manufacturing technologies and a worldwide service. The portfolio includes four complete process chains for additive processes using powder nozzle or powder bed technologies. For this integral offer DMG MORI combines its LASERTEC 3D models and the LASERTEC SLM series with the machining centres from its broadly diversified machine portfolio.

Four complete process chains • Comprehensive: Powder bed (SLM) and powder nozzle (LMD) for all materials and geometries

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• Unique: Four process chains with ADDITIVE MANUFACTURING and machining from a single source • 20 years experience in laser technology in a powder bed • Holistic competence in the field of metallic 3D printing.

• LASERTEC 3D hybrid / LASERTEC 3D: » Success on the market with laser deposition welding using the powder nozzle technique » Multi-material applications and graded materials in one component » LASERTEC 3D hybrid: finished part in a single setup • LASERTEC SLM: » Unique rePLUG powder module system for fast material change in less than two hours

» Open system for individual adaptation of all process parameters and free choice of material manufacturers » Additive manufacturing in the powder bed with 300 x 300 x 300 mm build volume » OPTOMET as an intelligent software for setting all process parameters • CELOS: integral software solution from CAM programming through to machine control • Excellence Consulting for the efficient transfer of knowhow in questions of technology and process Potential of additive manufacturing The steady growth of additive manufacturing technologies is

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TECH TRENDS

The portfolio includes four complete process chains for additive processes using powder nozzle or powder bed technologies

Cannot be achieved conventionally: Functional integration and lightweight structures ensure shorter cycle times thanks to selective laser melting.

alerting designers to the potential of this method in the construction of components and tools. The quality of workpieces produced with additive methods is also increasing as is machining speed. This has resulted in consistently positive forecasts: ADDITIVE MANUFACTURING is expected to grow by 20 to 30 percent by the year 2020.

“In particular as a complement to conventional production methods powder nozzle and powder bed processes offer expedient and extremely promising possibilities”, explains Patrick Diederich, responsible for ADDITIVE MANUFACTURING at DMG MORI. With its broadly diversified machine portfolio in both machining and ADDITIVE MANUFACTURING

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DMG MORI’s approach to this topic is clearly holistic. Patrick Diederich goes on to tell us: “If additive manufacturing is to become established on the shop floor, it is essential to integrate this method into existing production systems and process chains – especially where successfully progressing from prototype and small series production to serial production is concerned.” Cost efficiency plays a key role in this respect. “It is imperative to awake an awareness for the possibilities offered by additive manufacturing, which start with the design of components and extend throughout the entire life cycle of the product.” This is the only way to exploit its enormous potential.

DMG MORI has performed

successfully on the market for over five years now with the combination of laser deposition welding and metal-cutting machining on the machines of the 3D hybrid series.

In addition to establishing and expanding the digital process chain DMG MORI has also developed to become a full-liner in additive manufacturing. While the LASERTEC 65 3D is geared solely towards laser deposition welding as a complement to existing machining centres on the shop floor, the LASERTEC SLM series expands the portfolio to include the powder bed method using selective laser melting.

Thanks to the combination of additive manufacturing technologies with conventional CNC machines DMG MORI has realised four

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TECH TRENDS

The portfolio includes four complete process chains for additive processes using powder nozzle or powder bed technologies.

about 45 percent smaller.

DMG MORI completes the process chains in laser deposition welding with NC programming in hybrid CAD / CAM with SIEMENS NX, technology parameters from a material database plus process monitoring and documentation.

“Different materials can also be combined in one build process in the two process chains with the powder nozzle, a capability that can give parts special properties”, adds Patrick Diederich.

individual needs-based process chains.

LASERTEC 3D hybrid: Additive manufacturing using a powder nozzle and conventional machining in a single set-up The LASERTEC 3D hybrid and LASERTEC 3D machines are available for users in the field of laser deposition welding with a powder nozzle. The first combine additive manufacturing and conventional machining in a single set-up.

The LASERTEC 65 3D hybrid is designed for the 5-axis simultaneous machining of parts measuring up to ø 500 × 400 mm. The LASERTEC 4300 3D hybrid enables 6-sided turn & mill operations for workpieces with sizes up to ø 660 × 1,500 mm. Designed for the complete machining of demanding geometries the LASERTEC 3D hybrid machines enable flexible changeover between laser deposition welding using a powder nozzle and mill or turn operations.

LASERTEC 65 3D: The right addition to the machines already installed on the shop floor A second process chain based on

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Global full-liner for additive manufacturing.

the powder nozzle includes the compact LASERTEC 65 3D for 5-axis laser deposition welding and a machining centre for final finishing of the additively manufactured components. This makes the LASERTEC 65 3D the ideal addition to the machines already installed on the shop floor, a combination that ensures optimum utilisation of production capacity. With travel paths of 735 × 650 × 560 mm the work area of the LASERTEC 65 3D is around 40 percent larger than the hybrid version and its footprint is

LASERTEC SLM series: Two process chains with additive manufacturing in the powder bed DMG MORI offers the LASERTEC SLM series for additive manufacturing in the powder bed (Selective Laser Melting). The LASERTEC 30 SLM 2nd Generation has a 300 × 300 × 300 mm build volume and with its Stealth design offers optimum user comfort, while the new LASERTEC 12 SLM is designed for the high-precision build of thin-walled components. It has a 125 x 125 x 200 mm build volume and a focus diameter of 35 µm. Two process chains can be realised with powder bed technology: On the

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TECH TRENDS one hand, workpieces produced by means of additive manufacturing can be finished to the required surface quality on a milling machine such as the 5-axis DMU 50 3rd Generation.

On the other, the LASERTEC SLM machines can finish previously milled base plates and bases without any need for support structures.

The integral software solution for CAM programming and machine control CELOS rounds off the process chains with the LASERTEC SLM series. The coordinated and uniform user interface enables parts to be programmed externally with minimum time expenditure and transferred to the machine – regardless of their complexity.

The flexible rePLUG powder module enables material change in less than two hours.

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Thanks to the efficient flow of information and intuitive operation CELOS ensures optimum processes in the pre- and post-processing of additively manufactured parts. In addition the open system of the LASERTEC SLM series enables individual adjustment of all machine settings and process parameters, right through to include an unlimited choice of material manufacturers.

DMG MORI has developed the software OPTOMET in cooperation with INTECH, for the control of the

process parameters in the powder bed process. It has self-adjusting and learning algorithms that calculate the required parameters of the SLM process in advance within minutes.

This means layer thickness can be calculated freely, which in turn enables a faster and therefore also more productive build. OPTOMET has a material database that allows users to use material from all manufacturers without having to test them in advance. The open system also allows independent expansion of the database using the customer’s own experiments. OPTOMET is also able to adapt parameters in such a way that material properties, such as hardness, porosity and elasticity, can be changed or optimised.

LASERTEC SLM series: Fast material change with the rePLUG powder module system Flexibility, productivity and process reliability are the outstanding features of the LASERTEC SLM series that make it an impressive machine on the market of additive systems for selective laser melting.

One highlight is the flexible powder module rePLUG. “This enables a material change in less than two hours. In addition the closed material circuit ensures a high level of work safety and process autonomy,” explains Mathias Wolpiansky, Managing Director of REALIZER GmbH. The ergonomic construction of the machine in the new Stealth design also reflects the principle that DMG MORI has been pursuing and optimising continuously for many years, namely making work easier for the user by ensuring better accessibility to all key control features. “This will make working with the machine more efficient in the long term.”

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TECH TRENDS

Intelligence in Automation Systems S R Venkatesh Reddy, DGM – Marketing, CNC India Pvt Ltd

F

or any organization to sustain and succeed further it is imperative how effectively and efficiently the combined potential of work force, process and technology is harnessed. Beyond the obvious benefits of lower labour cost, it is for the better the organization recognises and enhances the human value in removing the rule based and mundane activities.

The advent of intelligence in automation not only limited to machine tending, assembly etc but collecting steams of situational data from sensors, analyse and respond to the given task. With IOT & Cloud computing, a conventional setup can be transformed into a smart factory with multi-tasking machinery interconnected using Intelligent /IOT Sensors and smart devices.

A simple shop floor can be effectively monitored with cloud computing that provides virtual computing resources over the internet that helps in monitoring the production load, variants and real time deliverables. This effectively increases the productivity of the organisation and takes on the evergrowing demand of the customer of versatility with ease.

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The idea of intelligence in automation starts with • Understanding the expectation • Provide proof of concept • Robust solutions • Leverage the complementing tools • Make IT/IOT an integral part of automation • Plan for Sustainability CNC India focusses on intelligence built in automation for manufacturing sector from machine tending, assembly deliverables and removing the mundane activities and increasing the value of Human Resources.

The above is an illustration of how a simple machine tending automation, can effectively affect any change in volume, variants on real time basis based on the requirement of change. It also provides data of

the machine health, cut time, ideal time & preventive maintenance etc.,The intelligence built using IOT, cloud computing enables faster reach of information /storing of data and decision making – thus making the automation cell a closed loop manufacturing facility.

The below illustration is an example of how a simple manufacturing facility is built with intelligent automation.

A mechanism can be built to ensure component variants, seating, clamping and after finishing operation - is moved to the next cell.

By introducing IOT enabled sensors any change in production volume or component variants can be effected in real time thus effecting the versatility lean manufacturing and complete close loop information flow.

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TECH TRENDS

Faccin Group expands its line of products

F

accin S.p.A. is a powerful group that combines a number of leading brands â&#x20AC;&#x201C; Faccin, Boldrini and Roundo - in plate rolling, profile bending & dished-heads manufacturing, all united under one roof & offering a wide range of highquality options available in the metal forming market. Using the synergies provided by each brand, technically and commercially, the company is able to offer an even wider range of options and tailored solutions. We focus on providing metal forming companies with powerful, accurate, reliable equipment that are critical in increasing a return on investment.

tion lines including technologically advanced presses, flanging machines and manipulators and has developed a range of special machines in response to specific fabricating needs. www.faccin.com

FACCIN, The Trusted Partner in Metal Forming Machines Manufacturers around the world chose Faccin for their most challenging fabrication needs. Faccin assures long-term production benefits by delivering high quality products due to 100% in-house manufacturing & highly experienced support in its after-sales service.

Faccin is leader in the design, production and commercialization of the widest range of plate bending machines available today. Faccin also offers various types of angle rolls that satisfy the most diverse profile bending requirements, complete dished heads produc-

Roundo, precise profile bending roll

Faccin high capacity CNC controlled plate roll to automate production.

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ROUNDO, original Swedish design powered by Italian engineering

SWEDISH DESIGN, ITALIAN ENGINEERING

ROUNDO, a division of FACCIN S.p.A., is a leading manufacturer of section and plate bending machines.

Since its beginning in 1964 the number of machines sold around the globe has exceeded 16,000 units.

Roundo machines are known for their extremely high-quality, performance, reliability, and long service life.

Combining organizational skills, the resources of 3 manufacturing sites and more than 100 people devoted to bending machinery & technology, ROUNDO supplies technological advanced new machines & spare parts according to the original ROUNDO design. www.roundo.com BOLDRINI, metal forming machines since 1905 Boldrini, a division of Faccin S.p.A., is recognized as one of the leading suppliers worldwide of hydraulic dished end presses, flanging machines, plate bending rolls & section bending rolls for the metal forming industry.

Boldrini has been operating uninter-

Boldrini highly technological hydraulic press designed to increase productivity

ruptedly since 1905 & its products are synonymous with excellence, high performance, reliability and durability with over 10,000 successfully installed machines around the globe.

Boldrini machines double the maximum production capacity of any other manufacturer. This combined with a simple operation procedure and the use of only the highest quality components, makes the brand Boldrini the worldâ&#x20AC;&#x2122;s number one preferred choice. www.boldrini.com For which industrial sectors Faccin offers industry-specific solutions in the following sectors; pipelines, wind tower cans, tubes and pipes, tanks & silos, metal structures, road/railway tankers, metal fabrication, pressure vessels and heat exchangers, shipbuilding, earth moving, heat and ventilation, power generation, petrochemical, hydropower components.

The latest developments It is our core business to develop top technology to help manufacturers obtain the maximum from our machines and we realise Industry 4.0 is one of the ways to capitalise on the technology we already provide. Our machines are ready for Industry 4.0 thanks to SMART packages.

Why manufacturers trust in Faccin S.p.A. With a combined experience of more than 200 years Faccin has been delivering indisputable high-quality products to the main players in the metal forming industry in locations throughout America, Europe, Asia, Africa and the Middle East.

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BUSINESS NEWS

EMAG automation delivers industry standard for laser beam welding

Over the past few years, the EMAG ELC 160 has established itself as the “industry standard” for laser beam welding of precision vehicle components. Most of the dual-clutch or automatic transmissions introduced on the market now also include components manufactured on an ELC 160. Steering components and an increasing number of parts for electric vehicles, such as electrified axles, are also manufactured on the ELC 160.

T Andreas Mootz, Managing Director EMAG Automation GmbH

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he ELC 160 was designed from the outset as a production machine for serial manufacturing. Its kinematics— fixed machining position/moving workpiece—is the perfect basis for a precise and, above all, robust production solution. The ELC 160 is easy to automate and, owing to its modularity, offers the perfect platform for creating manufacturing solutions even for complex processes.

In addition to the laser welding “core process”, it also includes integrated joining with forcedisplacement monitoring (EMAG

EC Join) and inductive pre-heating of workpieces (e.g. for high carbon equivalent materials or unfavorable structural properties) using induction technology from the EMAG affiliate EMAG eldec Induction GmbH. A further patented highlight of the ELC 160 is its ability to retool automatically, i.e. controlled by the NC program. On the ELC 160, several devices (two of which will be exhibited at the AMB) can be set up in advance and then loaded “at the touch of a button.” This relieves the operator and reduces the retooling time to just a few seconds. However,

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TECH TRENDS what is much more important is that the destructive testing of a sample workpiece, which would be required after a manual retooling procedure, can be dispensed with. As a result, post-tooling idle times are avoided, which is particularly favorable for small batch sizes and thus maximizes efficiency. This applies all the way down to flexible manufacturing in a “one-piece flow.”

The machine that will be on display at the AMB is equipped with a newly developed welding head suspension (B/Z-axis), which enables the welding of workpieces with an axial or radial weld seam position (or at any angle in between), the angle being configurable in the NC. This further increases the ELC 160’s flexibility.

Future-proof The high precision of the ELC 160 surprises many “experts” and is often considered superfluous. By now though, its advantages are becoming apparent: Many developments in the field of laser technology in recent years were aimed at improving weld seam quality, minimizing spatter formation and reducing heat influx into the component and thus warpage, by increasing the welding speed.

All these developments taken

A further patented highlight of the ELC 160 is its ability to retool automatically, i.e., controlled by the NC program. Several devices (two of which will be exhibited at the AMB) can be set up in advance in the ELC 160 and then loaded “at the touch of a button.”

together show that today’s requirements in terms of welding system precision are in line with those of a precision machine tool.

This is where EMAG’s know-how in developing machine tools and also the EMAG Group’s competence when it comes to workpiece clamping produce their full effect.

Global support The EMAG Group not only offers highly productive manufacturing solutions for precision metal parts,

but also supports its customers, e.g., in developing their processes and optimizing their components: Not only are laser application labs maintained at the headquarters of EMAG Automation GmbH in Heubach, Germany, but also in North America (Farmington Hills, MI) and in China (Taicang). These are superbly equipped with machine technology and, above all, staffed with experienced employees who more often than not quickly reach the required results.

EMAG will be exhibiting an ELC 160 at the AMB trade fair. It features the newly developed welding head suspension that enables NC-controlled welding of both axial and radial seams (or at any angle in between).

For more information,

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TECH TRENDS

Why Precihole provides the best value The firm has introduced new Additions to Honing and BTA Deep Hole Drilling Technology Solutions

P

recihole Machine Tools is a global leader in providing hi-precision deep hole drilling and hole finishing technology. Our focus on this niche technology over the last three decades has made us a highly recognized brand with the most complete range of solutions offered in this technology.

Our strength is to be creative and customize an engineering solution that is perfectly suited to the needs of the customer. This is by no means an easy task, since deep hole drilling and hole finishing solutions have over 150 different applications spread across 20+ industries. Our business strategy revolves around customer success by combining a state-of-theart machine tool, application support and excellent service together in our offering.

Precihole solutions are most suited in Defense and Firearm, Oil & Gas, Automotive, Aerospace, Medical Implants, Seamless Tube Manufacturing, Energy, Die and Mold, Hydraulic cylinders etc. We pride ourselves in the ability to truly offer a world class solution and guarantee performance and productivity over the life of the product. We are an ISO 9000 certified company that values product quality, our customers and employees.

New solutions Precihole has recently introduced two

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completed redesigned machines to its portfolio. The first one is a Vertical Honing Machine which is highly precisely and productive at the same time. The machine is extremely easy to tool up and is designed to work in challenging work environments in a 24 X 7 mode.

The machine has a compact footprint and produces impressive results in terms of output parameters like surface finish, roundness and cylindricity. Installation takes just a few hours and training is a breeze.

This technology and machine find applications in Automotive, Energy, Hydraulic cylinders, Firearm, Oil & Gas, industries.

The second addition is to the line of BTA (STS) Deep hole drilling machines. These machines are

Precihole solutions are most suited in Defense and Firearm, Oil & Gas, Automotive, Aerospace, Medical Implants, Seamless Tube Manufacturing, Energy, Die and Mold, Hydraulic cylinders

capable of drilling holes from 12 mm to 400 mm up to 10,000 mm in depth.

The new patent pending features on this machine really produce top quality output. The machine is robust enough to allow high feeds in process and withstand the incredible torques experienced during cutting operation. This a complete solution that includes cutting elements, oil filtration, oil chiller, chip conveyor, chip shedder and an oil centrifuge.

This machine finds applications mainly in Military, Aerospace, Oil & Gas and Energy industries.

Continued innovation Precihole continues to innovate continually and bring new products to market. Our strategy is to spend time learning new application requirements from our customers and to invest in R&D. We work very closely with our tooling partners all over the world to ensure that our products keep up with new trends and developments in cutting tool technology. Our upcoming pipeline of cutting-edge new products will definitely continue to push the boundaries of this technology and energize the needs of the industry.

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TECH TRENDS

T

he main driver behind this development has been the aerospace industry because it must perform highly accurate machining operations on very large components. Machine tools would achieve the required level of accuracy with ease but are either too inflexible or too expensive as special-purpose machines for the job sites and working spaces involved. A robot, however, can easily reach any position on a very large component, such as the fuselage of an aircraft, and can perform tasks on it such as drilling and milling.

Accuracy is impaired by many factors For these kinds of applications, however, the tool center point (i.e., the tool at the end of the robot’s arm) must be positioned and guided with sufficient accuracy. This is where the classic industrial robot runs up against its limits. Deviations result from a variety of factors: • In order to achieve the desired level of maneuverability, robots with serial kinematics are required, such as articulated robots with six axes.

• Each one of these axes is driven by a servo motor with a gear train. Zero position error, backlash, and joint elasticities are the main sources of inaccuracy.

• Applied forces and dynamic effects during the machining process affect the rigidity of the robot’s mechanics and negatively influence the absolute position accuracy.

Thanks to advanced calibration methods, it is already possible to move a tool center point to a certain position repeatedly to within several hundredths of a millimeter. Depending on the manufacturer, the repeatability of articulated robots as per ISO 9283 is ±0.1 mm or better.

However, when compared with repeatability, the absolute position accuracy that can be achieved within

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Figure 1: Classic HEIDENHAIN rotary encoder for motor feedback

HEIDENHAIN Encoders for industrial robots Significant accuracy improvement at the tool center point Speed, power and durability are key characteristics of industrial robots. These robots are typically used in applications such as welding or in lifting heavy components for vehicle assembly. Yet despite advanced calibration methods, the position accuracy of industrial robots has been inadequate for certain tasks. This is now changing thanks in part to highly accurate, output-side encoders from HEIDENHAIN and AMO. the robot’s coordinate system is worse by a factor of ten. Depending on their design, maximum range, and maximum load capacity, articulated robots currently achieve an absolute position accuracy of ±1 mm. This is insufficient for meeting the accuracy requirements of industries such as the aerospace sector. Yet robot manufacturers have been responding to this problem.

Step 1: highly dynamic motor control Classic rotary encoders continue to provide the servo motor feedback at the robot’s axes. Because servo motors require high control dynamics, the robust inductive rotary encoders from HEIDENHAIN, such as those of the ECI 1100 and 1300 series, or multiturn models of the EQI 110 and 1300 series, are ideal for this type of application.

These encoders deliver high control quality and system accuracy, and they

are resistant to strong vibrations. Since these encoders feature a purely serial EnDat interface, even applications exposed to strong electromagnetic interference do not impair data transfer quality or safety. These inductive rotary encoders support safety integrity level SIL 2, category 3 PL d. They can even attain SIL 3, or category 4 PL e, if additional measures are taken on the control. These encoders also provided the added safety advantage of mechanical fault exclusion against the loosening of the shaft and stator connection.

With this safety package, these inductive rotary encoders can also be used in systems designed for human-robot collaboration.

Step 2: secondary encoders for highly accurate position measurement Robotics manufacturers can significantly improve the absolute position accu-

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TECH TRENDS racy of their robots by using additional, high-accuracy angle encoders or rotary encoders at every robot axis. These socalled secondary encoders, which are mounted after each gear train, capture the actual position of every robot joint.

This allows the encoders to account for zero position error and backlash. The retroactive forces on each axis resulting from the machining task are measured as well. All of this results in a 70 to 80 percent improvement of the absolute position accuracy at the tool center point.

Modular angle encoders, such as the HEIDENHAIN ECA 4000 with optical scanning, the HEIDENHAIN ECI 4000 rotary encoder with inductive scanning, and the AMO WMR angle encoder, are well-suited for these applications. Thanks to their modular design with a scale drum or scale tape

Figure 2: Improvement of the absolute position accuracy through the use of socalled secondary encoders on every axis

Figure 3: High-accuracy HEIDENHAIN and AMO encoders for absolute position measurement on robots

and a separate scanning unit, these encoders are well suited for large hollow-shaft diameters and for the challenging installation requirements often encountered in robots due to space constraints. The signal quality of these secondary encoders is considerably better than that of the rotary encoders on the servo motor, meaning that the returned position values are significantly more accurate—even for highly dynamic movements.

Step 3: accurate position measurement for movable robots In order to reach all of the machining positions on very large or long components, such as an aircraft fuselage or for manufacturing large composite fiber components, robots can be moved along the length of the component on linear axes. For the highly accurate

Conclusion: highly-accurate position measurement improves accuracy at the tool center point The use of secondary encoders on all of a robot’s axes, as well as the use of linear encoders for positioning the robot relative to the workpiece, enables a level of accuracy at the tool center point that allows appropriately equipped industrial robots to perform positionally accurate machining and handling tasks on components. Angle and linear encoders from HEIDENHAIN and AMO offer not only the required system accuracy but also the necessary flexibility for installation in complex and compact robot mechanisms. The suitability of these encoders for safety-related applications also makes it possible to implement human-robot collaboration systems.

ECA 4000

ECI 4000

WMR

Absolute, Optical

Absolute, Inductive

Incremental, inductive

For more information

Inside diameter 70mm to 512mm

90mm / 180mm

60mm to 10 000mm

Web: www.heidenhain.com

Resolution

29 bits

20 bits

Depends on the subsequent electronics

System accuracy

±2“

±25“ / ±40“

±3“ per meter of arc length

Resistance to contamination

+

++

++

Mounting tolerances

+

++

+

Scanning principle

Table 1: Comparison of the most important specifications for typical secondary encoders

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positioning of robots with a linear drive, enclosed linear encoders from HEIDENHAIN are available in lengths of up to 30 m. Position measurement from a linear encoder compensates for thermal errors and other factors that influence the feed mechanisms. These factors cannot be captured by means of conventional position detection methods based on the pitch of the recirculating ball screw and the angular position of the rotary encoder on the motor.

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Figure 4 : HEIDENHAIN linear encoders

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TECH TRENDS

Use of TIP-TIG Technology in Process Equipment Plants

by Rakesh Choudhary, Head WAPS, Ador Welding Ltd. (with inputs from Plasch, TiP-TiG, Austria)

T

IP-TIG welding is a new advanced innovation of the common GTAW Process. This process uses new, patent-pending technology (TiPTiG), that delivers the highest possible weld energy with the lowest possible weld heat, all while still being user-friendly.

What is TIP-TIG welding?

TiPTiG new welding with a hot wire process can be used in every industry. It is very simple to learn, use and simple to teach. This process is so unique that higher travel speed, lower heat input, reduced cycle time, and an overall better-quality welding advantage can easily be achieved.

The Process The TIG weld receptivity for higher weld deposition rates is done by decreasing the speeds for the weld solidification process and increasing the fluid weld area. This allows for a 100%-400% increase in TIG wire feed rates, increasing the overall weld deposits. All these attributes like faster speeds and higher than normal weld energy, increase the resulting TIG weld quality and overall process productivity.

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The process is also slag-free and uses the lowest possible heat input of any welding process, producing a Heat Affected Zone (HAZ), all of which help to reduce distortion and weld stress. It produces some of the highest quality products with the best metallurgical and mechanical properties on all alloys, but also increases production up to four times the normal speed. There is also no inter- pass cleaning, creating availability for an increased Arc on time and weld quality.

The TIP TIG process is available in manual and automated capability to attain weld and clad quality levels way beyond the conventional TIG – Hot – Cold Wire TIG – Pulsed MIG

Fig.3

and the Flux-Cored process.

How it Works A TIP TIG welding system uses a wire fed GTAW system just like a typical TIG system, but it’s distinctive for the vibratory effect on wire at weld pool which is achieved by a linear forward and backward mechanical motion created by the customised wire feeder system. The forward and backward motion of the filler wire creates an oscillation that is then transferred to the weld, agitating the molten weld pool and ultimately disrupting the surface

Fig.1

Fig.2

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TECH TRENDS tension. In addition to this vibratory effect on the wire, a hotwire current (powered by a secondary power source) is also applied to the filler metal, prior to entering the weld puddle. The two pictures (fig. 1 & 2) describe the weld finish with Manual GTAW & Manual TIP-TIG process.

ChampTig 400P Power source from Ador Welding with the TipTig wire feeder.

Benefits of the TIG-TIP process • Increased fluidity of the weld pool • Greater tolerance to joint fit-up • Significantly reduced joint sensitivity • Greater ability to accept more wire into the weld pool, results in a higher deposition • 4-6 times increased travel times • Reduced cycle time and heat input • Cleaner welds with agitated weld pool • Reduced weld stress with the reduced heat input Approved Alloys TiPTiG welding can work on a wide range of alloys such as carbon steel, stainless steel, duplex and super duplex stainless steels, inconel, titanium, aluminium, copper, nickel, and many other critical materials like P-91, which are used in process plant production.

Heat Exchangers Heat Exchangers are commonly constructed from low Carbon Steel, Copper, Copper-Nickel, Stainless Steel, Hastelloy, Inconel, or

Fig.4

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Titanium. There are certainly some unique applications and challenges associated with the welding of heat exchangers, such as the position and access for the popular circumferential welding of Tube to sheet welds or the half tube shell welding.

A trained TIP-TIG welder can typically weld a 50mm tube in 30 seconds… or less with the highest quality and lowest heat input. Our typical travel speed for fillet welds will be between 300 to 500 mm/min on most applications. Compared with 80 to 150 mm/ min with conventional GTAW. TiPTiG manual system is a low cost semi-automatic solution to tackle any job by selecting a wide variety of torches for different applications, with modified 180 deg torch it allows a complete tube sheet welds without repositioning the wire or stopping, allowing for defect free welds.

The typical customers in the manufacturing and repair of various sized heat exchangers are in power plants, chemical plants, petrochemical plants, petroleum refineries, natural gas processing, and sewage treatment.

INCONEL CLADDING Normally, when you manually clad the end of a pipe ID with Inconelusing Pulsed MIG as shown in the picture and result is often not so good. However when we use TIPTIG, the results are visible as shown on the mentioned pictures.

In the pictureTIP-TIG cladded Job, TIP -TIG Inconel 800 pipe was welded with Inconel 82 wire on 10 inch pipe 3/4 Wall. The TIP TIG weld cycle time for the Inconel pipe was 40 – 50 minutes, whereas the customer used to take around 4 hrs with regular TIG. When your weld process can weld a complex incoloy*

Fig.5

pipe and make the welds look simple, that’s a process that should be given consideration. With TIP-TIG, no brushing, no grinding, no spatter, no weld rework, no feeding of wire, no foot control, less skills. Note weld smoke prep machining lubricants. (*Incoloy refers to a range of superalloys produced by the Special Metals Corporation group of companies. They are mostly nickelbased, and designed for excellent corrosion resistance as well as strength at high temperatures; there are specific alloys for resistance to chemical attacks)

Fig.6

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TECH TRENDS Duplex Steel Welding Applications Application The picture (fig.5) is of a very thin Gage Duplex Boiler. Traditional automated TIG process with cold wire may result in sluggish duplex welds.

The customer typically attained a maximum Hot Wire TIG weld travel speeds from 12 – 15 inch/min.

Then the customer switched over from Hot Wire TIG to the TIP-TIG process. The TIP TIG weld parameters and speeds were achieved using an 0.035 (1mm) 2205 Duplex wire, with TIP-TIG travel speed of 35 inch/min was achieved providing 200% increase in weld travel. The welds had a superior, less sluggish weld bead appearance and the parts had a dramatic reduction in weld distortion, (note the much smaller HAZ). Also the TIP-TIG process was much more stable and consistent.

TIP-TIG produces the cleanest welds from lowest possible oxidation. The welds will have the lowest possible weld pores and inclusions and the smallest possible weld HAZ. Welding of P-91 Material Welding of Grade 91 (9Cr-1Mo-V) chromium-molybdenum steel has presented numerous challenges since its introduction inthe 1970s. The gas tungsten-arc (GTAW) process can produce welds of high quality;

however, manual welding can be expensive and labour intensive, requiring skilled welders with extreme hand-eye coordination and dexterity. Grade 91 productivity can beincreased in either shop or field fabrication by introducing a semiautomatic high deposition metal transfer (HDMT) GTAWwelding process that combines controlled excitation of wire with a hot wire addition. This technique is costeffective and can beused for the entire weld from root to cap while producing high quality welds that industry expects from the GTAW process.

With TiP-TiG weld study, it indicates that semiautomatic HDMT GTAW welding process is capable of producing toughness valuescomparable to or exceeding manual GTAW and that the process provides an attractive alternative for welding P91 root and hotpasses or the entire weld from root to cap.Results of this study indicates that semiautomatic HDMT GTAW welding process is capable of producing impact valuescomparable to or exceeding manual GTAWT. The process also provides an attractive alternative for welding P91 root and hotpasses or the entire weld from root to cap. The semiautomatic HDMT GTAW welding process permits an increase in energy(heat input), larger weld puddle and increased deposition rate while still

Fig.7

Fig.8

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providing tempering of the previously deposited weldbeads or layers.

TIP-TIG HDMT (HIGH DYNAMIC METAL TRANSFER) FOCUS TIP-TIG HDMT FOCUS is a unique TIP-TIG welding process. Its precision and reliability make the TIPTIG HDMT FOCUS welding process particularly suitable for automatedapplications in combination with linear axles, robots and other guiding systems.

Nearly all steels, non-ferrousmetals or galvanized sheets can be welded in one layer with filler material; e.g.

CrNi-steels with a material thickness of up to 10 to 12 mm can be welded in single pass without any Joint preparation. Some of the welded examples are listed below. it has resulted in elimination of backing gas in austenitic stainless steel welds using high deposition metal transfer gas tungsten-arc welding(HDMTGTAW) TIP-TIG HDMT FOCUS PROCESS Example • Material: CrNi 8+8mm • Weld current: 500A • Weld speed: 46 cm/min • Wire feed speed: 2,0m/min Details of Welded Samples • Material: CrNi 10+10mm • Weld current: 500A • Weld speed: 32 cm/min • Wire feed speed: 1,8m/min TIP-TIG REDUCED COSTS BY OVER 60%, WHEN COMPARED WITH CONVENTIONAL TIG PROCESS TIP-TIG Cost Comparison The following comparison shows the actual savings calculated on a real stainless-steel welding application comparing conventional TIG and TIP-TIG on a pipe application (2” Sch 80 Stainless) in the 5G position.

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TECH TRENDS

Variable / Results

Units

Conventional TIG

TIP TIG Process

Welding process

GTAW

GTAW

Wire type

ER308L

ER308L

Wire size

mm

2.4

0.9

Wire deposition speed

mm/min

100

1900

Melt off rate

g/h

200

580(3 times)

Deposition efficiency

%

100.00%

100.00%

Deposition rate

g/h

200

580(3 times)

Duty cycle

%

100.00%

100.00%

Final deposition rate

g/h

200

580(3 times)

Argon

Argon

Gas type Flow rate

cfh

30

30

Gas/Wire ratio

cf/g

63.05

23.62(60% Reduction in gas per gm of wire)

The above data shows, the deposition rates approx. 3 times to standard TIG process which reduces the production costs by 60%.

Conclusion TIP-TIG is an innovative TIG process and good alternative to standard gas tungsten-arc (GTAW) process. Its versatility and simplicity makes the manual welder to give higher output.

The Automated High Deposition Metal Transfer (HDMT) GTAW welding process that combines controlled excitation of wire with a hot wire addition and gives very

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promising results to challenging applications.

Plant equipment manufacturing, wherever GTAW is applicable, is possible to be replaced by TIG-TIG process which gives very high output without compromising on quality. The success in P91 welding with TIP-TIG, also increases the application possibility in that area.

References: 1. Paper on ‘ACHIEVING TOUGHNESS IN P91 WELDS FROM ROOT TO CAP USING SEMIAUTOMATIC HIGH DEPOSITION METAL TRANSFER (HDMT) GTAW WELDING PROCESS ‘ by Charles W. “Pat” Patrick 2. Information from TiPTiG USA 3. Information from TiPTiG International AG .

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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  Ethernet GigEVision/RS422  Direct connection to PLC  Red laser / blue laser

+91 20 2674 1009 | info@micro-epsilon.in | www.micro-epsilon.in

TECH TRENDS Engineering focused on fast, light automation systems may pay too much attention to speed specs when acceleration is what really counts.

L

ook through the specifications of any linear bearing, and you’ll come across a maximum speed.

It’s an important spec, but not nearly as important as many engineers think it is.

Speed does play a role in bearing life. Consistently moving loads above a bearing’s speed limit can result in premature wear. It is also possible, usually though a control error, to drive a bearing so fast that it will fail. For example, recirculating ball linear guides can experience end cap failure when driven at high speeds or accelerations. And roller bearings can freeze up at extremely high speeds.

Yet these over-speed conditions are rare in well-designed motion system.

What’s more, bearing speed is rarely the limiting performance factor in today’s motion applications. Standard linear bearings can handle speeds of 3 m/s without any difficulty, while highperformance models can reach 5 m/s.

Some bearings are even faster, with top speeds approaching 9 m/s. The majority of automation applications, meanwhile, run at top speeds well under 5 m/s.

So if today’s bearings have speed to spare and overspeed conditions are rare, what good are speed specifications? The answer is that speed doesn’t tell us all that much as stand-alone value. Only when considered in the context of acceleration and the overall motion profile does speed become important.

ACCELERATION CONSIDERATIONS: There is a connection between speed and acceleration beyond their

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Understanding Linear Bearing Speed & Acceleration mathematical relationship. Bearings that are engineered to withstand high speeds also tend to be robust enough to withstand high acceleration and vibration forces. These are the forces that make or break most realworld motion applications. Acceleration and its rate of change (or “jerk”) are the chief determinants of a motion system’s stability and ability to hit position targets. When control engineers do overtax a linear bearing, excess velocity is rarely the culprit.

More typically, the engineer has pushed the system past its ability to handle acceleration, deceleration or vibration forces. In mild cases, this condition can manifest itself as

skidding, which can increase wear and shorten bearing life. In extreme cases, excessive acceleration may result in catastrophic bearing failures.

WORKING WITH THE MECHANICS: Control engineers can obviously limit these forces when they program a motion profile, but only if the profile realistically relates to the bearing’s mechanical limitations. All too often it does not. Motion profiles are routinely created around speed targets without reference to the fundamental limitation of the mechanical components. When this disconnect between the motion profile and the mechanical components happens, no

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Linear solutions global provider.

C

M

Y

M

MY

Y

MY

K

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.

Bangalore, India January 24-30, 2019 Hall 3B, Stand C104 ROLLON India Pvt. Ltd. - INDIA 1st ďŹ&#x201A;oor Regus Gem Business Centre 26/1 Hosur road, Bommanahalli Bangalore 560068, INDIA www.rollonindia.in - info@rollonindia.in

TECH TRENDS

Connection between speed, acceleration and motion profile.

amount of drive tuning will help. And keep in mind that not all the remedies for acceleration difficulties involve the motion programming.

Preloading the bearing, which is purely a mechanical process, can help too. Some amount of preloading is often desirable because it removes excess clearance between the rolling elements and the rail surfaces, eliminating uneven contact conditions and minimizing wear.

As acceleration rises and skidding becomes a risk, keeping the rolling elements in contact with the rail at all times becomes even more important.

Increasing the preload also makes the system stiffer, which helps improve positioning accuracy when acceleration, jerk and vibration forces are high. In general, high acceleration applications demand a higher preload.

But there are a couple of trade-offs in that preloading reduces the bearing’s load carrying capacity and increases wear. These trade-offs can be kept to a minimum by experimenting to optimize the preload levels. There is usually a level at which the needs of an aggressive motion profile can be met without sacrificing much load carrying capacity or life expectancy.

Experimenting with different preload levels will require some physical adjustments to the bearings.

And not all bearing systems make this task all that easy. Some systems have their preloads determined by their factory set-up.

The preload on recirculating ball guides, for instance, relates to the size of the ball bearings in relation to raceways. Changing the preload on these systems typically requires

changes to the slider, the rails or both. Other bearing styles allow simple preload adjustments in the field. Rollon’s Compact Rail system can be adjusted from outside the rail by turning screws that compress the rail flanges. Aside from allowing adjustments without removing the slider from the rail, this system allows localized fine-tuning. Preloads can be set higher in areas where high dynamic loads occur, for example, where the carriage reverses direction.

Minimizing the amount of the rail subjected to higher preloads reduces the wear effect accordingly. It may always be tempting to look at a linear bearing’s maximum speed to see if it will do the trick in a fast motion system. But focusing solely on speed without regard for the underlying mechanics of the linear bearing system will only slow you down.

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 info@rollonindia.in www.rollonindia.in

The right preload level will help to achieve the desired motion profile without sacrificing load capacity or reducing life expectancy

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TECH TRENDS

‘How lubricants can help in improving Machine Shop’s performance’

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ith manufacturing activities taking a centre stage in India over the past few years, the sector is on a strong growth trajectory. Extensive use of technology and modern machinery form the base for these manufacturing set-ups. However, optimization of productivity and reduction of downtime still remain a concern for the sector.

In order to attain advanced productivity, manufacturing setups should consider solutions which focus on improving the performance of the machine tools.

ExxonMobilTM, is committed to offer a range of lubricants that are reliable and ensure optimal operational

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benefits to the customers, thus driving increased productivity and profitability for them.

ExxonMobil has established itself as one of the leading companies to provide lubrication for heavy machinery and services to increase the life time of a machine shop. In addition to the high performance lubricants and fluids, Mobil also provides a range of technical services to help keep the machine shop running at peak efficiency - also extending the life of the machine, reducing downtime and lowering operating costs.

With commitment to the core business ethos of Advancing Productivity, Safety and

Environmental care, Mobil has a portfolio of lubrication solutions and technical services that are tailor made for the Machine Shop segment.

A few of Mobil’s key offerings are: Slideway Oils: Poorly formulated slideway oils may not separate readily from aqueous coolants. This results in the formation of ‘tramp oil’ which compromises the effectiveness of the coolant by shortening its effective life and adversely altering cutting performance. Tramp oil can also lead to bacterial growth resulting in foul odour, short service life and potential health as well as safety concerns.

To identify high performance

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TECH TRENDS slideway oils, maintenance professionals should seek out products such as Mobil Vactra™ Oil Numbered Series of slideway oils with the following performance characteristics: Exceptional coolant separability which enhances the performance and life of water based metal working fluids, outstanding frictional properties which enable increased machine accuracy and reduced chatter, and stick-slip.

Mobil Vactra Oil Numbered Series are premium-quality slideway lubricants specifically designed to meet the requirements for accuracy, aqueous coolant separability, and equipment protection of precision machine tools.

Water Soluble Cutting Fluids: To optimise productivity it is very important to choose technologyleading aqueous coolants. The highest performing coolants can reduce maintenance requirements by resisting biological attack thereby extend batch life. Ease of maintenance needs to be balanced with performance as well as protecting the Machine Tools components from corrosion and sticky deposits. In addition, the fluids should meet the latest Health and Safety regulations, be easy to monitor and maintain in service.

Collectively, these properties will help deliver long service life, excellent cutting performance and reduced maintenance downtime.

The new Mobilcut™ series from ExxonMobil, comprises of milky emulsions, high performance micro-emulsions and a fully synthetic grinding fluid. The high performance, long life semi-synthetic cutting fluids in particular have been designed to meet the wide variety of applications and operations found

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in medium to small sized Machine Tools.

Mobilcut 250 is a high performance semi-synthetic fluid formulated to enhance performance when machining aluminum and aluminum alloys and where low staining potential is important on sensitive components. Containing high levels of lubricity agents, it provides high machining performance of carbon and alloy steels and yellow metals.

Neat Cutting Oils: Neat or straight cutting oils are used in applications which are beyond the typical performance profile of aqueous coolants, such as tapping and threading of high alloy steels. They improve machining in high speed automated machining centres through outstanding cutting performance, reduced tool wear and enhanced surface finish. Ideally they should be light coloured to allow clear visibility of the workpiece; have low misting characteristics to help workplace safety and product usage; and are chlorine free to support environmental concerns,

while balancing with a high degree of lubricity and machining performance.

Specially designed to meet the increasing demands of today’s sophisticated machining centres, tooling trends and health and safety regulations, Mobilmet™ series of cutting oils and the new series of Mobilgrind grinding oils from ExxonMobil have been developed for applications where excellent surface finish, high precision machining and improved productivity are the primary objectives.

Spindle oils: Spindle oils are used for high speed spindle bearings and equipment where high speeds and fine clearances are involved. It provides exceptional lubrication of closetolerance bearings which helps keep the bearings running cool and helps maintain the precision required by many of today’s critical machine equipments. These are designed for spindle bearings, they exhibit the required properties to function as low pressure hydraulic and circulating oils as long as the proper viscosity is selected. This feature helps minimise inventory costs and reduce the potential for product misapplication.

The Mobil Velocite™ oils are premium performance products primarily designed for the lubrication of high-speed spindles in machine tools. They are also used in some critical hydraulic, circulation systems and air line oilers where the appropriate viscosity grade is selected.

For more information on Mobil Industrial range of lubricants and services, visit mobil.com/industrial

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TECH TRENDS

DesignTech works as a ‘Mech-in-India’ Partner to the World’s First Nuclear Fusion Reactor

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esignTech has had an opportunity to make valuable contributions in an internationally recognized multicountries collaborative project of building World’s first Nuclear Fusion Reactor.

ITER (International Thermonuclear Experimental Reactor) is an international Body that comprises of 7 countries coming together to build one of its kind experimental nuclear fusion reactor.

India’s involvement The Government of India nominated and funded an Indian agency, Institute of Plasma Research, Ahmedabad, to manage and oversee the execution of part of the project that was assigned to India. This state funded agency, formed a separate subordinate organization, ITER-India to dedicatedly assign, manage, and review the tasks through the network of services partner vendors. ITERIndia selected DesignTech as one of the partner vendors to work in the field of and furnish mechanical designs, and conduct Virtual validation of various systems and subsystems. DesignTech also had to extend the required manufacturing support and guidance to the systems manufacturing Partner in India. These sub-systems were to be designed and manufactured in India and structurally integrated into the main reactor to be installed in France.

Having been consigned with the responsibility of ‘design-formanufacturing’, DesignTech had to evaluate manufacturing feasibility of the parts of the sub-systems designed, and work with the manufacturing

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partner accordingly to support and guide them in manufacturing planning and execution.

Challenges: • Lack of reference material: Being the first of its kind project, there was no past reference material that could be used to understand and strategize the execution of such a vast and ambitious assignment.

This being the world’s first experimental nuclear fusion reactor,

lot of studies had to be conducted, numerous ‘what-if’ and worst case scenarios had to be considered to anticipate and plan for the imminent challenges that could be encountered while executing this mammoth engineering venture.

• Extensive Collaboration: It wouldn’t be an exaggeration to say that this could very much be one of the biggest concurrent engineering assignments in the world; requiring extensive collaboration and collective efforts with the organizations in other countries and IO (International Office), in terms of apprising other partners with updates on tasks progressions, regular knowledge and data sharing about key insights, learnings, findings, deviations if any, and discussing consequent improvisation of execution plans and strategies.

• Project Management: Concurrent engineering, manufacturing execution and reactor erection would require perfectly congruous tasks progression. Seamless implementation of the project entailed breaking down of big tasks to the tiniest of details and minutest of action items with frequent monitoring and inspection.

Selection and Task Delegation DesignTech was chosen through a bidding process and after conducting detailed technical capabilities evaluation. DesignTech was selected as a mechanical design and engineering partner charged with the responsibility of working on detailed product engineering including design, virtual validation and design-

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Solitaire No. 2 - 10" (250 mm) Precision Centerless Grinder

INDIAN ENTERPRISE

AMERICAN RIGIDITY

ITALIAN INNOVATION

Combined to give you Customized Centerless Grinders Solitaire Machine Tools Ltd. 292, Dharamsinh Desai Marg, Chhani Road, Vadodara - 390002, Gujarat, India Tel.: +91-265-2761776, +91-265-2773585 Email: sales@smtgrinders.com www.smtgrinders.com

TECH TRENDS for-manufacturing of various subsystems. This required the company to contribute in: Design and Development: • Ideation and conceptual designs of certain parts and components • Preparation of detailed parametric and engineering designs through the reference data provided by the Principal Body – keeping in mind design guidelines, packaging and manufacturing aspects, product performance objectives, and logistics consideration to transport the manufactured parts to France to be integrated in the mainframe of the Reactor.

Analysis and Simulation: • Conducting detailed product design and engineering analysis through virtual tests and simulations to identify design fallacies or errors if any, evaluate systems functioning to predict failures and enhance performance.

• Performing structural analysis and design optimization was crucial to maintaining the overall structural integrity of the sub-systems so as to ensure and prevent any adverse causal compounding impact to the overall structure.

• Design optimization facilitated in streamlining agile and lean manufacturing processes through diligent use of resources thus helping to achieve greater operational efficiency • The team of engineers had to use their expertise in the fields of advanced CAE applications such as electromagnetic analysis, thermal analysis, structural analysis (including static, modal and vibration analysis), piping simulations, and design-formanufacturing for ensuring desired results and required quality output.

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Geometric Dimensioning and Tolerances analysis: • The team had to work within extremely strict tolerances that limited the scope of deflection or warpage to be contained within the specified target in few millimetres.

To ensure this level of high precision and accuracy, the team had to work on critical geometric dimensioning. This required the team to design the special fixtures that would be fabricated into the sub-system to withstand the anticipated forces and loads under all conditions and circumstances.

Manufacturing processes, assembly mechanisms, and design constraints with respect to the peripheral structure had to be meticulously deliberated while working on these fixture designs. The structure had to be considered in its entirety while working on one of its aspects, making it an intellectually stimulating exercise.

• Considering the time and costs involved in reiterative designs and analysis processes, the team had to work on getting the designs right the first time, as the cost of error would be humongous.

Design-For-Manufacturing: • Optimal manufacturing processes had to be configured after careful study of product designs. Effects

of manufacturing on the material properties of the products had to be also duly analysed to prevent design deviations. In case of anomalies, manufacturing process had to be revisited, and redefined to achieve the desired output.

• Detailed manufacturing drawings had to be prepared and submitted to the other partner from India appointed by ITER-India that was tasked with the manufacturing responsibility. DesignTech worked closely with this Manufacturing partner to duly execute manufacturing operations based on the ‘design-for-manufacturing’ specifications of the sub-systems and fixtures that were worked out in conjunction with them.

Meeting Compliances standards: • The team had to abide by all the requisite and stringent international and nuclear design codes, norms and standards such ASME and EJMA. DesignTech’ s involvement panned across and expanded beyond the stipulated sub-systems engineering design and advance CAE validation; traversing into the specialised areas of geometric tolerances studies, Digital mock-up studies, manufacturing feasibility studies, and fixtures design for achieving greater structural robustness. The team worked on and supported this project for over 10 years. At any given point in time, a maximum of about 40 engineers were dedicatedly working on this pioneer project of international scrutiny DesignTech’s contribution in this paradigm shifting engineering project was well appreciated by the Principal international body and associated industry fraternity. The success of this reactor would imply end to the world’s energy crisis.

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TECH TRENDS

TwinSAFE: consistently modular, scalable & distributed safety applications Reduced hardware and engineering costs through new generation of safety controllers

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ith its focus on increased modularity and scalability, the new generation of Beckhoff safety controllers allows optimum adaptation to the specific safety requirements of individual machine concepts. The ability to distribute the intelligence of an entire safety application across multiple TwinSAFE Logic-capable I/O modules enables the flexible implementation of increasingly modular architectures that can be adapted to given system requirements even more effectively than before.

With the new safety controllers based on the EL6910 TwinSAFE Logic, it is possible to adapt the TwinSAFE system even more specifically to the individual requirements of a machine concept as well as to a broader spectrum of safety applications. The new I/O components include: • TwinSAFE EtherCAT Terminal EL1918: digital terminal with eight safe inputs • TwinSAFE EtherCAT Terminal EL2911: safe potential supply terminal with four safe inputs and one safe output • TwinSAFE EtherCAT Box EP19570022: IP 67-protected digital combi module with eight safe inputs and four safe outputs More options for distributed safety applications Just like the TwinSAFE Logic-capable I/O and motion products that are already available, the three new I/O modules can be used as controllers for the direct execution of customer-specific safety projects. A special feature is their communication capability,

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With the new TwinSAFE controllers, distributed safety applications can be implemented more efficiently, i.e. with minimum engineering and cost requirements.

because like a dedicated controller, the safety project to be executed on the corresponding I/O component can establish direct communication relationships with other safety-relevant devices & preprocess the data internally.

This makes it possible to implement highly granular machine modules with distributed safety applications. The central safety controller, if it exists in the application scenario, only needs to process the data that has already been accumulated.

The consistent hardware and software modularity TwinSAFE system simplifies the implementation of even very complex safety applications, and the combination of I/O and TwinSAFE control functionalities in a single I/O component makes it easier to distribute safety tasks across individual machine modules. It also reduces hardware costs. In terms of engineering, the

customizing function speeds up the process and makes it more convenient.

It also ensures minimum validation effort, which in turn further reduces the development costs.

More efficiency through customizing Safety projects can be modularly designed in TwinCAT as usual. However, with the new customizing function, the operating modes “temporary deactivation”, “permanent deactivation” and “passivation” can now be configured for each of these modules. With the corresponding configuration of replacement values for the interfaces between the different modules, users can thus implement highly complex, modular and scalable architectures while reducing their development costs. For example, a single safety project can be used for an entire family of machines by simply deactivating any modules that may not be needed according to the given requirements.

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TNC 640 â&#x20AC;&#x201C; 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 turningâ&#x20AC;&#x201D;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

TECH TRENDS

YASDA - Ultra Precision

Machining Solutions

World-Class 5 Axis Machining Center - PX30i

Machine Model - PX30i

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ASDA developed the 5-axis high precision vertical machining center PX30i to supply customers with a top quality, highly reliable machine tool for the machine shop market, and OEM users in high end automotive, aviation, medical equipment. YASDA has focused on precision, reliability, automation and versatility all at a cost effective price for this high precision 5-Axis machining center.

The PX30i is outstanding in versatile 5-axis applications, precision in parts, drilling, face milling, boring,

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milling from and excellent for hardened steel, tough materials like titanium and inconel. The PX30i has an excellent design for automation, usability and productivity.

Unprecedented popularity PX30i has become popular in Japan, USA and European market due to its unprecedented machine design features and specifications. PX30i has large work envelope. The PX30i has highly rigid integrated portal structure for superior precision and heavy duty cutting. The machine has symmetrical

construction for minimizing thermal deformation. Equipped with a highly rigid and high precision B/C-axis tilting rotary table unit is mounted on Y-axis, minimizing weight differences in movable bodies of each axis, and setting the heavy movable bodies to lower center of gravity. The C-axis has Direct Drive precision motor. The machine has superior precision linear roller guides and mounted at the straightness of 1 micron.

YASDAâ&#x20AC;&#x2122;s unique technology of the preload self-adjusting spindle that applies a large preload at lower-speed

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Ever since the inception in 1993, CNC India has been in the forefront working extensively on new concepts, new solutions and Intelligence in Automation Systems. CNC India has understood the dynamic market trends and growing demands of customers to offer cutting edge solutions. In order to provide a simple yet effective and economic intelligent automation solution for customers, CNC India will be showcasing an integrated solution of Machine Tending Inspection and Assembly related intelligent automation including the IOT’s of the next generation at

IMTEX 2019 : Hall – 1A, Stall No B116 24 - 30 January 2019

Hall - 1A, Stall No. B116

24 - 30 January 2019 Bangalore International Exhibition Center (BIEC)

Corporate Office : #64, ‘A’ Wing, 3rd Floor, Parimala Tower, MES Road, Yeshwanthpur, Bangalore – 560 022, Telephone : +91-9845079769, 9880215189, 9980945068 Works : #A320, 7th Main Road, Peenya Industrial Area, 2nd Stage, Bangalore – 560 058 Telephone : +91-80-28367838, www.cnc-india.com, enquiry@cnc-india.com

TECH TRENDS rotation while preload decreases in accordance with the amount of heat generation of the spindle bearings at high-speed rotation. A two coil type spindle motor is employed for realizing both high speed and low speed rotation at high torque drive.

In addition, the slim nose shape ensures good accessibility to workpieces. Cooling oil is circulated in the spindle and spindle motor to ensure minimum amount of heat is generated at heavy duty cutting.

PX30i is designed to meet global top requirements in automation, consistent production. ATC Tool capacity of 323 tools allows long time continuous machining and large volume production. ATC operation is through easy to understand icon based touch panel system. The machine has a standard 33 Sets of pallets with stocker system, largest in its class to allow 24 hours unattended production even on holidays. PX30i also use latest, unique operating

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The PX30i is considered as a workhorse for customers with the most demanding accuracy, quality and diversified production requirements system connecting operator and machine in most modern way.

Outstanding accuracy PX30i has achieved outstanding accuracy of 3.1 microns of circularity in a tilted cone machining test according to NAS979 standard, which is commonly used for simultaneous 5-axis machining accuracy. PX30i has optical scale feedback for precise positioning.

The PX30i has many optional features of tool length/ radius probing,

Thermal displacement compensation, and many more to allow longer unattended production with highest possible precision.

The PX30i perform different kinds of high accurate face machining, 5-axis simultaneous machining, hence it is considered as workhorse for customers with the most demanding accuracy, quality and diversified production requirements of high mix of parts with various sizes and complicated shapes. Arhan Technologiesâ&#x20AC;&#x2122; Machine Tools division will support sales & service of these machines in India.

For more information YASDA machines E-mail: mtd.support@arhan.co.in

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Visit us at :

Hall: 2A, Stall: A121 24 - 30 January 2019 Bangalore, India

TECH TRENDS

Sanyo – A Trusted Name in Broaching, Transmission Parts Machines

S

anyo Machine of Japan is a Unique manufacturer in both Machine tools and Automation Solutions, ready to help you in diverse, precision, and sophisticated machining requirements.

Sanyo is a specialized and highly trusted name in manufacturing of Broaching, Gear Checker, Deburring/ Chamfering, Rack Rolling, CVT/ Net Shaped Parts Machining, Gear Grinding, Cutter Re-sharpening machines. Sanyo’s reliable machining ensures high performance through increased productivity, consistent quality and throughput with rich knowhow of 32 years at Japanese automobile industry.

Sanyo is Japan’s No. 1 Broaching machine manufacturer and manufactures the complete solutions in Broaching Machines that include, CNC Servo Broach, Hydraulic Broach, Surface Broach, Helical Broach, Hard Broaching machines. Both Table moving and Tool moving types are available to meet customer’s requirements. All broaching machines come with options of Multi-Station Broaching, Broach ATC System, Complete Automation, Cutter Burr cleaning, Component Air Cleaning

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to meet customer’s Global standard requirements. These solutions improves productivity drastically with built-in Consistent Quality.

Multi-Station broaching machines increases productivity in single machine with minimum space and running costs. Highest number of high tonnage and long strokes machines are manufactured by Sanyo in Japan.

Sanyo is also Japan’s leading Gear Checker machine manufacturer.

Simple gears to complicated gears can be checked for various parameters online. These machines are supplied with full options of Gantry loader Automation, Washing System, Dryer System and Gears sorting for OK, NG and Nick Correction. These Gears are most accurate and quick to measure with load/unload when compared with competitors in India. This improves Quality, productivity and dependability on the system. Most of Leading car manufacturers in India and Asia use Sanyo Gear Checkers.

Sanyo’s third leading machine segment is Deburring and Chamfering Machines. A complete solutions in these applications are available in various models of 1-Axis Gear Chamfer, Horizontal type Gear Chamfer, 2-Axis/3-Axis/4-Axis Deburring and Chamfering Machines, Gear Pecker, 2-Axis/ 4-Axis R Chamfering Machines, 2-Axis Angle Chamfering, 5-Axis/ 9-Axis Corner chamfering, Inner Circumferential Gear Rolling, 5-Axis Hypoid Gear Chamfering, Hypoid Gear Semi Topping machines.

Sanyo is also reputed manufacturer for roll forming (Rack rolling) machines. These machines are manufactured in both Vertical and

Horizontal rack rolling construction.

Sanyo machines have unique advantage due to dual servo controlled rack systems, dual servo system for tail stock control, machine temperature control, a complete reliable automation with shuttle system and loading arms.

These machines are economical yet most rigid, high performance and proven in India and Globally.

Sanyo has machines are used at all leading automotive transmission parts manufacturers in India and Asia as reliable, economical machines with automation. Sanyo has excellent design team to suggest customized solutions and all components and manufactured in-house for high quality performance and meet quicker machine deliveries.

Sanyo’s President Mr. Makihira has assured customers in India to support them in better solutions, quick deliveries and better pricing to meet desired cost/piece. Longer machine life and high productivity gives more profitability to our customers.

Sanyo has established a dedicated sales, service system in India at Arhan Technologies Pvt. Ltd. for a complete engineering support.

For more information Email: mtd.support@arhan.co.in

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TECH TRENDS

Emulsion Stability in Semi-Synthetic MWF formulations As soon as the emulsion stability becomes insufficient, corrective action must be taken

Experimental study In this study, key variables were the base oil characteristics, the emulsifier package comprising primary surfactants and coupling agents, the amine base selection, and the water hardness.

The emulsifier chemistry, based on anionic and non-ionic surfactants, was employed in three different formulations from Sasol Performance Chemicals, developed for the needs and appetites of different markets around the world. We investigated the properties of emulsions formed by each package in three different Naphthenic oil viscosities: 9, 22 and 110 cSt (KV@ 40 °C).

Thus, nine different semi-synthetic emulsion concentrates were prepared, and by selecting hard (°dH 20) or soft (°dH 0) water in the final emulsion, giving 18 samples in all. The properties studied were the droplet size distribution (DSD) and its evolution over time, and the correlation of this to emulsion stability over time.

Results and Discussion The results show that the different base oils respond differently to the different surfactant package chemistries, and also to the water hardness. In general, smaller droplet size was found for soft water, see Figure 1.

For these semi-synthetic emulsions, the mean droplet size in general was much smaller than what was found in our earlier studies on Soluble (Conventional) oils, indicating even better emulsion stability.

The 9 cSt base oil showed good compatibility with two of the packages. The 22 cSt base oil shows very broad compatibility with the three different surfactant packages.

For the 110 cSt base oil, more stable emulsions formed in hard water.

These systems did display sensitivity towards water

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0°dH 12 10 Dx (50) (µm)

E

mulsion stability is a fundamental property of a metalworking fluid emulsion system. As soon as the emulsion stability becomes insufficient, corrective action must be taken, usually resulting in system downtime. To further investigate how the chemical composition of the surfactant blend and other formulation parameters affect the emulsion stability, a series of semisynthetic translucent “micro” emulsions of three different Naphthenic base oils have been formulated.

8 6 4 2 0

T9_ MWL 1

T9_ MWL 2

T9_M WL 3

Day 0

0.496

0.246

Day 1

0.396

0.274 0.248

Day 7

T22_ MWL 1

T22_M WL 2

T22_M WL 3

T110_ MWL 1

T110_ MWL 2

T110_ MWL 3

10.6

1.42

11.3

1.70

0.297

0.253

6.79

7.80

0.319

0.309

10.1

10.9

1.50

0.348

0.179

3.70

Figure 1. DSD in soft water.

hardness, as expected from the anionic surfactant chemistry. The extent and character of the effect was different for the different base oils. The broad investigations of Naphthenic base oils (9, 22 and 110 cSt) clearly demonstrates the wealth of the semi-synthetic emulsion chemistry. However, even in a simple screening study like the present one, clear indications of suitable formulation chemistries may be learned.

Conclusion • Emulsion stability is a key requirement of emulsion-type metalworking fluids • Emulsion stability can be modelled in test systems • The droplet size distribution (DSD) method offers a wealth of data, and can generate a well-resolved mapping of the stability properties • The water hardness made a difference in several ways in the semi-synthetic emulsion systems We would like to propose that the results obtained in these studies would indeed be useful as a component selection guide to metalworking fluid formulator across geographical regions, with varying water hardness, and different access to base oils suitable for metalworking emulsion formulations References Norrby, T.; Malm, L. and Wedin, P. Nynas AB, Nynäshamn, Sweden STLE Annual Meeting 2017, Atlanta, USA “Base oil and emulsifier selection principles Part II - a metalworking fluid emulsion stability study”

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NINJA® OFFERS YOU THE PERFECT GLOVE FOR WORKING IN LOW TEMPERATURES Getting workers to wear a glove for the length of their shifts is one of the biggest safety challenges facing organizations today. Gloves must not only provide mechanical protection but must also be adequately comfortable so that workers don’t need to take the gloves off and make a conscious choice to wear them. Time and again, it has been seen that unprotected hands are more prone to injuries and thus comfort is no longer a “good to have” but a must when it comes to hand protection.

Choosing hand protection for applications like cold storage, plumbing, frozen food handling, construction and outdoor winter use requires gloves that not only keep hands warm but also prevent water from seeping in, because as soon as water permeates the glove, wearer comfort is compromised, increasing the chance that the worker would need to take them off.

What should workers consider while selecting low temperature hand protection?

1) Water Repellency to provide protection from water to prevent it from seeping into the gloves 2) Right combination of materials to provide warmth and comfort 3) Mechanical properties according to the task at hand – Cut/Abrasion/Tear/Puncture 4) Dexterity to reduce motion fatigue and increase efficiency 5) Flexibility in lower temperatures – Most PVC and Nitrile based coatings become stiff at lower temperatures so selecting a glove that retains its flexibility is important to perform tasks efficiently 6) Hand hygiene to minimize odor and keep hands fresh The Ninja® HPT™ Ice gloves enjoy a loyal following in the world among fishermen, winter cyclists, freezer workers, and other cold weather enthusiasts for its ability to stay soft and flexible in freezing temperatures.

The HPT™ (Hydropellent Technology) coating used in the Ninja® HPT™ Ice glove is revolutionary in many ways: • The porous coating channels away liquids from the surface to provide a firm wet/oily grip • Provides an excellent 360-degree anti-wet feature that beads away liquids from the glove but at the same time, also allows air to flow through which in turn keeps hands dry • Coating remains soft and flexible in freezing temperatures so that the wearer can work continuously • Encapsulated air molecules provide a cushioning effect to minimize impact

NINJA® HPT™ ICE CROSS-SECTION HPT COATING Water Repellent, Grip NYLON LINER Insulation, Water Repellent, Flexibility, Breathability BRUSHED ACRYLIC INSERT Insulation, Comfort, Moisture Absorption

Best-in-Class Hand Protection for Cold Applications • Repels liquids for a firm wet or dry grip and offers 360-degree water repellency so hands stay dry all day • Coating remains soft and flexible in freezing temperatures • Two-layer liner/Dual-Shell construction for durability • Polyester brushed micro terry liner on the inside for warmth and comfort • Encapsulated air molecules in outer shell provide a cushioning effect to minimize impact • Ergonomic construction for hand conforming fit • Treated with Sanitized® to inhibit bacteria growth, helping to prevent odour • High visibility for low-light environments FOR USE IN cold storage, frozen food handling, construction, utilities, agriculture, and outdoor winter use

THERMSMART

Cold protection

GRIPSMART

Wet, dry and oily grip

Q 2231X

Superior Grip and Dexterity

FITSMART

X2X

Form-fitting design

Contact:

Private Limited, India

Email: customercare.in@midassafety.com

BREATHESMART

360° breathability

TECH TRENDS

Monitoring tasks in

3D printing

The 3D printing process is currently experiencing a genuine boom. Whereas 3D printers were originally intended only for the production of prototypes and for the production of individual parts, they have since been used for series production too. To create high quality products, precise guidance of the print head and accurate positioning are required. Reliable real-time control is provided by high precision optoNCDT 1420 laser sensors from Micro-Epsilon.

E

xperts estimate that in the future, 3D printing will play the most important role in the custom-made production of components. Whether plastic parts for the automotive industry or precision manufactured aircraft parts - the process in which material is applied layer by layer and thus creates threedimensional objects is becoming increasingly affordable and at the same time more popular. In a very short time, even complex components can be produced, without prior molding, shape change or additional processing steps. As well as plastics, a wide range of metals and alloys can be used for 3D printing.

Micro laser sintering technology is an additive production technology based on digital 3D design data,

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whereby a component is constructed layer-by-layer from metal powders using a laser beam. This procedure is also known as industrial 3D printing.

This process involves a powder layer applied through a print head.

This powder layer is removed by a squeegee to the correct thickness.

Subsequently, the powder is fused in the component cross-section using a laser and the construction platform on which the component is created, lowers. These steps are repeated until completion. An optoNCDT 1420 laser sensor is mounted directly adjacent to the print head and moves with it via the component platform.

Due to the high temperatures, it is necessary to cool the sensor in order to obtain stable measurement values throughout the entire process. The

laser sensor measures the distance to the component from above.The high accuracy, in conjunction with the small laser point size, enables precise positioning of the print head, whereby homogeneous material application can be achieved. The check is carried out in real time, thus a direct intervention in the printing process is possible in case of deviations from the norm. The laser sensor can also be used to verify whether the print head is running or whether the component platform is correctly aligned in the horizontal and vertical axes. The component boundaries are also recognized correctly, which is to prevent deformation of the object.

With the optoNCDT 1420 laser triangulation sensors, MicroEpsilon sets new standards in

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TECH TRENDS laser triangulation in terms of functionality and design, which was recently recognized with the Red Dot Award Industrial Design 2016. The extremely compact optoNCDT 1420 displacement and distance sensor has an internal controller. The high measuring rate of 4kHz makes this model ideal for measuring tasks in 3D printers. There is limited space and the print head moves at high speed, so measurements with a high measuring rate are required. The sensor lens produces an extremely small light spot, which enables the measurement of very fine details.

Another advantage of the laser sensor is its material and surface independence. This enables distance measurements on different materials from plastics to metals and different object colors from white to black with

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the highest precision.The sensor can even detect a change from mat to glossy surfaces and thus from weak to strong reflection. The Auto Target Compensation (ATC) feature provides fast control of different reflections and enables a smooth signal frequency of the distance signal. The innovative web interface makes it easy to operate using predefined setups for the various surfaces.

The laser triangulation principle is based on a simple geometric relation. A laser diode transmits the laser beam onto the measurement object. A lens focuses the reflected rays onto a CMOS array. The distance to the measurement object can be determined by the threepoint relationship between the laser diode, the measuring point on the target object, and the projection on

the CMOS array. The measurement resolution can achieve a fraction of a micrometer.

Laser-based optical displacement sensors measure from a large distance to the target using a very small spot which enables measurements on the very small parts. The large measurement distance in turn enables measurements to be taken against difficult target surfaces such as hot metals. The non-contact principle also enables wear-free measurements as the sensors are not subject to any physical contact with the target.

Furthermore, the laser triangulation principle is ideal for very fast measurements with high accuracy and resolution.

For more information, Website: www.micro-epsilon.com

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TECH TRENDS

High Efficiency Coolant Saver / Dust Collector KN-V300 Product Features • To solve the cutting of iron filings, aluminum powder, fine sediment...and other long-time deposition in the CNC water tank troubled.

• Take the air pressure drive way, to avoid pubilc security problems.

• Widely used in metal cutting, aluminum processing, grinding process, engineering plastics.

• Patented technology-easy to deal with oily and water-soluble cutting fluid.

• Patented technology-special dehydration drying method, can clean CNC water tank. processing liquid, sludge can also be a short time to cleat.

• The maximum filter accuracy zan to 1um.

Use Value • Reduce the CNC machine failure rate, processing non-performing rate.

• Water and Coolant Saving.

• Reduce the cost of CNC mechanical downtime and personnel operations.

• Maintain the tank liquid capacity, reduce the temperature rise.

Easily Recovered

For more information:

GALAXIEE CONSULTANCY PVT. LTD. Galaxiee Machine Tool Sales & Service M: +91 9860012619 info@galaxieemachines.com / galaxieepune@gmail.com

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www.qviindia.com

Dimensional Measurements for Quality Control Advanced optical and multisensor systems from QVI are engineered for use in everyday manufacturing settings.

Hall 1B, USA Pavilion Stall No. C-103

TECH TRENDS

Coolant Purifying Unit for all CNC Machines

K

ing Nice Techâ&#x20AC;? one of manufacturer by oil-water purifier, waste water purify, oil purify, oil filtering, coolant treatment, oil recycling, oil, water, coolant regeneration equipment group.Our unique design features make installation easier and operation reliable. And our wide selection of colors and sizes allow you to solve virtually any CNC machines.

Our main goal is to deliver the excellent system, which comes with high quality but low price, allowing you to focus with confidence on establishing your business.

KN-PLUS2: OIL WATER COOLANT PURIFIER MACHINE: KN-plus2 oil-water purifier - is detachable oil skimming device, the skimmer, degreasing machines, floating oil collector, oil-water separators, skimmers can be directly connected to the CNC machine. Provide oil-water separation technology, oil and water separator principle, slick processor, widely used in CNC machine, CNC lathes, drilling machines, milling machines, grinders and anycother machines where it is used as water based coolant separation.

PURIFYING: Specialist cleaning to avoid the tramp oil mixed with coolant.

UNCONSUMABLE: Free electrical connection.

SLUDGE FILTER: Water purify in separated the tramp oil, chips & powder.

HEALTH: Reduces the risk of skin, irritation and dermatitis.

ENVIRONMENT: Environment-Friendly without any chemical process.

LOW RUNNING COSTS: Easy installation save maintenancee.Reduces addition of the new oil quantity.

PATENT CERTIFICATE: Patented design product.

FRESH: Do the circulation and totally clean the water tank. Disinfections and remove the bad smell.

Advantages:1. Reduction of bacterial growth by removing tramp oil.

2. Removal of floating dust particles.

3. Reduction in coolant changeouts.

4. Increase the life of coolant & tool.

5. Environmental safety.

6. Foul odour removal.

7. Reduction in water consumption.

Why Coolant to Be Purified?

The era of high oil prices, to keep the purification of cutting fluid for cooling, lubrication, rust, pseudoconcentration, grease cleaning, corrosion (bacteria, fungi), to enhance the performance and functionality of impurities can be prolong life. for you accumulate wealth, achieve profitability.

PATENT T.P.M Description Grease retention method is mainly applied different principles proportion of oil and water, the proportion of different to make oil floating, separated from the water, while separating the oil trapped in the tank plus.

For more information:

GALAXIEE CONSULTANCY PVT. LTD. Galaxiee Machine Tool Sales & Service M: +91 9860012619 info@galaxieemachines.com / galaxieepune@gmail.com

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15

15

Visit us at :

Hall: 3A, Stall: F101 24 - 30 January 2019, Bangalore, India

TECH TRENDS

O

ver recent years, there has been an increase in demand from end users to increase the use of electric rod style actuators, and reduce the use of pneumatic actuation in factory automation equipment. Numerous factors are driving the conversion but most significant is improved machine performance, flexibility, reduced maintenance and total cost of ownership.

Once the decision to replace pneumatic actuators with electromechanical actuators has been made, the next step is to select the right electromechanical actuator from among the many brands.

While fundamental thrust specifications may be similar, there are significant differences in the areas of lifecycle performance, maintainability and environmental resistance.

Lifecycle performance Generally speaking, the larger the diameter of the ball screw, the greater the thrust potential, but achieving this requires proper mating of the thrust bearing and all fixation points, including extension tube, the inner ball nut system, bearing housing and wiper housing. Otherwise, any increase in thrust would come at the expense of system life. A component that is too weak to handle its load will wear out much faster or even become damaged.

Given two actuators, each fitted with a 16 mm ball screw and providing 750

Fig. 1 shows the contact areas in thrust and side load conditions

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Technology & Design Advances Drive Trend Towards Electromechanical Actuation Niklas Sjรถstrรถm from mechanical motion control manufacturer Thomson Industries explains the key factors.

Newtons of thrust, for example, one may have travel life of 2000 kilometers, while another could provide 8000 kilometers of travel.

Moreover, due to larger ball screw diameters correlating also with cost and footprint, properly mating the ball screw and other components can reduce both. To meet an application requirement of 3200 Newtons of force, one vendor might utilize a ball screw with 20 mm diameter, while another vendor with properly mated components, might achieve the same thrust with a screw of only 12 mm diameter, thus being able to downsize without sacrificing performance.

Further, a larger carrier body, (Fig.1) can support larger external radial loads, by maximising surface contact area in a side load situation. The ability to side load electric actuators would raise performance, precision and compactness to a level that is not attainable with pneumatic actuation.

Likewise, increased contact area in a pure thrust situation reduces play, providing support for lateral loads on

the extension tube.

While maximising surface areas impacts radial and lateral load capacity; it does not necessarily impact stability.

This is often addressed by interlocking elevated legs into grooved channels.

These support legs also help reduce vibration, which can add noise and contribute to wear. Most designs use one or two such ridges, which remove some play but can generate clicking sounds as the system begins to wear over time. Using four legs instead of two, however, reduces wear and noise, providing more effective and more durable anti-rotational protection. The additional legs will also help ensure cling-free return motion, further reducing the amount of play in the system due to wear.

Additionally, curving these carrier legs outwards creates radial preload, which centers the carrier body and ball nut, eliminating the need to shim the carrier to the extrusion and compensating for wear over the life of the device.

While close tolerances are critical for wear and noise reduction, if there is no

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TECH TRENDS air gap at all, pressure can build when the actuator is running at high speed.

This can cause overheating, contributing to lubrication problems and other durability issues. Thomson addressed this by making two of the male key features on the carrier legs lower than the remaining two. This provided just enough of gap to prevent pressure build-up. As seen in fig 1 two of the male key features on the carrier legs that is orthogonally situated are lower than the remaining two. This is what prevents the pressure build-up.

usable in only three steps.

Additionally, the use of a straddlemount bearing strategy eliminates the risk of misalignment. Besides, it protects the motor shaft from impact by radial loads, which also reduces noise and further extends system life.

Environmental resistance A very important point in which electromechanical actuators differ from each other is their ability to resist against harsh or environmental conditions and withstand frequent high pressure wash downs. This is basically Maintainability a matter of the exterior profile design, Ease of maintenance certainly affects material choice and sealing strategy. lifecycle performance and contributes Compared with grooved surfaces, an to immediate productivity benefits. exterior profile with a smooth surface Electromechanical actuators differ in is cleaner, because it avoids accumulatheir lubrication and motor handling. tion of dust and fluids in grooves. This Most systems retract to expose parts makes it more appropriate for harsh for lubrication only partially, maybe environments when frequent wash 60 or 70 percent. Technicians remove down is required. the caps, locate the parts that need luEnvironmental resistance also depends on the material composition of brication, add grease, and may need to the extension tube. Most systems use repeat the process. A better approach, however, is to extend or retract the tube chrome steel, but stainless steel is a much better choice for harsh environcompletely, revealing all components ments. for maximum coverage.

A key indicator of resistance to Another key factor is installation solids and liquids in the environment time that is consumed in mating up is the Ingress Protection (IP) Code of the motor with the mechanical actuathe National Electrical Manufacturer tor. Traditionally mounting the motor Association (NEMA). Achieving an IP in a parallel configuration can take rating of 65, for example, means that 20-25 minutes. Once the motor is bethe system is completely dustproof and ing mounted, a technician must use a protected against low pressure water variety of tools to adjust it for proper jets from any direction, belt tension and alignas might be found in ing.. But if the actuator a food and beverage design comes with a industry wash down oppre-assembled paraleration. Only a few eleclel solution, the belt tric actuators available can be pre-tensioned today meet this, but in during assembly, corrosive environments eliminating the need it is critical. An IP rating for the multistep tenof 54 provides some sion adjustments, and degree of dust protection enabling the motor to Fig. 2: Actuator design with a be bolted down and pre-assembled parallel solution. and protection against 210

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splashed water, making it acceptable for some wash down applications but not if pressure is involved. An IP rating of 40, which is quite common among linear actuators, implies that there is no dust or liquid protection.

A higher IP rating is mainly related to a higher sealing strategy. In this case, every compartment is sealed, including motor mounts. All gaskets should also be sealed and extend all the way back to the motor, instead of stopping at the mounting plate.

Gearing up for the next generation of motion control As the market drives demand for high productivity solutions, shorter changeover times, increasing reliability and greater energy savings, even greater benefits can be obtained with careful comparison among different brands of electric actuators. Always interpret ‘load carrying capability’ in the context of claimed system life and space requirements. There are very real trade-offs in these areas. Carrier design impacts precision, lateral and rotary load bearing capabilities, so pay close attention to the overall design used to secure the carrier in the channel, as well as to the shape and size of any guidance mechanisms used. Improved mechanisms and parts such as support legs and leg designs, which are curved for better gripping, will have a large positive impact to accuracy and wear.

Considering the appropriate exterior profile, material choice and sealing strategy are important key factors for environmental resistance. Smoother profiles, stainless steel materials and higher IP ratings tend to offer the greatest protection.

By Niklas Sjöström Product Line Manager, Systems Group Thomson Industries, Inc. www.thomsonlinear.com thomson@thomsonlinear.com

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TECH TRENDS

New Frontiers for Power Skiving Power Skiving is the new competitive alternative for hard finishing, with the potential for major savings.

W

hat began a few years ago as a promising, but specialized, process alternative for cylindrical gears with challenging interference contours is now exceeding performance and application expectations. There are now Gleason Power Skiving solutions for soft cutting and hard finishing of internal and external gears and for machining shafts, worms and special profiles such as cycloidal gears, as well as for gears as large as module 9 mm and diameters up to 800 mm.

Getting here hasnâ&#x20AC;&#x2122;t been without its challenges. Power Skiving places considerable demands on the overall system of machine/clamping device/ tool/process. The best possible result can only be achieved if these elements are working in harmony with one another and the system as a whole has the necessary stiffness.

Gleason has worked hard to put the complete system in place: process simulation, production machines and metrology equipment, workholding, tools and support services â&#x20AC;&#x201C; all working in concert.

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Effective Machining of Small Internal and External Gears Internal and external gears with small overrun space can be produced more economically than shaping using the 100PS, the smallest machine in the Gleason Power Skiving family. In the case of external gears with small overrun space, Power Skiving may even outperform hobbing, since small hob diameters actually impede the efficiency of the hobbing process, while highly productive Power Skiving cutters with relatively large diameters can instead be used.

The horizontal arrangement of the workpiece axis and equipment with a tailstock make the 100PS an outstanding choice for machining both shafts (Figure 1) and internal gears. Furthermore, the 100PS can be equipped with an integrated

chamfering/deburring station for external gears. The chamfering process is interpolated before the final cut and helps achieve finished machining quality afterwards. For internal gears, the 100PS has a patented deburring unit which can be programmed via 2 NC axes. As a special feature, the machine provides the option for skiving worms (Figure 2).

Medium and Large-Sized Workpieces With Integrated Deburring For medium and large-sized workpieces up to 800 mm in diameter and module 9, there is a whole range of Gleason Power Skiving machines, from the 300PS to the 600PS, which can be expanded to a diameter up to 800 mm.

The machine concepts with extreme stiffness are perfectly

Fig. Fig. 12

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TECH TRENDS complemented by modular workholding equipment in various sizes. The precision and reliability of the overall system results in shorter cycle times, as well as outstanding gear quality and surface finish. Not only can cycle times be reduced by a factor of 2 to 5 (depending on the application) but, when compared to gear shaping, tool cost per workpiece is significantly reduced as well.

Hard Power Skiving: Attractive Alternative The demand for quieter gear boxes and higher torque increasingly require finishing of hardened gears.

Now, for the first time, Hard Power Skiving brings economical hard finishing solutions to the small to medium-sized internal gears market.

Tooth space position is detected with the stock dividing sensors â&#x20AC;&#x201C; similar to those on grinding machines (Figure 3). The combination of the extremely stiff machines with direct drives, simulation software, process expertise and modern carbide tools combine to achieve quality and surface finish levels that are perfectly adequate for the majority of finishing applications.

Power Skiving for Bevel Gear Cutting Machines It is also possible to install Power Skiving onto the current generation of Gleason bevel gear cutting machines with an expansion package. Various tool systems, including solid carbide or PM tools,

Fig. 3

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as well as indexable carbide-insert cutting blades, are incorporated in these Power Skiving solutions.

Simulation Software Most importantly, Gleason Power Skiving technology and simulation software (Fig. 4), enables the end user to simulate the entire skiving process in advance to determine the most effective process strategy and tool design. The simulation software analyzes the impact of various tool geometries and process parameters on chip formation, gear-cutting quality and the collision situation, as well as effects on cycle time.

Closing the Loop on Quality Finally, the Gleason Closed Loop method optimizes the production

Fig. 4

JANUARY 2019

process by networking Gleason Power Skiving machines directly with Gleason GMSÂŽ metrology equipment. Measurements and the resulting corrective actions are fast, accurate and automated.

Despite significant and sustained progress in recent years, the potential of Power Skiving is far from exhausted. It will be exciting to see where Gleason goes from here.

Udo Stolz Vice President Worldwide Sales and Marketing Gleason Corporation

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TECH TRENDS

Reliable safe guard monitoring with Pilz’s safety gate systems, PSENmlock

P

SENmlock offers safety gate monitoring and safe guard locking for the protection of personnel and processes to the highest category PL e in one device.

The slimline, yet robust design and many different installation options make PSENmlock both flexible to use and easy to install.

PSENmlock is a reliable door guard both for small and for larger heavy doors and gates, whether swing or sliding gates or covers and flaps.

Above and beyond these possible applications , the flexibly mounted actuator ensures high tolerance compensation and unrestricted functionality even with sagging gates.Thanks to a bistable magnet, the currentless guard locking system reduces the energy consumption of the safety gate system. Diagnostic data is easily identifiable in many installation positions, LEDs on three sides of the housing, support user-friendly diagnostics whatever be the installation situation.

This makes PSENmlock ,particularly suitable for machines with a hazardous overrun that makes guard locking up to PL d or PL e absolutely essential, such as rotating knives, flywheels Or robots. In addition, an integrated mechanical restart interlock prevents the guard locking system from being activated inadvertently, without the need for separate accessories. Not only does the restart interlock make operating the machine safer, it also prevents an inadvertent restart during maintenance operations!

Use of PSENmlock

Irresistibly strong With a holding force of 7500 N and the integrated latching force of 30 N, the safety gate system prevents the guard from opening inadvertently.

PSENmlock with appropriate door handle

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Safety first!

In machines with an overrun, the greatest risk to the safety of the operator comes, when the safety device opens inadvertently or too early.This makes it particularly important to avoid the hazardous situation when disabling a switch.

The two-channel PSENmlock guard locking control ensures that ,opening the gate does not present any risk.

Even fault scenarios such as shortcircuits are detected safely, allowing any unintended opening of the gate to be prevented.

Safety Gate System PSENmlock

Benefits of the safety gate system PSENmlock • Safe guard locking and safe guard interlocking up to PL e / SIL 3 in a single product • No inadvertent activation of the guard locking due to the integral restart interlock • Flexibly mounted actuator ensures high tolerance compensation – even with sagging gates • Long service life ,thanks to robust mechanics and housing • Reduced power consumption in operation • Reduced wiring work ,thanks to series connection • Simple and comprehensive diagnostics in combination with the SDD • Easy installation and lowmaintenance solution with the remote escape release.

For more information, Pilz India Pvt. Ltd. Website: www.pilz.in

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TECH TRENDS

5-axis measuring technology enables measurement without compromise Automotive is one sector benefiting from this technology with manufacturers finding unparalleled advantages in the expanded SFP2 surface finish measurement product range, offering operator independent data collection and the opportunity to eliminate dedicated surface finish equipment 218

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M

easurement is an essential part of manufacturing, used to control processes and verify products. However, measurement time is often viewed as non-productive, causing unwanted bottlenecks and putting pressure on manufacturersâ&#x20AC;&#x2122; operating margins.

Renishawâ&#x20AC;&#x2122;s 5-axis measurement product range for co-ordinate measuring machines (CMMs) claims to be one of the biggest step-changes in measurement capability ever introduced in industrial metrology and goes a long way to overcoming these

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TECH TRENDS

physical nature of the CMM structure constrains further improvement.

REVO® 5-axis systems approach this challenge from an entirely different perspective, minimising CMM accelerations whilst moving the stylus very rapidly over the component surface through the simultaneous control of the three machine and two probe head axes (X, Y, Z and A, B).

challenges.

The need to retain accuracy has historically compromised the ultimate speed of the measuring process due to the characteristics of a CMM’s structure. The non linear motion of a Cartesian CMM induces accelerations and decelerations that twist and deflect the machine structure, and result in measurement errors that increase with speed and acceleration.

CMM manufacturers work relentlessly on software and machine improvements to overcome those limitations, but ultimately the

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Unmatched flexibility Additionally, the REVO® system offers five different probe families, each specifically designed to maximise the advantages of 5-axis motion and infinite positioning. The probes are automatically interchangeable and include tactile scanning, touch-trigger, surface finish and non-contact vision probes. All are used within a common co-ordinate reference frame and provide the choice of an optimum tool to measure multiple features all on a single CMM platform.

Automotive is one sector benefiting from this technology with manufacturers finding unparalleled advantages in the expanded SFP2 surface finish measurement product range, offering operator independent data collection and the opportunity

to eliminate dedicated surface finish equipment. By integrating automated roughness measurement and drastically reducing the number of probe styli required to measure complex parts, REVO® systems have a direct impact on powertrain manufacturing effectiveness.

Renishaw has always been an innovation leader in industrial metrology. The company’s first product, the touch-trigger probe, led to a revolution in three-dimensional co-ordinate measurement. Ever since, a strong commitment to research and development has brought to market products that have been milestones in industrial metrology. The REVO® 5-axis measurement system is leading a new revolution in quality control, enabling manufacturers to stay competitive, push the boundaries of their production processes and improve the cost effectiveness of their manufacturing.

For more information, Website: www.renishaw.com

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TECH TRENDS

Innovations in centerless grinding machine & its operations

C

enterless Grinding operation is a mass production process in which cylindrical components are ground without reference to center.

This operation is used as the final process in majority of the components where the tolerances and the quality parameter are stringent.

The grinding process is basically designed for mass production. As the cost of manufacturing is increasing, the users are trying to extract more & more production from a grinder in order to lower the cost per piece.

The user feedback and experiences highlighted the problems faced during day to day work, and solutions need to be implemented for future expansion projects and existing machinery.

Below are some suggestions, to improve the quality level and productivity, while bringing down costs in Centerless grinding: • Land costs are at an all-time high, which necessitates the reduction of machine foot print and floor space dedicated to a single machine.

• In any centerless grinding operation, the major non-productive time is the dressing time. Hence, a method needs to be devised so that the dressing time also can be used productively.

• As the working cost is increasing, more automation is required so that an operator can run more than one machine.

• With cost of power increasing all around the world, more energy efficient motors should be explored.

• The fuel prices are increasing at a phenomenal rate and it is essential to produce fuel efficient vehicles.

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This calls for components with higher quality standards and a need to explore different materials to reduce vehicle weight. Consequently, machines with capability to grind these components efficiently need to be devised.

To resolve the above issues, our engineers did brain storming and devised various options: 1. To reduce the floor space there should not be any compromise in terms of the rigidity and stock removal capabilities of the grinder.

We designed a grinder similar in size to our smallest model. At the same time, we increased its rigidity by adding weight to make it equivalent to our bigger sized model.

The center of gravity was kept constant at the working area so that the vibrations would always be at that point. The vibration analysis was conducted to ensure that it was maintained at a very low level.

2. Total Usage Time = Productive Time + Non-Productive Time (Dressing Time) The challenge for us was to convert the non-

productive time into productive time. To achieve the same, we designed a diamond roll dresser for the machine. The CNC controls were programmed in a manner that when the dressing is done on the wheel, grinding of the component is also in process. Therefore, the total usage time is now equal to the productive time. This enables the customer to grind more components. The savings was substantial in terms of productivity.

3. Working Cost = Running Cost (Power + Employees + Overheads) + Consumables (Hydraulic Oil + Coolant + Grinding wheel + Regulating Wheel + Diamond Dresser) To reduce the working cost of a machine, it is important to reduce all the above costs to an optimum level. a. Power Cost: The maximum power consuming motor is the grinding wheel motor. We procure the motor such that during idling time of grinder in each cycle it would draw very low current, while providing full torque during the grinding process. Such motors

Diamond Roll Dresser

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Intelligent Collaboration Redefined.

The CobotPump brings to a new generation of intelligent vacuum generators that do not require compressed air and that have an integrated interface for gripper systems and robot connection.

WWW.SCHMALZ.COM/AUTOMATION T: 020 40725500 Schmalz India Pvt Ltd · EL 38, J Block, MIDC, Bhosari, Pune 411026 · schmalz@schmalz.co.in

TECH TRENDS

Linear Guideway

have rating of Eff 1 or better. The other options include soft start for grinding wheel motor or Variable Frequency Drive for regulating and grinding wheel motor. These options avoid peak current required for start-up of the motor. b. Employees Cost: Machine automation is designed in such a way that the operator can run more than one machine at a time. In mass production plants, the focus is to have one skilled person to look after the setting and inspection of finished components for all grinders. Loading, unloading and other routine operations are done by unskilled employees.

CNC options also reduce the operator intervention to a large extent and thereby reduce the cost. At the time when customer sends the plant layout, we give suggestions and inputs to reduce material handling and make it ergonomically convenient in order to reduce operator fatigue. Variable Frequency Drive is installed to achieve Constant Surface Speed for Grinding Wheel. This helps in reducing the dressing frequency even when the wheel diameter is

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reduced. Hence, the grinding wheel is used to its optimum level. c. The other consumables like oil, coolant, diamonds and wheels are selected with the help of various manufacturersâ&#x20AC;&#x2122; input and expertise, to suit each application.

4. The increase in fuel prices and depreciation of Indian currency has put a lot of burden on manufacturers to improve the fuel efficiency of vehicles. This calls for more close tolerance in manufacturing parts. Quality Parameters are a combination of Size Tolerance, Roundness, Cylindricity and Surface Finish. We use Precision Linear Guideways to achieve practically friction free movement.

This enables the slide to move with high accuracy, as close as 0.25 microns and helps in maintaining size in close tolerance.

To achieve roundness in 1 to less than 1 micron, it is necessary to have rigid spindles and vibration free grinding. We mount Automatic Wheel balancers, which balance wheel with vibration level less than 1 micron. This also helps improve Cylindricity.

Coolant supply while dressing the

Servo Regulating Wheel Drive

wheel has to be forced at the point of contact of diamond and wheel.

Proper forced coolant supply helps to dress well, which in turn helps in improving surface finish on component. Coolant supply during grinding is conventionally done by free flow of coolant on the part.

Due to air turbulence because of wheel rotation, most of the coolant does not reach the actual grinding area. With redesigned nozzles and flapper to stop air turbulence, the coolant now reaches grinding hot spot to almost 90% level. The overheating of parts and burning marks are reduced and surface finish improved.

The above are some of the innovations & adaptations incorporated in the machine to meet the demand of the industry for better & greener tomorrow.

by Harsh Badani, Technical Director, Solitaire Machine Tools Ltd., Vadodara

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Your gate. Our system. Your safety.

Are you looking for an individual solution to safeguard your safety gates? Do you have special requirements? At Pilz, your solution is our solution: Our modular safety gate system allows you to flexibly combine individual components – in a way that is optimally tailored to your application. Simply customise your safety gate monitoring system with our optional economical series connection, rapid diagnostics, additional operating and pushbutton elements, escape releases and door handles.

You benefit from our many years of experience in the field of safe automation: sensor technology, control technology, drive technology and visualisation. The complete solution from Pilz – a one-stop shop!

HANNOVER MESSE 2018, Hall 9, Stand D17

Pilz India Pvt. Ltd. 6th Floor, ‘CYBERNEX’, Shankar Sheth Road, Swargate, Pune - 411 042 Pilz GmbH +91 & Co.(0) KG20 49221100/101/102, 73760 Ostfildern Email: 0711 3409-0 info@pilz.com www.pilz.com Telephone: info@pilz.in, marketing@pilz.in, Web: www.pilz.in

TECH TRENDS

New Development in Hard Chrome Replacement: HVAF Flash Carbide Coating

Dr. Andrew Verstak, President. Vermetico Inc., USA

BACKGROUND • Traditional hard chrome plating produces Hexavalent chrome as effluent which is a known carcinogen. The process also produces large volumes of Toxic Waste.

• The HVAF (High velocity Air Fuel) spray coating technology for deposition of high-quality carbide coatings developed by Kermetico, USA and Spraymet to replace hard chrome plating in critical engineering wear applications is a very important process breakthrough towards eliminating carcinogenic hexavalent chrome from shop floor.

• The concept of “Flash Carbide” coating is developed, targeting deposition of high-quality coatings at low cost, duly meeting traditional chrome plating cost by reduction of coating thickness

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Mr. P T Bindagi echnical Director Spraymet Surface Technologies Pvt Ltd., Bangalore

and elimination of the need for dimensional grinding in the process.

Issues With Hard Chrome Plating • The process produces large amounts of hydrogen gas in the gas bubbles burst throwing hexavalent chrome solution into the air as fine mist.

• Hexavalent chrome is a known carcinogen.

• The process produces large volumes of toxic waste.

• EPA and OSHA have mandated more stringent stack emission levels and lowering of permissible exposure limits for workers.

• This results in increased costs and business risks.

Combustion Breakthrough • Ability to use heating in long/ slowgas combustion chambers • long time for “soft” heating of spray powder • High pressure in the chamber =Better heat Transfer • Result: High energy efficiency leading to higher spray rates Particles Velocity Breakthrough • Kermetico HVAF: 1200-1800 mts/ sec • There is practically no restriction on the nozzle length thus and flame velocity • Higher acceleration of spray particles • Higher and Uniform acceleration means uniform coating structure and properties Breakthrough in Results : WC-10Co-4Cr Flash coating by HVAF A superior quality and performance of carbide Coatings deposited with HVAF has has been proven by multiple R&D and industrial applications.

Kermetico HVAF process: How and Why

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TECH TRENDS

After 150 Hours salt spray test (no corrosion)

After 150 Hours salt spray test (80% corrosion)

dense WC-10Co-4Cr powder • (30 micron) • Polish surface to needed roughness (remaining 22-25 micron of coating)

Flash Carbide: Salt Spray Corrosion Test

• Total cost of coating to 38 mm OD x 300 mm L rod, Ra 0.2 mm finish: <15 USD

Cavitation resistance of Wc-10Co4Cr of JP 5000 HVOF and Kermetico HVAF Coatings CPRI, Bangalore (India): Kermetico HVAF Wc-10Co-4Cr Coatings are: • Harder (related to cohesion strength) • More Ductile (related to Co-matrix properties) • More resistant to cavitation, erosion and abrasive wear

Hard Chrome Plating Microcracks

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HVAF FLASH CARIDE COATING: 25 µm (0.0010“) thickness as sprayed Comparison of Hard Chrome Plating to HVAF Flash Carbide Process • Dimension-grind the part to lowest tolerance, Ra 0.5 micron • One pre-heating/cleaning pass with the gun flame • Pass(es) of coating, HVAF fine/

Some Applications : Gas Compressor Piston Rod HVAF coated and super finished to 0.05 Ra

Micro porosity max 1 % (No through passage)

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TECH TRENDS Earlier the rod was induction hardened and chrome plated Hydraulic cylinder: Biggest Single Application for Hard Chrome Replacement alternative by HVAF

This hydraulic cylinder rod with a diameter of 700mm and a length of 1,700mm is coated with WcCoCr by HVAF process CYLINDER BORE APPLICATIONS Flash Carbide as Economic Alternative to Hard Chrome Electroplating • The most economical coating is not the one sprayed with the highest DE. It’s the thinnest coating.

• The HVAF Flash Carbide coating technology is based on the similar to Flash Chrome principles: a. The coating thickness is

comparable to tolerances for the final Coated part (i.e., 20-25 micron) b. The coating roughness is low – “ground-like” Ra 1.5-1.7 micron c. Such coating does not require dimensional grinding d. Polishing to Ra 0.2-0.3 micron removes only about 5 micron of “as- sprayed” thickness The final cost of Flash Carbide is 1/10 of conventional WC-coating

SUMMARY • Multiple data confirmed improved quality of HVAF-sprayed FLASH Carbide coatings as compared to Hard Chrome Plating. Herewith, in many industrial applications it is reasonable to sacrifice some quality to achieve higher DE and correspondingly lower cost with HVAF, still meeting the specified coating quality requirements.

• A line of AK HVAF guns of different power is created to address the variety of industrial applications with the best efficiency. The hardware allows operation in different modes to balance the coating quality and cost.

• The HVAF FLASH carbide coatings are developed to meet existing Chrome plating application requirements, while depositing lower cost coatings utilizing high spray rates and lower thickness. And most importantly doing away with hexavalent chrome all together. A major step toward “GREENER coatings”.

PROCESS BENEFITS: Comparison of Chrome Plating vs.

HVAF FLASH carbide Hard Chrome Plating

HVAF FLASH carbide

Process of coating

Electroplating Bath

HVAF spray

HRC

55-60 HRc

70-74 ( 1150-1400Hv)

Typical Thickness to get Hardness and corrosion

60-100 microns

40-60 microns

Pre and Post treatments

Hydrogen Embrittlement tempering is required.

No post treatment.

Wear resistance ASTM G 65

Good

Very good (due to 72 HRC )

Corrosion resistance ASTM B 117

Typically 150-200 Hrs Salt spray

>700 Hours (salt spray test with sealer ~ 2000 Hours )

Temp resistance

Upto 450 deg C

Upto 450 deg C

Environmental factor

Hexavalent chrome ( carcinogenic) Difficult to control

No pollution except overspray dust ( only need dust collector)

Most of Industrial Hard chrome is now replaced by HVAF in the following applications : Hydraulic piston rods, Steel mill rolls, Corrugated rolls ,Ball valves ball and seat, plug valve , gate valve, pump plungers, etc.

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TECH TRENDS

Vibration measurement in process monitoring

M

easurement of vibrations and accelerations plays an important role in process monitoring on machine tools.

Vibration measurements are used in different ways for the safeguarding and stabilization of processes: as signals from the machine control or from external sensors. Vibration measurement is made as close to the process as possible. Sensors are integrated directly into the spindle or placed on the workpiece holder.

How is acceleration measured?

Acceleration can be measured with a sensor integrated into the spindle or with external sensors placed in the machine. A transducer then converts the values for the process monitoring system into information about the vibration speed. ARTIS offers sensors in the measurement range between 10 Hz and 5 kHz for acceleration measurement on one to three axes.

Acoustic emission, a special form of vibration, is measured with external sensors and transmitted over a separate fieldbus. The sensors for acoustic emission cover the measurement range of 10 to 250 kHz. With learning curve In mass production, monitoring is performed using a comparison procedure. A learning curve is generated over one or more machining processes; signal peaks and troughs are used to monitor breaks; and the area under the curve (cutting work) is used to monitor wear and missing.

Collision monitoring as well Acceleration sensors can be used for collision monitoring. When tool and

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workpiece collide, which the sensor detects from the sudden change in material vibration, the machine shuts off immediately. Here, the measurement means a gain of approx.

200 milliseconds until the machineâ&#x20AC;&#x2122;s overload protection would take hold.

It is exactly during this time after a collision that serious damage results, because the machine at first â&#x20AC;&#x153;reactsâ&#x20AC;? to resistance with increased power.

Not detectable with the naked eye Run-out errors in the workpiece, e. g. during centerless grinding, cannot be detected with the naked eye, but generate clear signal peaks, which provide an early warning of problems and which schedule the workpiece for rework. Vibration measurement thus contributes to quality assurance, supported by process monitoring systems.

Optimization in the ongoing process Vibration measurement is also used for process optimization, such as in gear cutting with profile milling cutters. Tool wear here depends on the vibration speed of the tool.

Experiments show that an increase

in cutting speed of only 10 % results in a significant decrease in the vibration speed. So here, optimization can be achieved by simple means.

Additionally, with Adaptive Control, the vibration behavior at the milling head can be optimized in the ongoing process.

Comprehensive Process monitoring looks at the entire process complete with workpiece, machine tool and peripheral equipment. The knowledge gained can be used in many ways for safeguarding production. The examples described show the benefits of vibration measurement for process monitoring, machine protection and process optimization.

For more information, Website: www.marposs.com

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FACE TO FACE

Allied–Wohlhaupter: Collectively Fostering Superior Service & Empowering the Customers In 2016, Allied Machine and Engineering acquired the majority shares of Wohlhaupter GmbH. Over the last two years, the companies have worked to form a cohesive “Allied– Wohlhaupter” identity in India and have made a strong impact by delivering the lowest cost-per-hole in a wide range of drilling, boring, reaming, burnishing, and threading applications. In an extensive interview with MTW, Wohlhaupter India’s Executive Director, Keshav Khurana tells us about how the company is meeting the ever-changing requirements of the customers, challenges and opportunities in Indian market and the company’s future vision. Excerpts: Mr. Keshav Khurana, Executive Director, Wohlhaupter India

Q. Please take us through the journey of Wohlhaupter and Allied Machine & Engineering in India.

Our story begins with Wohlhaupter GmbH, which was founded as a small mechanical workshop in Germany in 1929 and had been selling boring systems in India through distributors but Indian customers were looking for full support. In response, Wohlhaupter India Pvt. Ltd. was created as a subsidiary of Wohlhaupter GmbH in 2011 to provide engineering, technical support, and onsite application services within India.

Allied Machine and Engineering had been manufacturing holemaking and finishing tooling systems for over 75 years and acquired the majority shares of Wohlhaupter GmbH in 2016. Collectively, they empower Wohlhaupter India to deliver the lowest cost-per-hole in

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a wide range of drilling, boring, reaming, burnishing, and threading applications. With the establishment of Wohlhaupter India, customers all over our country receive engineering support and technical service from fully trained tooling experts for Wohlhaupter GmbH and Allied Machine products.

Q. How far along has Wohlhaupter India come since inception? What are some of the milestones you have achieved in the journey?

Over the span of seven years, we have grown from offering engineering and technical support solely for Wohlhaupter’s esteemed boring systems to providing expertise in drilling, reaming, burnishing, and threading applications in addition to precision boring solutions.

Three years after Wohlhaupter India was established in New Delhi,

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FACE TO FACE we introduced Wohlhaupter’s PrimeBore boring tools to the India market with great success. Since Allied Machine’s acquisition in 2016, we’ve also launched the material-specific GEN3SYS XT Pro replaceable tip drilling system, the AccuThread T3 thread mills, and the GEN3SYS XT Pro structural steel insert.

Beyond product innovations, Wohlhaupter India is also grateful for the relationships we’ve strengthened with key manufacturers in various industries as well as machine tool builders (MTB). Within the OEM sector, machine tool builders increasingly trust us to find the optimum tooling for their projects based on the unique application criteria provided. As a result, we have partnered on many successful projects with highly reputable manufacturers across India.

Q. With IMTEX around the corner, what are your expectations from the mega event being held in Bengaluru from January 24 to 30?

IMTEX is always exciting because it is the perfect opportunity to see current clients we support and value as well as meet many new prospects.

We enjoy the chance to share our extensive range of holemaking and finishing products with such a

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diverse group of manufacturers from all over India.

Q. Tell us about the products you are showcasing and are there any new launches?

We are excited to feature two new innovations at IMTEX: the NOVITECH vibration dampening intermediate module system and the 4TEX indexable insert drilling system.

The NOVITECH vibration dampening intermediate module increases the productivity, surface quality, and process reliability in boring operations while extending the life of both the insert and the machine center’s spindle. Mounted inside the patented NOVITECH system, the viscoelastically mounted damper modules reduce vibrations when machining diameters ranging from 50mm – 205mm (1.97” – 8.07”), with lengths up to 10xD. The NOVITECH features the MultiBore system (MVS), making it simple to use with existing Wohlhaupter components while maintaining compatibility with any machine spindle.

We will also feature 4TEX, our new indexable insert drill ideal for making shallow 2xD, 3xD, and 4xD holes in the 12-47 mm (.472” – 1.850”) range. This drill provides higher penetration rates than standard twist drills for light duty machines and is

also an excellent choice for making interrupted cuts or drilling on angled surfaces. The drill’s design provides increased core strength resulting in improved hole size and straightness.

Dual twisted coolant outlets improve penetration rates by enhancing coolant flow and generating superior chip formation and evacuation. 4TEX inserts are 4-sided to maximize the tool life of each insert. They are available in geometries developed for steel, stainless steel, high temperature alloys, non-ferrous, and iron, which are optimized for excellent chip formation and wear resistance in difficult applications.

Q. Please update us on the recent developments and trends in the holemaking & boring tool segment?

The cutting tool market continues to be strong, but faces continued challenges with new materials emerging every day. Cutting tool manufacturers are developing products for these new materials as well as improving their current products. New innovations reduce their customers’ manufacturing costs by increasing productivity and tool life.

The most recent development in the boring tool sector is digital boring heads. They have historically been used in higher production facilities, but are becoming more widely used by shops of all sizes. They are great for high production facilities that need to adjust boring tools quickly and often, but they are also great for very small shops because of their ease in adjusting diameter. Machine operators of all skill levels can make a diameter adjustment when a boring tool is equipped with a digital readout. Not only do digital readouts eliminate the required skill-set of reading Vernier, they eliminate adjustment errors created by backlash. We are in a digital age

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Shavo Technologies Pvt. Ltd. 29/2 Kharadi, Off Pune Nagar Road, Old Kharadi Mundhwa Road, Pune: 411 014 Tel. No.: +(91) (0) 7030938211, 7410004817, Fax No.: +(91) (080) 28395963 Email: shavogroup@vsnl.com | Website : www.shavogroup.com

FACE TO FACE

and boring tools are no longer just for the elite.

Q. How do you perceive India as a market?

The India market holds a lot of promise and as a developing country, we have many opportunities for growth.

I feel India will be a prestigious hub for the entire Asian market.

Q. Comment on the opportunities and challenges that you see in the country in your segment?

We see many opportunities in infrastructure development, as well as with the automotive industry due to the increased buying capacities of the middle-income. Within the metal cutting industry itself, manufacturers are adopting lighter and stronger materials that offer great benefits, but provide new obstacles for machinists.

In reality, these challenges are the perfect opportunity to promote our tooling expertise and to develop new insert geometries, substrates, and coatings. These subtle yet intricate changes are resulting in remarkable improvements in productivity and cost savings.

Q. Which sectors do you primarily cater to? Tell us about your key clients.

We cater to manufacturers in the

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automotive, oil and gas, general engineering, and aerospace industries as well as their tier one, two, and three vendors.

Q. Please elaborate on how expectations and demands of Indian buyers is evolving with time?

Regardless of their industry, Indian buyers are eager to compete in the international market. They want tooling and technical support that reduce scrap, minimize tooling inventory, offer longer tool life and excel in exotic materials like titanium and super alloys.

Q. How does Allied Machine and Wohlhaupter meet these requirements to ensure customer satisfaction?

At times, special assistance is needed to optimize productivity or improve surface finish, hole straightness, or other key factors in challenging applications or unique materials. Evaluating a cutting tool application is an involved process.

Assessment should include tolerance allowance, material specification, coolant configuration, and machine limitations such as rigidity, max thrust, power, and much more. Other essential data can only be gathered through observation at the spindle as a part is running. That is where

our staff excels. We listen to our customers and work to troubleshoot and optimize their holemaking and finishing processes.

Also, free online utilities are in place to help customers navigate through the tool selection process.

In fact, Tool-Architect and ToolMD allow customers to virtually configure and customize tools based on customer specifications in just a few clicks of the mouse.

They can build, save, and download 2D drawings and 3D models for use in facility software for collision testing, etc. We also offer Insta-Quote, a user-friendly utility designed to help customers not only design customized tooling, but obtain quotes and place orders in minutes.

Q. What is your future vision and growth plan of the company?

Over the last two years, we have worked to form a cohesive â&#x20AC;&#x153;Alliedâ&#x20AC;&#x201C;Wohlhaupterâ&#x20AC;? identity in India and have made a strong impact by providing outstanding service to our customers. In the next three to five years, our strategy entails expanding our field support to provide outstanding engineering and technical support locally to more areas within India after IMTEX.

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FACE TO FACE

SBS Precision : The dynamic balancing & process control expert Mr. Rajesh Parsramka, Director SBS Precision Systems (India) Pvt Ltd B.E. Electronics & Communications Engineering B.I.T. Mesra Post Graduate Diploma In Business Management I.I.M. Calcutta

Q. SBS Precision being in the industry for longtime & has gained bounteous market share in Indian machine tool industry, please brief SBS Precision’s journey from the beginning & share some its achievements?

From a few handful customers a decade ago to hundreds of satisfied customers all over India today the journey has been full of challenges and success stories. We are now an important player in Dynamic Balancing & Process control business in India.

Q. What are the market prospects for the SBS Precision products in India and How do you plan to position these products?

Unlike our competition SBS is highly focused and specializes in providing solutions for complex applications for dynamic balancing and process control with the widest range of products available to meet customer’s technical specifications as well as budget constraints

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Q. Please elucidate in brief about the SBS Precision infrastructure & What are the measure that are being taken from the product manufacturing to distribution?

SBS Precision sees India as one market instead of breaking it up into regions like East, West, North Our quick and effective customer support is biggest strength. We provide single window solutions to all customers for any issue instead of creating separate departments for sales, service, administration etc.

Q. What are the key technological trends that are driving machine tool industry?

Manufacturing tolerances are becoming tighter with every passing day, product life cycles are becoming smaller, Manufacturing process have become highly flexible to adapt to any sudden changes in the business environment. All this provides high incentive to manufacturers to go for dynamic balancing and process control equipment.

Q. How do your perceive the future of the Indian machine tool industry?

Future is very bright and there are immense opportunities for growth Q. What is your vision for SBS Precision?

To continue to be the best choice for customers for dynamic balancing and process control equipment and always try to improve our services through innovation and hard work Q. Please address the issues that are affecting the machine tool industry?

Scarcity of working capital has been a serious concern with machine Tool OEM’s coupled with very high uncertainty about deliveries creating a long chain of blocked & un productive working capital. Lack of trained professionals in machine Tools industry is another big issue. The next generation of professionals are not yet ready to take over from the present generation who have rich knowledge and experience.

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Taming power quality is now child's play

When you use DigiVolt Stabilizers, Tranquil Ultra Isolation Transformers and Powercon Power Conditioners from Unity Controls, power quality is under total control and would no more hamper your production and product quality.

These silent sentinels protect your sophisticated, high precision production equipment from the ill-effects of voltage, spikes, surges, transients, sags, noise and harmonics affecting AC power lines. Thus ensuring continuous uptime and enhanced productivity and consistent quality.

Intelligent Microprocessor-based, High Efficiency, Energy Savers specially designed for CNC machines

Our equipment are approved by major OEMs and exported (up to 2000 KVA) to countries in Europe, Middle East, Africa

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So leave power quality and energy management to the experts â&#x20AC;&#x201C; Unity Controls.

With our nationwide network we are only a phone call away!

Contact us for Power Quality & Harmonic Audits to Conserve Energy and Save Costs.

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Ahmedabad l Bangalore l Chennai l Delhi l Gurgaon l Hardwar Indore l Jalandhar l Jamshedpur l Kolkata l Kanpur l Mumbai l Pune l Rajkot

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UNITY CONTROLS PVT. LTD

DRAG FINISHING UNITS - DF SERIES We get you to the FINISH with μ PRECISION OTEC-optimized surfaces ensure that workpieces full the high requirements of our customers. The focus here is on the nish or properties of the surface. In series production, reliably repetitive results and costeffectiveness deliver a real competitive edge.

Deburring

Rounding

Smoothing

before with burring, after completely free of burrs

cutting edge before and after nishing

droplets before and after nishing

highly polished surface, Ra 0.01 μm

Polishing

CLEANING PROCESS The Ultrasonic Cleaning process is efcient, Economical & Environment-friendly. Each industrial cleaning task requires its own flexible and optimized process.

Manual and automatic ultrasonic cleaning systems manufactured in series for standard cleaning process for precleaning, intermediate and nal cleaning.

TOOL MEASUREMENT. ROBUST. REPEATABLE. World wide leading tool manufacturers use Alicona for Quality assurance of Cutting edges and geometries within their production .

Measurement of Radius and Form

Chipping Measurement

Tool Roughness Measurement

Angle Measurement

CVD EQUIPMENT Advanced Chemical Vapor Deposition Coating Systems Bernx – CVD systems are the most CVD machines on the market. Since their introduction in the 1970s they have proven their reliability in hundreds of installation world wide. They are used in all major manufacturers of cemented carbide inserts and are increasingly used for coatings on forming tools .

Millenia Technologies 311, Options Primo, Plot No. X-21, CTS-31, Near Passport Ofce, Kondivita, MIDC, Andheri (E), Mumbai-400093, Maharashtra, India. • Tel: +91-22-28316101 / 28320401 Email: sales@millenia-technologies.com • URL: www.millenia-technologies.com

CVD Coating for Cutting Tools

Meet us at IMTEX 2019 Hall No. 3B & Stall No. C 120, BIEC Bengaluru International Exhibition Centre, Bengaluru, India

FACE TO FACE

Mr. Sivakumar Krithivasan Business Unit Head – India Midas Safety Private Limited

Midas Safety : The success journey through innovation Q. Midas is today India’s leading Personal Protective Equipment Manufacturing enterprise and one of the leading hand protection manufacturing companies in the World. Tell us something about your awesome journey so far.

We are one of the largest private label manufacturers of gloves in the world.

Midas started its journey in 1977 to manufacturing knitted gloves in Canada. Midas expanded and diversified into making cut & sewn gloves

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in Sri Lanka and later ventured into polymer dipping of gloves with PVC, Latex, Nitrile and PU over time. In the early 90s, Midas established its distribution division in Dubai focused on ‘Head to Toe’ personal protection and offering a one stop PPE solution to the customers. Midas serves customers in over 50 countries across the world.

Q. How is Midas positioning itself in the Indian Fire & Safety market?

In India, we have diversified into

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MGM-Pubblicità(210x297)_Layout 1 08/04/13 10.33 Pagina 1

HIGH QUALITY FOR YOUR MACHINERY

MGM brake motor main features

VARVEL production lines

• TEFC 3-ph asynchronous brake motor (0.09kW-130kW) • AC 3-ph brake (no rectifier) or DC brake on request • Oversized brake disc for higher brake torque, longer life and reduced maintenance • Fine and easy brake torque adjustment (as standard) • Very quick brake reaction time • Frequent START/STOP cycle applications • Manual brake release (as standard) • Hexagonal hole on non drive end of the shaft for manual rotation • Single speed or two speeds motors • All motors designed for inverter duty

• RS-RT worm gearboxes: 28 to 150 mm centres.

One stage worm, helical/worm and double worm.

• RD helical gearboxes: 50 to 2300 Nm. Two and three stages.

• RN parallel shaft gearboxes: 180 to 3300 Nm. Two and three stages.

• RO-RV bevel/helical gearboxes: 180 to 3300 Nm. Three stages.

• RG precision planetary gearboxes: 10 to 230 Nm. One and two stages.

• VR dry friction speed variators: IEC63 to IEC90 1 to 5 stepless speed range, 300 to 1500 rpm.

• VS planetary speed variators: IEC71 to IEC112 1 to 5 stepless speed range, 200 to 1000 rpm.

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A new generation of electric motors and gearboxes for power transmission quality from the alliance of two dynamic italian companies.

For those who want quality.

MGM-VARVEL Power Transmission Pvt Ltd Ware House No. G3 and G4 • Ground Floor • Indus Valley's Logistic Park • Unit 3 • Mel Ayanambakkam • Vellala Street Chennai - 600 095 • Tamil Nadu, INDIA • Phone: +91 44 64627008 • info@mgmvarvelindia.com • www.mgmvarvelindia.com REGIONAL OFFICE: KOHLI TOWERS • 4th Floor, Dapodi • Near Bharat Petrol Pump • Pune - 411012

FACE TO FACE

cotton, high performance knitted and dotted gloves, masks and helmet production. For other safety products we have established relationships with reputed global suppliers who produce at international standards.

Midas spares no efforts to be a one stop solution for Head to Toe PPE requirements to its customers.

The Indian market is unique and at a nascent stage in PPE adoption.

It has a mix of customers from - the well informed to the not so aware.

Multinationals with manufacturing bases in India, are bringing in the best global practices in safety and demanding PPE of international standards in their own plants. They are also enforcing these standards on to their vendors. Many medium and small manufacturing enterprises, are also initating basic PPE; to improve employee welfare and safety at the least possible cost.

The Indian government is on a reformative drive to bring positive changes to labour laws and is working out enforcement and compliance mechanisms, to ensure labour welfare. In my opinion, we have many exciting years ahead and the journey will be enriching for both, Midas and the industry.

We at Midas believe that Safety is for all, no matter how small or big. For the diverse requirements of the Indian market, we have product offerings from basic to extremely specialized usage and these are made available with the best in class comfort and performance.

Q. What is your new launch about?

How it is different from existing product ranges.

We have reorganized our existing

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product offerings, addressed portfolio gaps and have launched 3 brands - NINJA, TECHTION & VALPRO. NINJA is our international offering of Hand Protection already servicing safety needs across high compliance driven regions of North America, Europe, Australia and Latin America.

TECHTION and VALPRO are Midas Head to Toe PPE offerings, which have gained massive popularity within the Middle East and other emerging markets of the world Q. Please tell us how you and your company go about spreading awareness about safety wear among both your clients and people at large who need to know? Is mere advertising enough?

While advertising does play an important role to create awareness around safety, it’s not always enough. As a responsible safety solutions provider, Midas encourages active engagement from its teams with customers and end-users.

During these customer engagements, we at Midas learn of some real safety needs and get an opportunity to educate how our brands can provide great solutions that address their risks with relevance. Awareness also comes from using and experiencing our safety brands. This is facilitated through product demos and display sessions at end-users, interactions during safety week and product trials etc.

Our brand strategy is aligned to address the diverse requirements of the Indian market and every customer will find a safety solution, matching their needs.

Q. What is the competition you face today in your business?

The Indian market is still at the early stage of PPE usage and is expected to grow as awareness for safety increases. There are already established local and international manufacturers serving the Indian market. However, there is room for everybody and given the diverse segment and nature of the Indian market, there are numerous choices.

Midas will always uphold its global reputation of being a responsible, trusted and innovative provider of PPE solutions.

Q. What are the challenges faced by Midas in India & how are you going to out beat those challenges?

I touched upon this earlier and one of the principal agendas for our brands Ninja, Techtion & Valpro will be, to create adequate awareness around safety–with actual users and employers. This calls for a paradigm shift in thinking - “Return on Investment in PPE” versus “Reduced PPE Expenses”. Midas believes no short-cuts and consider in this to be the only way to garner long term growth for the industry and its brand offerings.

Q. What are the Future Plans of Midas for Indian and the Global market?

“Make in India” and “Make for India” … is the mantra. We have recently doubled our factory’s capacity at our Coimbatore plant and are fueling additional investments behind masks and helmets. Given the PPE potential, Midas is committed to significant manufacturing and R&D investments for India.

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FACE TO FACE

ROLLON: The linear motion leadership Q. Would you like to briefly introduce the Rollon Group and his global strategy?

The Rollon Group is a global company specialized in the production of components for linear motion. Rollon is having worldwide presence, the companies headquarter is in Italy (Milano) and the global sales activities are organized by our German Branch in Dusseldorf. Furthermore, our presence is very strong all around Europe and US market, today we are focused on India, China, Japan, Korea, Russia and Brazil, because our interest is developing the international market.

Rollon is the global leader for linear motion products in many different industrial sectors, especially the company is ranked first globally in markets like railway, warehouse logistics and aerospace industry. The strong point of Rollon Group is its ability to provide both standard and “customized” solutions to satisfy customers requirements for an industry or a specific application.

Rollon’s global strategy is strongly focused on emerging countries so

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Mr. Vikash Poddar Country Manager India Rollon India Pvt. Ltd.

in this direction, in March 2014, Rollon India Pvt. Ltd has been opened in Bangalore. The idea is to accommodate all the demand of our Indian customers with a local office, local people and a complete logistic centre, with the purpose of handling the requests with very short delivery times. The main segments are industrial machines, railways, transportation, defence, special vehicles, medical equipment and industrial automation.

Q. What could you tell us regarding to the development and the quality policy of the Rollon Group?

Rollon has become the international point of reference in all sectors for many different applications.

Customers can count on a highquality product that is both trustworthy and enduring. One of the most appreciated characteristic is the self-aligning capacity offered by our rails, in fact this is clearly demonstrated by the reduced costs associated with surface preparation and installation. Rollon success is determinate by at least other two

factors: firstly, our capability to develop applications that are ever increasingly specific and diversified based on the reference market, right up to making customized products, in some cases even co-designed with customer, and secondly our worldwide network of assistance centres. Every manufacturer or exporter of Rollon products may make use of the specialized assistance service provided by our team of engineers. They can also find our products in their own countries, avoiding extended waiting times and benefiting from the technical assistance whenever required, for a truly all-round technical support service as it happens in India.

Q. What is the function of R&D activity in your company?

The Rollon’s commercial approach on international markets are based on innovation and competitiveness so the constant involvement of the R&D department is remarkable in looking for solutions dedicated to the specific application of its customers in the manifold industrial sector and in all

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FACE TO FACE the major countries in the world.

Although our sales with customized products hits 35%, we keep improving our products in order to develop new to satisfy the requests and to offer a fulfilling system solution, not just products.

Q. What are the major technological trends that are leading your linear motion solutions?

There is a worldwide growth of linear motion market. The main engines are the automation of industrial processes, robotic movements and the global industrialization. We are keeping finding new applications and challenges to evolve and to produce new options.

The use of Rollon linear rails affords many solutions for multiple linear motion applications for industrial machines. The lateral sliding of protective devices, the movement of control panels or the movement of tools in machining centre are a few examples of linear rails. The potential of Rollon products is to avoid misalignment, most of all on the rails. Many of our products are built on a fundamental value that is the spirit of Rollon’s attitude: ‘C’ profile rails housing different types of sliders operated by rolling elements such as ball bearings.

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The rail-slider has a very compact configuration and enhanced uses of increasing spaces available: this manufacturing principle is essential to guarantee the ability of Rollon’s components to offer more benefits than other solutions available in the market. Moreover, internal circuit guarantee appropriate and high quality protection from possible shocks and dirt. To intensify rails’ weight capacity and duration the raceways of almost the entirely Rollon linear and telescopic rail are subjected to an induction hardening process. Furthermore, to expand rail’s sliding abilities some products undergo a grinding process.

Q. What are the market opportunities for Rollon products in India?

We are very optimistic regarding the opportunities for machine tool industry in India and consequently for the solutions proposed by Rollon, especially for our strong industrial markets like railway and automation projects. The linear rails, telescopic rails and actuators made by Rollon ensure proper function and improved performance of machine tools. What industrial machines should assure is adequate efficiency in the production process: especially machining centres, cutting machines, painting machines, and machines for processing wood or marble must be capable to provide a proper implementation on an extended period, often with challenging cycles and critical conditions

(presence of liquids, process residue, contaminants or corrosive substances). Procedure complications or machine interruptions create a lack of efficiency and additional costs. Every element must supply the proper functioning of the machine, guarantee an extreme accuracy and simplicity during the assembly and in replacement phases, keeping the maintenance down.

Q. Which Rollon products are particularly suitable for the Indian market?

Our production range has a three main lines: the linear line that contains linear caged ball bearings and recirculating ball bearings rails, with different profiles and kind of sliders. The telescopic line with full and partial extraction telescopic guides, accessible in several rail profiles and characteristics like load capacity, inflexibility and proper functioning. The actuator line with linear components available in many extremely load capable and accurate typed of belt and ball screw driven models and arrangements. At this time the Indian market is particularly developing in the automation, logistics, defense and medical sectors: this is why the telescopic rails, the seventh axis system, the actuator line (uniline system and smart system) are widely used.

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 info@rollonindia.in www.rollonindia.in

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CASE STUDY Chennai-based Classic Engineering was in a predicament when their customers demanded a scale down in the costing of their product and needed a consistent solution to improve productivity, quality and on time delivery. Speroni was able to pitch in and be a part of the solution offering a measuring tool that would help reduce the production time thereby meeting the demands of the customers without losses

Speroni’s Measuring Tool System Improves Productivity and Quality “Speroni tool has been very helpful in increasing efficiency.

Subsequently, it reduces manpower as the tool sets the machine explicitly in the correct parameters which optimizes our production.”

A.K.Chenniappan, Managing Director, Classic Engineering

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C

lassic Engineering is a manufacturing company that specializes in fabricating machines parts for varied engineering industries and are also the leading manufacturer of wind mill components like Mainframe, Hub Rear frame in India. Welding, metal finishing, heavy metal fabrications are some of the other services provided

by Classic Engineering.

Speroni is an Italian company that provides solutions for technical glitches with greater added value that simplifies the complexities that

occur in manufacturing. They have a glorious history of aiding varied industries with their unique problem – solving methods and delivering esteemed quality products that are cost effective which serve as a great help for a manufacturer. Advancing the use of resources to create the right tool for the right machine stipulates competence and precision to be decisive and accurate.

Challenge While operating a machine it is very important to have all the tools of accurate size as even a marginal misfit can hinder the function. There are two aspects to the functionality of a machine; one is less in cost but high in operation of the machine and vice versa, high and cost but low in operation. If a tool needs to be 30 microns flat with no line then even a minute difference in the tool can be a huge roadblock in the operation of the machine that results into the increase in cost. Consequently, Classic Engineering had a customer that needed Windmill components

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CASE STUDY however when the target price was decided by the customer it became a challenge for Classic Engineering to deliver the requirement without compromising on quality or bearing any losses. Hence, they had two major challenges: first to meet the target price of the customer and second to provide quality components on time.

How Speroni’s Solution Helped Classic Engineering Using reverse engineering, Classic Engineering started analyzing ways to reduce production time. They needed to find a solution that would optimize production with effective use of manpower and machine and a fix that would be high performing reducing the operation cost. Classic decided to invest more on high end tools that would serve as a solution to all the problems and thereby fulfill all the above requirements. Speroni offered their Tool Measuring System that was as per the set parameters which worked like a permanent and steady solution for the problem. With the help of this tool Classic was able to meet the customer demands on time without a dip in quality.

The second aspect was that the tool could be used until it wore out up to 80% after which it needed to be replaced again with utmost precision and accuracy meeting every parameter correctly. Speroni ensured that the tool was replaced explicitly without any errors in the required parameters.

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Classic Engineering was able to function efficiently after overcoming this major setback. Customer’s needs were met as they delivered the products in time as per the criteria.

This also developed a relation of trust between Classic and Speroni thereafter Classic made sure that every tool is validated by Speroni before utilizing it.

Classic Engineering explained their precise acumen in quite an amusing

way. While driving it is apparent to use a seatbelt for safety and protection that assures confidence, focus and control especially when you speed up. Similarly, with a machine high speed changes the concept of machinery with proper measures and provides no room for human errors. Hence, the tool measuring system works like a seatbelt for the high speed machine, as the tool of a machine is constant rest everything is variable.

“The production time has reduced the utilization of machines by 25% and it is being used as an inspection machine for combination tools that sets the machine accurately in the right parameters. The product has been very helpful, Speroni is not an instrument, it is like a machine, very rigid,” says Dinesh, Shopfloor Manager, Classic Engineering.

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CASE STUDY

EFFICIENT & ULTRA-DYNAMIC: SIMULTANEOUS MILLING & TURNING An extremely impressive machine concept providing the option of milling and drilling without re-clamping and – above all – a high level of process safety with maximum accuracy for workpiece machining. Impressed by these benefits, the services provider HETEC located in Breidenbach, Hessen, has become a loyal GROB customer in the field of milling.

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tuttgart, AMB Trade Fair in September 2010. Hans Rink, Head of Rink Werkzeugmaschinen and GROB Representative for the Hessen region, mana-ged to persuade HETEC MD Friedhelm Herhaus to visit the GROB trade fair stand. Back then, Friedhelm Herhaus was rather sceptical about the size of GROB as a com-pany, as he couldn’t believe that he would really be taken seriously as a regional sup-plier of tool, die and machine manufactu-ring products from one of the world’s big-gest machine tool companies. But he soon knew better.

2010 saw him standing in front of a world first from GROB – the first fully hydrau-lics-free, fully CNC controlled machining center. Back

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Deep-hole drilling on a G550 – Use of extra-long tools without restrictions on the maximum part size

then, he wasn’t interested in all the arguments for and against hydraulics-free machine tools. He was much more interested in the horizontal spindle position on the G550 and that you could mill and drill with it at the same time without having to re-clamp

the workpiece or take it to a deephole drilling machine. An important factor for tool and die construction, but for many mechanical engineers, too, when they have to drill deep holes. The highly experienced Friedhelm Herhaus had never seen

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CASE STUDY milling and drilling on a single machine of this kind before. So it initially got his interest, at any event.

He found the travel and GROB kinematics – the whole machine concept in fact – very appealing.

Thorough preliminary research & intensive technical analysis Nevertheless, the disinclination to opt for a GROB 5-axis universal machining center was strong. Basic issues needed to be clarified first as to whether HETEC actu-ally wanted to implement the axis sys tem (with rotated Y axis). An axis system that was totally new territory to HETEC at the time. But as he traveled back from the trade fair, Friedhelm Herhaus called Hans Rink to discuss the machine’s axis symmetry and the machining technology for workpieces with long tools. He was increasingly persuaded, recognizing that workpieces can be machined with long tools with the GROB machine and that the horizontal spindle position enables opti-mum chip removal for both drilling and deep cavities. The question of the extent to which the GROB machine would suit existing HETEC machine tools also needed to be clarified, and

GROB‘s automation solution – the rotary pallet storage system PSS-R

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whether this type of GROB machine with its specific axis con-cept could be integrated in the HETEC environment successfully.

Friedhelm Herhaus could instinctively see the potential of the GROB machine. Fur ther discussions took place in Mindelheim and Breidenbach – with long phone calls – and they finally hatched the idea of deve-loping a “fantasy component”, for which the GROB machine concept minus re-clam-ping and multiple clamping would deliver rapid results.

There was also a requirement to create various contours on the GROB machine. Chip removal with deep pockets was another major issue on the check list. “We were really impressed by the assistan-ce we received from the GROB technicians.

Even at an early stage of our collaboration, when we hadn’t even bought a machine yet, we quickly realized that GROB loo-ked after new customers really well, the aim being to find the best user solutions”, Friedhelm Herhaus looks back to the time with fondness.

HETEC team impressed by GROB technology The more Friedhelm Herhaus and

his tech-nicians got to grips with the technology of the GROB machining centers, the more they could see the strength of these machi-nes. First the benefit that – thanks to the special axis concept – the entire length of the tool can be used in each axis setting – even at maximum workpiece size. And the special tunnel concept means that the whole work area can be used, as the motor spindle plus tool withdraws into the spindle shaft, meaning that the machine table can rotate and swivel with the workpiece and clamping mechanism without colliding a definite plus point. Something comple-tely new to the die HETEC technicians. In Mindelheim for training during the initial and test periods, the machine operators soon appreciated another benefit provided by GROB machines: The spindle is positio-ned almost at eye level, giving a good view of the machining tool.

From the first G550 to the G550 with rotary pallet storage system (PSS-R) After successful testing at GROB in Mindel-heim, the HETEC management team finally took the decision to buy a G550. Particularly because the axis concept allows for machi-ning deeper cavities with good

High-precision machining of complex part contours

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CASE STUDY GROB in-house trade show in 2015.

The HETEC management team were impressed by the benefits of a G550 with a rotary pal-let storage system (PSS-R), purchasing one soon afterwards with a master computer.

A major plus point in their eyes was the fact that, even with the GROB automation ap-plication, the machine operator still had a good view and access to the work area.

f.l.t.r.: Mr. Friedhelm Herhaus (CEO), Mr. Hans-Hermann Rink (GROB sales agency Hesse) and Mr. Tom Herhaus (HETEC machine operator of the GROB G550)

chip remo-val and drilling operations with deep hole drilling tools (Ø 8 x 650 mm) went without a hitch. The first GROB G550 was then in-stalled as planned for machining modelling components with complex contours, high surface requirements and parallel introduc-tion of cooling bores in a single clamp. La-ter on, HETEC soon saw the machine’s ac-tual potential at HETEC for machining used in die and mold construction.

The G550 was ideal for machining the high-strength, hardened steels typically used in this area. HETEC technicians were amazed by the option of full introduction of cooling and ejector bore with tool lengths of

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up to 650 mm in the same clamp.

Continuing close collaboration between HETEC and GROB, allied with a desire to introduce automation for die- and tool-ma-king processes with typically long running times, led to the purchase in 2014 of a G350 with a zero point clamp system and a pallet system that made it possible to set up workpieces outside of the machine. Completed pallets were replaced by newly fitted ones manually. But it was also clear that simultaneously setting up the workpie-ces while the machine was running would result in greater flexibility and improved spindle running times. And then came the

A solid partnership is formed At an early stage of discussions and the process of getting to know each other, HETEC dismissed fears of a David and Goliath situation. Both sides soon learned to value each other as they looked for the best solution.

The GROB philosophy of “nothing’s impossible” ultimately won the day. GROB acceded to nearly all of the customer’s wishes, developing special solutions. The purchase of a G550 seven years ago marked the beginning of a solid collaboration based on trust – something that HETEC had never before experienced in over twenty years of existence.

HETEC are also really impressed by the GROB Ser-vice hotline and expert technical support. So it’s no surprise that Friedhelm Herhaus is really pleased with his Swabian Bava-rian partners, buying more machines in Mindelheim.

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CASE STUDY

Gala Precision’s Deburring, Finishing & Cleaning Solutions

Gala’s automatic, multi-stage ultrasonic cleaning machine for precision cleaning

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hane-based Gala Precision Engineering is a one-stop solutions provider when it comes to de-burring, finishing, washing and cleaning of machinery parts and components. It offers the whole gamut of systems and services for carrying out the said operations.

Gala’s Automatic Multi-stage Ultrasonic Cleaning Machine is a workhorse designed for precision cleaning of engine parts, shock absorbers, clutch housings, aluminium die castings, transmission parts and manifolds. It features spray, ultrasonic and immersed flood processes enabling multiple washing and rinsing operations. Its pre-programmed, automatic material handling system facilitates higher productivity due to simultaneous handling of multiple baskets. The gradual step-down type multi-stage filtration and contamination separation mechanism ensures that filtered fresh cleaning medium is available for every cycle, leading to consistent cleaning quality. On the other hand, the basket rotation mechanism ensures maximum exposure of component surfaces to washing, rising and drying processes.

Case Studies Galore Gala has come up with interesting case studies. One case study pertains to Multi-stage Ultrasonic Cleaning of a shock absorber part which was contaminated by buffing dust. Hitherto the customer was adopting manual cleaning. The solution Gala offered was 2-stage ultrasonic cleaning with on-line filtration. The cleaning media used was aqueous, alkaline. And the cleaning was done in two stages. The first stage was ultrasonic cleaning and the second stage involved hot dip rinsing. The operation helped in increasing productivity and reducing labour cost for the customer.

In another case study, Gala describes the solution it provided for removal of buffing dust from swash plate. The input component was contaminated with water-based coolant and loose burr. Gala used a Single piece flow ultrasonic cleaning using aqueous and alkali. The cleaning was carried out in four stages. In the first stage it used ultrasonic cleaning. This was followed by spray rinsing, air blow-off and finally hot air blow-off.

The entire operation was done without manual intervention. The result was consistent cleaning and 70% reduction in labour cost.

The 3rd case study is on cleaning of clutch hub with the input contamination of loose burr. The client was using batch washing to make the surface free from loose burr. Here Gala

An engine housing : before cleaning & after ultrasonic cleaning www.mtwmag.com

used conveyorised spray washing using aqueous, alkaline media. The machine followed the following four stages: spray washing, spraying rinsing, air blow-off and hot air blow-off.

It resulted in the following advantages: single piece flow, no manual intervention, and reduced labour cost.

The fourth case study related to precision cleaning of engine housing. The input contamination was oil and loose burr. The client wanted gravimetric value of less than 2 mg and particle size of less than 600 micron. In this case, Gala resorted to Multi-chamber, Multi-Process Ultrasonic cleaning. As in the earlier case, the cleaning media were aqueous, alkaline. The cleaning process involved three stages: spray + ultrasonic + immersed flood; spry + immersed flood; and hot air blow-off.

The result achieved was high productivity and consistent cleaning quality.

Cleaning Chemicals : Gala has some 10 types of chemicals for cleaning aluminium die casting parts involving different applications such as degreasing, de-scaling, cleaning oil and other contaminants, achieving bright surface finish of components, etc. It also offers high performance de-rusting, degreasing & finishing compounds and media which can achieve a Millipore value less than 1 mg particle size as per class A, and Ra value improvement up to 0.5 micron.

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CASE STUDY

Laser interferometry assures spherical lens quality

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pherical optical lenses are a critical component in a wide range of high-resolution industrial and scientific research applications, from imaging systems in the aerospace sector to mask alignment in semiconductor manufacturing.

Ensuring the complete accuracy of spherical lens geometries is vital in assuring any system’s image processing quality, with even the slightest error in lens manufacture having a profound impact on system reliability and performance.

Beijing Institute of Technology (BIT), China, has used Renishaw’s XL-80 laser interferometer to develop a high precision instrument capable of simultaneously and reliably measuring all the key dimensional parameters of a spherical lens.

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Background Founded as a public university of science and technology in 1940, BIT today sits proudly in the top 1% of the Essential Science Indicators (ESI) global rankings in five different disciplines: chemistry, engineering, material science, mathematics and physics.

As a part of its on-going research

into spherical lens parameter measurement, BIT’s School of Optoelectronics recognised a fundamental need to dramatically increase the efficiency and capability of existing instrumentation.

While industry had already developed a variety of methods of measuring spherical lens parameters, they required the use of multiple

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CASE STUDY

XL-80 laser interferometer

instruments. In many sectors measurement technologies, for example surface shape measurement , though very mature, still lacked precision.

BIT therefore embarked on a program to design and develop a differential confocal laser interferometry-based instrument that would successfully address the weaknesses and deficiencies of existing measurement solutions. A crucial enabling technology at the heart of BIT’s radical new instrument was Renishaw’s XL-80 laser interferometer.

Dr Weiqian Zhao, Professor at BIT’s School of Optoelectronics said, “Our technical focus was on combining differential confocal measurement technology with surface shape interferometry technology to create an integrated system capable of performing a complete set of synthetic parameter measurements on all kinds of spherical lens.”

Challenges The accurate inspection and verification of any convex (converging) or concave (diverging) spherical lens demands a complex set of measurements to be made. These include: lens surface shape, curvature radius, focal length, refractivity, thickness and axial gap.

The development of an instrumentation system architecture

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flexible enough to enable the high precision measurement of every one of these spherical lens parameters set a very clear challenge for BIT. And while a wide choice of alternative laser interferometry solutions could deliver the measurement precision, not all could provide the assured stability and reliability demanded by repeated lens inspections.

Verification of laser interferometer performance was required.

At the same time, BIT’s instrument would also aim to minimise the amount of manual handling and setup time required by each lens for each successive parameter measurement.

Finally, instrument compatibility with clients’ systems provided some further essential design criteria, ensuring transparent access to interferometry measurement data.

Solution BIT’s differential confocal laser interferometer harnesses the light intensity response signal curve properties of differential confocal principles. This is used to precisely locate the target lens and implement high precision measurements of curvature radius, focal length, refractivity, thickness and axial gap. The principles of multi-step phase-shifting interferometry are also employed to carry out the surface shape measurements.

With most of the key components

developed in-house at BIT, the instrument’s system architecture essentially consists of: a main differential confocal unit (including differential confocal optical path); a standard lens; aerostatic slideway; multi-dimensional adjustment stage; electromechanical movement platform and the Renishaw XL-80 laser interferometer.

Dr Zhao explained the instrument’s operation, “The main differential confocal unit fires a measuring beam at the target lens and concentrates it at the focal point of the standard lens; the target lens is mounted on the aerostatic slideway using a multidimensional adjustment stage; the electromechanical movement platform moves the adjustment stage along the optical axis of the target lens.

“When the measuring beam’s convergent point overlaps with the front vertex or rear vertex of the target lens surface, the beam is reflected back along the path by the surface of the measured lens for data analysis, while a length measurement laser interferometer simultaneously captures instant position coordinate data for the target lens.”

He added, “We chose the XL-80 from Renishaw as it is one of the very few laser interferometers capable of providing the precision we needed along with assured stability and reliability.”

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CASE STUDY

The measurement principles employed by BIT for typical spherical lens parameters are explained below: • Focal length - pinpoint the focal length of the target lens, measure the distance between the focal point of the lens and the rear vertex.

• Surface shape - the interferometry system integrates reference beam phase-shifting to measure the interference patterns formed by the light reflected back from multiple measured elements and the reference beam, and uses a phaseshifting algorithm to process the interference pattern and ascertain the surface shape of the lens.

• Curvature radius - pinpoint the vertex and sphere centre of the measured spherical surface and calculate the distance between the two points.

• Thickness/refractivity - pinpoint the point of intersection between the front surface and the optical axis of the target lens, the point of intersection between the rear surface and the optical axis, and the position of the target lens when the lens for measurement is both present and absent. Then use the position of the measuring lens and the previously measured curvature radius, focal length and pupil size

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of the measuring lens to perform facet-ray tracing calculations on the two spherical surfaces of the measured lens and the reference reflector, and thereby implement high-precision measurements of the refractivity and thickness of the measured lens.

• Axial gap - pinpoint the vertex of each lens, then combine with the numerical aperture of the measuring beam, the curvature radius of each surface in the measured lens group and the refractivity of each lens, and use the ray tracing method to obtain the axial gap between each transparent surface.

Result With its unique ability to simultaneously measure all key parameters of a spherical lens, BIT’s differential confocal laser interferometer is enabling users to significantly reduce expenditure on equipment by replacing several different instruments with just one.

Its all-in-one instrument design and innovative lens mounting system means that users are also able to dramatically reduce set-up time and so increase measurement efficiency, by eliminating the need to disassemble the target lens and

readjust the optical path for each new parameter measurement.

Importantly, the inclusion of the XL-80 laser interferometer ensures excellent system compatibility.

During the software development process, BIT engineers were able to use XL-80’s dedicated dynamic link library within their programming, enabling real-time laser interferometry data to be easily integrated with client systems.

Dr Zhao said, “Renishaw provides a range of laser interferometry analysis software offering some really powerful functionality. This functionality though also enables us to perfectly integrate real-time measurement data into our own proprietary analysis software, providing us with even greater flexibility when we are developing customised instruments for clients.”

He continued, “We also like to work closely with our suppliers during the system integration and commissioning process, and we have found Renishaw’s after-sales service to be impeccable. Their engineers are very willing to take the time to discuss technical issues with us and offer valuable, expert advice.”

For more information Website: www.renishaw.com

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PRODUCTS SHOWCASE

PRODUCT SHOWCASE KING CUT PRO – The Large Gantry Type CNC Cutting Machine Ador’s KING CUT PRO is a CNC portal cutting machine which is very precise and reliable. The machine has one head for plasma sheet metal cutting & one head for flame cutting of sheet metal with a dual side longitudinal drive with AC motors.

The standard equipment comes with a basic machine package with CNC controller, one torch, central gas diffusion with manometers and a remote flame ignition.

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

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

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The CNC Controller – Phantom: The Phantom brings you the performance of a cutting edge CNC that is built on more than 40 years of experience in the motion control and cutting industries.

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

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PRODUCTS SHOWCASE

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

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

Following are some of its unique features: • Intelligent microprocessor-based system(available in new digital models) • Digital interface with large LCD display and keypad • Auto re-start, adjustable output voltage, trip bypass, fault list • No hunting, oscillation and noise generation • Innovative transformer design to minimize power loss • Constant output voltage across a wide input voltage range • Single phasing prevention, surge suppressor and EMI / RFI filter With the best-in-class response time and correction rates, Steady Volt offers improved power quality and greater energy efficiency, thereby saving the cost of breakdowns and energy utilization. Apart from protecting your equipment from damage, Steady Volt also saves energy during continuous operations.

The new Gast 86/87R Series of oil-less rocking piston compressors & 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.

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

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Designed to performs : “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.

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Heavy Load Series-FSVH Features : Focused on improvements of contact points of balls and thread grooves, ball diameter and circulation system for new type, FSVH. The rated dynamic load has been increased to as two times as that of conventional type, FSVC. Long Life : Structure of the newly developed circulation system is designed to distribute the load uniformly to the load balls and it also increases the life of ballscrews. On conventional circulation system, FSVC, the returning tube is inserted into the holes on ballnut perpendicularly which forms an advancing angle. While ball moves into returning tube, it will hit tube end area and then move into returning tube. New circulation system, FSVH, ball will move into returning tube smoothly by tangent line as the same direction as lead angle. It can increase the life of circulation system structure.

High DN Value: With the newly developed circulation system, ballscrews can meet the demands of high speed running with high DN value.

For Product Enquiry Contact Superslides & Ballscrews Co. India Pvt Ltd SUPERSLIDES HOUSE, A-774 T.T.C Industrial Estate, MIDC, Firebrigade Road, Off Thane- Belapur Road, Koparkhairne, Navimumbai-400 701 (INDIA) Tel.: 022-4935 5555 (40 Lines), Fax: 022-4935 5556 E-mail: sales@superslides.in / info@superslides.in Website: www.superslides.in

Low Noise: To use tangential circulation system structure, it can eliminate the noise while balls run into the returning tube.

Various Specifications Combination : PMI can supply various ballscrews with diameter 40~120mm and lead 10mm to 60mm (Please contact PMI or your specific design requirement) Application: Plastic Injection Machines / Press and Forging Machines Semiconductor Equipments / General Machines

BILTZ AEROSPACE TOOLS

For Product Enquiry Contact BILTZ CUTTING TOOLS COMPANY J-351 M I D C Bhosari, Pune 411026 Mob : 9823022042 Ph : 02046761014 Email : biltz@vsnl.net Web : www.biltzindia.com

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Biltz Cutting Tools Company is An ISO 9001-2015 certified company has developed High Performance Endmills For Aluminium machining .

The High Performance Endmills are majorly used by Aerospace Industries to machine structural parts of Aircraft where high precision along with very good structural properties are required Biltz End Mills for Aluminium are designed with geometries of 35°, 40°, and 45° Helix and are specifically engineered to accelerate metal removal rates and achieve a quality finish in aluminium and non-ferrous materials. These Endmills have offset chip breaker geometry that creates smaller chips for optimal evacuation thus requiring lesser torque and horsepower while machining. Endmills are also offered with through coolant facilities and cylindrically reduced necks for Long reach for deep pocketing applications. Endmills with corner radius manufactured on request.

BILTZ End mills are built to last and excel at aggressive running parameters, meaning user will experience greatly reduced cycle times, heightened productivity, and superior part finish. This translates directly to savings and efficiencies in your shop, and positively affects your bottom line.

BILTZ also make Solid Carbide Cutting Tools, Drills, Endmills, Profile Cutters, Thread mills, Special Tools as per drawings and customers specifications. BILTZ also undertake Regrinding and Recoating of cutting Tools.

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PRODUCTS SHOWCASE

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

VARIMETER RCM: Reliably identify current faults!

For Product Enquiry Contact DOLD Electric India Pvt Ltd (100% Subsidiary of E.DOLD & Sohne Kg - Germany)

B – 3 Vishranti Heritage, Gotri Road, Vadodara – 390 021 Call: +91 990 9001585 Website: www.dold.in

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Increased availability of machines and devices The residual current monitor RN 5883 of the VARIMETER RCM family from DOLD, sensitive to all universal currents, records current faults either with DC or AC components in earthed supply systems (type B). Through early recognition of insulation faults, the RN 5883 provides a preventative service and maintains machines and devices. System downtime and production disruptions can consequently be avoided. The residual current measurement takes place over an external current transformer.

The residual current monitor RN 5883 provides an informational advantage for specific and cost-effective maintenance - before the machine stop working. As well as the clearly visible LED chain for measured residual current, the LEDs indicate operational status, pre-alarm and alarm. In addition, the device indicates test functions and optional analogue output through breakage. This residual current monitor finds its place in fourfold usage, and increases the availability of energy supply whilst simultaneously minimising the risk of fire. Devices, in which current faults can occur due to porous cables, moisture or dust deposits, will be reliably monitored with the RN 5883. Examples of application include building automation, data centres, traffic engineering, climate & air conditioning devices.

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“Ninja” High Performance Range Indian Tool Manufacturers “ITM” – (A division of Birla Precision Technologies Ltd.) has newly launched NINJA Taps, Drills and End Mills. ITM focuses on its R&D department to continuously develop exceptional quality products for its customers. As a result of this extensive study and continuous efforts, we proudly introduce ITM “NINJA” High Performance Series a new range of products to compete with international standards to ensure Superior Performance, Extra Tool Life and Guaranteed Results.

I) NINJA series Taps trare made out of the finest grades of HSS materials. These High Performance Taps are manufactured on our latest CNC Machines, with special geometries to suit different machining applications, based on work materials. ITM NINJA series Taps consists of Spiral Flute, Spiral Point, Roll Form, and Straight Flute-Cast Iron. To get enhance the performance of taps, we can supply theses taps with surface treatment like TiN, TiAlN, TiCN etc., 1. Spiral Flute Taps are best Suited for Blind Hole applications and are specially designed to eliminate chip clogging, they are available in size range of (Size Range: M3 to M16).

2. Spiral Point Taps are specially designed for Through-Hole application and are suitable for higher cutting speed for higher productivity. Size range is from M3 to M16.

3. Roll Form Taps is best suitable for both Blind and Through-Hole application. Roll forming operation is chip-less operation, forming a thread by displacement of materials and not by cutting, hence these taps are best suitable for soft materials like Aluminum, Brass, Bronze etc., the size range is from M6 to M16.

4. Straight Flute - Cast Iron Taps are best suitable for Cast Iron material and size range is from M3 to M16.

II) NINJA series of Drills are also made out of the advanced grades of HSS premium materials. These Drills are produced on our latest CNC Machines, with unique geometries to give better accuracy holes and best performance. These drills are developed to machine hardened steel materials like Stainless Steel, Nickel Chromium Steel and Forged Steel etc. These NINJA High Performance Drills are designed having Special point geometry to reduce thrust forces while drilling. Ninja drills are made with special Surface treatment for maximum wear resistance. Size range in metric as per IS 5101 Metric Size 3.0mm to 13.0 mm Inch size as per BS 328 Inch Series: 1/8”to ½.”

For Product Enquiry Contact Birla Precision Technologies Limited Email: itmth@indiantool.com

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III) NINJA Series of End Mills are made out of best quality of HSS grade of Materials. These High Performance End Mills are manufactured from our latest CNC Machines, with special geometry to give better performance with higher productivity. These End Mills best suitable for materials like Stainless Steels, Nickel Chromium steels and tougher machining applications.

These new series of our “NINJA” range of Products are new generation tools which will work at higher cutting parameters on latest CNC Machines and we are very confident that these products are best solutions for your higher productivity.

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ADVERTISERS INDEX COMPANY NAME

PG. NO.

A

COMPANY NAME

PG. NO.

D

ACCUSHARP CUTTING TOOLS PVT. LTD.

207

DAHANUKAR MACHINE TOOLS

211

ACE MICROMATIC GROUP

BACK PAGE

DELTA ELECTRONICS INDIA PVT. LTD.

97

ADEPT PROSIGN PVT. LTD.

203

DMG MORI INDIA

23

ADOR WELDING LIMITED

231

DOWEL ENGINEERING WORKS

227

ALEX MACHINE TOOLS PVT. LTD.

165

DUTCH TECH TOOLS PVT. LTD

122 - 123

ANCA MACHINE TOOLS PRIVATE LTD

9

DVS TECHNOLOGY GROUP

149

E APEX PRECISION MECHATRONIX PVT. LTD.

237

ARHAN TECHNOLOGIES PVT. LTD.

53

ASHWINI ENGINEERING INDUSTRIES

173

ASIAN MACHINE TOOL CORPORATION PVT. LTD.

133

ATUL MACHINE TOOLS

209

B BECKHOFF AUTOMATION PVT. LTD.

11

BHAVYA MACHINE TOOLS

131

ELECTROTHERM (INDIA) LTD.

17

ELGI EQUIPMENTS LTD.

29

EMAG INDIA PVT. LTD.

77

EMUGE-FRANKEN INDIA PVT. LTD.

171

BLASER SWISSLUBE INDIA PVT. LTD.

39

C CHIRON INDIA MACHINE TOOLS PRIVATE LIMITED

27

CNC INDIA TOOLS & SERVICES (P) LTD.

193

CNC SOFTWARE, INC.

INSIDE BACK COVER

PG. NO.

GEDEE WEILER PRIVATE LIMITED

21

GEM ORION MACHINERY (P) LTD.

213

GIVI MISURE PVT. LTD.

139

GLEASON WORKS (INDIA) PRIVATE LIMITED

69

GLOBE-TECH ENGINEERING EXPO - 2019

249

GP PETROLEUMS LTD.

91

GROB MACHINE TOOLS INDIA PVT. LTD.

87

H HEIDENHAIN OPTICS & ELECTRONICS INDIA PRAIVATE LIMITED

191

113

HOSABETTU HEAVY MACHINERY LLP

73

ENGIMACH - 2019

55

I

EPPINGER TOOLING ASIA PVT. LTD.

246 - 247

IMTEX - 2019

67

ERWIN JUNKER MASCHINENFABRIK GMBH

25

IMTOS - 2019

251

INTEC - 2019

43

EXXONMOBIL LUBRICANTS PRIVATE LIMITED

41

F BIRLA PRECISION TECHNOLOGIES LIMITED

COMPANY NAME

J JYOTI CNC AUTOMATION LTD.

19

FACCIN S. P. A.

81

L

FATTY TUNA INDIA PVT. LTD.

89

LUBECO

FENWICK AND RAVI

93

M

FIBRO INDIA PRECISION PRODUCTS PVT. LTD.

157

MACO CORPORATION (INDIA) PVT. LTD.

225

FLIR SYSTEMS INDIA PVT. LTD.

117

MARPOSS INDIA PVT. LTD.

127

MEERA CASTING

229

MEGADYNE GROUP

111

G GALAXIEE CONSULTANCY PVT. LTD.

169

JANUARY 2019

119

MACHINE TOOLS WORLD

267

ADVERTISERS INDEX COMPANY NAME

PG. NO.

COMPANY NAME

PG. NO.

COMPANY NAME

PG. NO.

MEIBAN ENGINEERING TECHNOLOGIES PVT. LTD.

197

PMT MACHINES LIMITED

199

SOLITAIRE MACHINE TOOLS LTD.

187

MGM-VARVEL POWER TRANSMISSION PVT LTD

243

PRECIHOLE MACHINE TOOLS PVT. LTD.

129

35

MICRO-EPSILON INDIA PRIVATE LIMITED

SPANISH MACHINE TOOL TECHNOLOGY EXHIBITS AT IMTEX

179

SPRAYMET SURFACE TECHNOLOGIES PVT. LTD.

233

SUNTECH LANDRIANI MACHINE TOOLS PVT. LTD.

155

MIDAS SAFETY PRIVATE LIMITED

201

MILLENIA TECHNOLOGIES

240 - 241

MITSUBISHI ELECTRIC INDIA PVT. LTD.

15

MMC HARDMETAL INDIA PVT. LTD.

INSIDE FRONT COVER

MOTULTECH INDIA

37

MULTI AXIS CNC

107

MULTIDIMENSIONS

183

145

PRECISION MOTION INDUSTRIES, INC. ( PMI )

189

Q QVI INDIA PVT. LTD.

205

R

N N-GRAVETEK

PRECISE CUTTING TOOLS

137

RADIUS ENGINEERING SOLUTIONS PVT. LTD.

161

RAVIK ENGINEERS PVT. LTD.

153

RAVISON'S CORPORATION

195

RENISHAW INDIA (PUNE)

105

ROLLON INDIA PVT. LTD. - INDIA

181

RR KABEL LIMITED

31

TECROOT SPACE (OPC) PRIVATE LIMITED

245

TIRUPATI INDUSTRIES

175

TRUCUT PRECISION TOOLS PVT. LTD.

FALSE COVER, 13

TYROLIT

33

U UCAM PRIVATE LIMITED

57

UNITED GRINDING GMBH

63

UNITY CONTROLS PVT. LTD.

239

NICOLAS CORREA, S. A.

45

NISHA ENGINEERING WORKS

141

RUDRALI HITECH TOOLS PVT. LTD.

NORD DRIVESYSTEMS PVT. LTD.

215

S

NYNAS NAPHTHENICS PVT. LTD.

109

SBS PRECISION SYSTEMS (INDIA) PVT. LTD.

101

V M TRADERS

135

SCHMALZ INDIA PVT LTD

221

VOLLMER TECHNOLOGIES INDIA PVT. LTD.

95

SCHMERSAL INDIA PVT LTD

FRONT GATEFOLD

W

SEVEN STEPS BUSINESS TRANSFORMATION SYSTEMS

85

SEW-EURODRIVE INDIA PRIVATE LIMITED

217

SHAVO TECHNOLOGIES PVT. LTD.

235

YAMAZAKI MAZAK INDIA

58 - 59

SMC PNEUMATICS (INDIA) PVT. LTD.

65

YG-1 INDUSTRIES INDIA PVT. LTD.

INNER GATEFOLD

O OERLIKON BALZERS COATING INDIA PVT. LTD. OPEN MIND CADCAM TECHNOLOGIES INDIA PVT. LTD.

INNER INSIDE FRONT COVER

121

V

115

P

268

T

PARAGON MACHINERY CO. LTD.

83

PILZ INDIA PVT. LTD.

223

MACHINE TOOLS WORLD JANUARY 2019

WOHLHAUPTER / ALLIED MACHINE & ENGINEERING COMPANY

49

Y

THE FUTURE STARTS HERE

To see how Mastercam 2019 helps streamline your entire process, from job setup to job completion, visit Mastercam.com/2019.

Preparation/ Setup

Tool Support

CNC Programming

Validation

Job Management & Documentation

RNI No. MAHENG/2015/64267 Postal Reg. No. THC/173/2018-2020. Posted at Mumbai Patrika Channel Sorting Office G.P.O. Mumbai 400 001 on 15th of every month and Published on 10th of every month

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