MACHINE TOOLS WORLD JULY 2018

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Volume 04 No. 02 | July 2018 | ` 150

Pages 118 | RNI No. MAHENG/2015/64267

Tru Hold QUA

LITY TOOL HO LDE RS


CEO CORNER WORK HOLDING - The critical factor Machine tools are a manufacturer’s most important investment outside of good employees, but it is only a portion of the equation. A machine tool is only as productive as the workholding that is used. The importance of proper workholding should not be underestimated. The right workholding takes the machine tool from good to great, allowing it to work to its full potential. Workholding affects a great number of areas in the manufacturing process, though its importance is too often overlooked. Improving the process in any or all these areas can lead to lower production costs and more machine tool uptime, which is ultimately what every manufacturer is chasing. The next time you purchase that new, faster, higher accuracy, more complex CNC machine tool for hundreds of thousands of dollars, look at the whole process and consider what the proper, much smaller workholding investment could do for your company’s bottom line. An efficient manufacturing process requires good machine selection, proper cutting tools and the right workholding. The first two areas typically receive substantial consideration, but workholding is often overlooked. The correct workholding selection can increase manufacturing process stability, efficiency and safety. Careful workholding selection isn’t only important in turning operations. With manufacturing operations of all kinds using higher cutting speeds that place more force on workholding equipment, choosing the correct system to hold on to the work is trickier than ever. Often, customized solutions are the answer to troublesome workpieces and manufacturing that demand high accuracy and repeatability.

CEO

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MACHINE TOOLS WORLD JULY 2018


FX Linear provides exceptional value for money offering a wide range of options to increase productivity and accuracy.

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


www.mtwmag.com

Publisher & Printer Shirish Dongre

CEO

Contents

Vol 4 Issue 02 | JULY 2018

COVER STORY

Shekhar D.

Editor Shilpa Dongre

Assistant Editor Shweta Nanda

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

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

Online Division Ganesh Mahale

MAC Group : Embracing technology innovation for excellence

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

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

An interface with: From left Mr. J. Vijayakumar, Director, Hoshi Tools, Mr. J. Nagarajan, Managing Director, MAC Group of Companies, Mr. C. J. Badrinath, Director, CNC India

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

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

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

BUSINESS NEWS

Printed & Published by Shirish Dongre on behalf of DIVYA MEDIA PUBLICATIONS PVT LTD., Printed at Anitha Art Printers 29/30, Oasis, Next to Vakola Market, Santacruz(E), Mumbai-400055, published from 303/304, Harmony Tower, N.S.Road, Court Naka, Thane West, Thane-400601. Editor : Shilpa Dongre

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MACHINE TOOLS WORLD JULY 2018

INDUSTRY FOCUS

18

Meech launches IonWash System for 3D component cleaning

20

TAL Manufacturing Solutions launches Six Axis Robot BRABO TRO6-6

22

CNC Software, Inc. releases Mastercam 2019

24 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

34

44 Ace Micromatic Group: A pioneer in the metal cutting industry

46 SW’s Cloud Platform provides greatest transparency in manufacturing process

COMPANY PROFILE

IMTMA Design Institute organizes alumni meet

24

Dormer Pramet explains the process of creating a new cutting tool

30

Elesa+Ganter receiving the IF DESIGN AWARD

48 Jay Shree Machines : Trusted for quality excellence

50 Gala Precision’s Forte: Precise Surface Engineering Solutions


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

Machining Center for Impeller and Small-size Complex Shape Processing

Specifications

A-Axis

X-A

xis

xis

Z-A

B-Axis

Ram Type Moving (X/Z-Axis)

Ø200

mm Table Size

15

kg Workpiece Weight

40,000 (HSK-E40)

r/min Spindle Speed

20

EA No. of Tools

300/300/200

mm (X/Y/Z-Axis) Travel

50/50/50

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

200/200

rpm (A/B-Axis) Rotary Table Speed

2G/2G/2G

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

SIEMENS 840D sl

CNC Controller

Rotary Tilting Table(A/B-Axis)

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


Contents IN FOCUS

38 World over the most successful firms are the ones that build their business on the foundation of quality in products as well as services

64

CASE STUDY

Vol 4 Issue 02 | JULY 2018

Rollon Technology for Intralogistic Systems

58 62

Renishaw conformal cooling solutions prove a boost to moulding productivity

PRODUCTS SHOWCASE

110

KING CUT PRO – The Large Gantry Type CNC Cutting Machine

111

MVX DRILL - New Chipbreakers & Grade for Hardened Steels & Aluminium

TECH TRENDS triangulation sensor sets new performance standards in industrial displacement & distance 70 Laser measurements

82

112

New transmission elements

92

113

Steady Volt Servo Voltage Stabilizers

113

90

114

104

Nexgen Refrigerated Air Dryers

Networking as the Basis for Smart Tool Production

The benefits of the New Renishaw Equator 500

FLIR C3 - Powerful, Compact Thermal Imaging System

114

Ground Ballscrews with Rotary Nut- FSWT Series 10

MACHINE TOOLS WORLD JULY 2018

98



Editorial Board

Editorial Index A Ace Micromatic

44

Ador Welding

110

ANCA CNC Machine

82

D 24

E

AMT- The Association For Manufacturing Technology

Grob Machine Tools India Pvt. Ltd.

Mr. GK Pillai Managing Director & CEO Walchandnagar Industries Ltd

30, 112

ELGi Equipments

86

F 90 114

G 50

GEM Equipments

113

GROB

58

H

Effica Automation Ltd.

Renishaw Metrology Systems Ltd.

Bettinelli Automation Components Pvt. Ltd.

111

P

78

J

114

R Renishaw

62, 104

Jay Shree Machines

48

M

SCHUNK

MasterCam

Werkzeugmaschinen (SW) 46 Shavo Technologies Spraymet Surface

Sanjay Tools & Adhesives

Mr. P.K. Balasubbramaniian President VBS Corporate Support

12

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

MACHINE TOOLS WORLD JULY 2018

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

88

T Solutions

20

102

Unity Controls

113

22, 30 18

Z ZOLLER

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

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

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

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

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

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

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

20

United Grinding

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

Association of Ludhiana Machine Tool Industries

112

34

Meech

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

96

U

Marposs

Manjit Singh Matharoo General Secretary

64

S

TAL Manufacturing

MAC Group

Mr. Dinesh Khambhayta President MTMA-RAJKOT

98

Precision Motion

Technologies

HEIDENHAIN Mr. Rupesh Paparaju Director,

MMC Hardmetal

Schwäbische

Gala Precision

Ms.Samina Khalid Marketing Manager

70

Rollon India

Faccin FLIR Systems India

Mr. Arjun Prakash Managing Director

Micro-Epsilon

Industries

Elesa+Ganter Mr. A.P. Jayanthram Consultant

38

Phillips Machine Tools

Dormer Pramet

Mr. Arun Mahajan General Manager

Metal Power

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

92


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BUSINESS NEWS

Meech launches IonWash System for 3D component cleaning Meech International is announcing the launch of its newest technology, the IonWash, designed for the fast and consistent removal of contamination from 3D components in the automotive, aerospace and electronics sectors, among others. The freestanding 3D component cleaning system incorporates extremely powerful ionisation, as well as blowing and vacuuming airflows, providing a more efficient alternative to manual cleaning. “From the point of inception, the IonWash was developed with ease of use and cleaning efficiency in mind,” explains Adam Battrick, Sales Director at Meech. “Historically, the cleaning of 3D compontents has always been undertaken either by operators handling air guns, or through the use of a compressed air powered unit controlled by a foot switch. However, both of these approaches are heavily reliant on the operator, which leads to inconsistent results – sections of the component may be unevenly cleaned, while contamination blown into the atmosphere may redeposit on the product’s surface. The IonWash single-handedly addresses these issues while also side-stepping others, achieving optimal cleaning performance.” Key to the IonWash’s design are its multidirectional ionising airflow nozzles. The system

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MACHINE TOOLS WORLD JULY 2018

is capable of providing 40 different nozzle placement possibilities, ensuring that the 16 multi directional nozzles can be positioned to cover all surfaces of a 3D component. The flexible design allows the high volume ionising airflow to be directed for a programmed optimal time onto uneven surfaces of the components being cleaned – such as a vehicle lighting clusters or a speedometer casings – neutralising static charges and loosening contaminants in the process. Simultaneously, high volume negative (vacuum) air flow extracts the contamination by pulling it into a vacuum chamber where it is filtered. By providing instant positive and negative high volume airflows, the cycle time is significantly reduced. Adding further to the overall flexibility of the IonWash is the presence of an access point on two sides of the system, enabling installation between two lines. The system is available in two standard size cleaning chamber sizes. Another key feature of the IonWash is the inclusion of in-built safety features and intelligent performance monitoring systems. In the event the system experiences any technical issues, an alarm will notify the operator. This helps to ensure that thorough cleaning is maintained at all times, allowing the IonWash to continue working to its full capabilities. Light guard sensors automatically stop the doors from closing when the sensor is interrupted, ensuring operator safety is maintained, and an emergency stop button is also included. Adam goes on to elaborate on the key benefits of utilising this technology: “Meech provides an advanced service and support that begins at the design stage and goes through to delivery, including adaptation of the system to suit particular applications. With a tailored design, the IonWash can be adapted to specification, so that it can be easily incorporated into the end user’s production line. Because it is such a time-efficient and effective technology, the end user is getting a consistently high level of contaminant removal with every cleaning cycle – the more contamination is removed from the component’s surface, the higher the quality of the finished good will be. By having such a thorough

system in place, the reject rate as a result of poor cleaning is exponentially reduced.” Adam concludes: “As production techniques have advanced, so have customers’ quality expectations. Today’s suppliers are looking for more ways to stand out from the competition and product cleanliness plays a key role in that. With IonWash, we have delivered a product that is tailored to multiple industries and incorporates the latest cleaning technology while also taking into account our customers’ needs and expectations. Our current users have already reported a four month return on investment, proving to be a value-added asset to their business. We certainly look forward to seeing how it will perform across all our sectors.”


The Trusted Partner in Metal Forming Machines


BUSINESS NEWS

TAL Manufacturing Solutions launches Six Axis Robot BRABO TRO6-6 TAL Manufacturing Solutions recently launched their 6-axis variant ‘BRABO TR06-6’ robot in New Delhi to cater to Robotics Automation requirements across different industries. After the phenomenal reception of their 5-axis variants of BRABO in the Indian market, the much awaited 6-axis variant comes with articulate motion capabilities needed for complex manufacturing applications. The BRABO TRO6-6 has the standard advantages of its predecessor and is easy to install, use and maintain. The modular design of BRABO TR06-6 enhances the work envelope, ensuring path accuracy and low noise emission. The teach pendant for the robot is light and its superior design along with user-friendly interface will make robot teaching a child’s play. The robot is capable of automating tasks such as welding, cutting, sealing, gluing, material handling, vision inspection, chamfering, deburring, and other applications requiring precise motion. BRABO TR06 -6 will cater to robotics automation in industries such as

electronics, metal fabrication, plastics, foundry, and FMCG besides automotive industries. Following extensive research and real time field trials across various industry segments and the encouraging results received from their beta customers, TAL decided to go ahead with the new product. BRABO TR06-6 will improve quality, productivity and bring in flexibility, allowing industries to rapidly adopt robotic automation independently. The design of BRABO TR06-6 is such that workers without any previous experience of using a robot can also operate it. The robot is ideal for SMEs and MSMEs. TAL even has a tie up with TATA Capital for assistance in financing the robot’s purchase. Speaking at BRABO TRO6-6 launch, Amit Bhingurde COO TAL Manufacturing Solution Limited, said, “We are excited to announce the launch of BRABO TRO6-6. This is a stepping-stone in our commitment to provide ingenious automation solutions catering to the manufacturing requirements across industries. BRABO TR06-6 will allow both large and small

manufacturing players to implement world-class engineering solutions in their work processes and transform their businesses into technologically advanced ecosystems.”

UNITED GRINDING Group continues its course of success with new owners One of the world’s leading machine tool manufacturers, the UNITED GRINDING Group, has a new owner. The new owner structure comprises a strategically aligned pool of investors organized by the Swiss BZ Bank Aktiengesellschaft. The sale of the Group by the Körber technology group was completed with effect from the end of June 29, 2018, following approval by the responsible supervisory authorities. The UNITED GRINDING Group has experienced a very positive development in recent years and has been able to further expand its strong position in the

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MACHINE TOOLS WORLD JULY 2018

machine tool market. Investments in innovative solutions, modern production technologies, the Group’s international locations and consistent focus on customer benefit, have all contributed to this positive development. The new owners want to systematically continue this success with UNITED GRINDING and the course previously pursued so successfully. “BZ Bank is delighted to be able to offer its customers the opportunity to invest in a highyielding international industry group, which is one of the leading providers in the relevant markets,” says Martin Ebner, CEO of the BZ

Bank Aktiengesellschaft. “For our long-term oriented investors, the ongoing positive development of the Group is of crucial importance. Further strengthening the Group’s solid foundation is therefore of great interest”, emphasizes Ebner. “Our aim is to remain one of the market leaders, based on our broad and thus unique product portfolio. We also want to shape further developments in our customer industries

actively. Together with our new owners, we will continue our international course of expansion and invest even more intensively in technological and digital innovations in our products and services portfolio,” says Stephan Nell, CEO of the UNITED GRINDING Group. “We are pleased that the new strategic owner can open up further development opportunities for the UNITED GRINDING Group in order for them to continue to lead and actively shape their market in the future,” says Stephan Seifert, Chairman of the Executive Board of Körber AG.



BUSINESS NEWS

CNC Software, Inc. releases Mastercam 2019 CNC Software, Inc., developer of Mastercam, the world’s leading CAD/CAM software, announces the release of Mastercam 2019. It is now available for purchase. Mastercam 2019 was developed to streamline the manufacturing process from job setup to job completion. Mastercam 2019 increases machining productivity and reduces overall production costs with new 2D through multiaxis milling automation features, CAD and model preparation improvements, expanded 3D tooling, Accelerated Finishing™, and powerful turning and Mill-Turn enhancements.

CNC Programming Mastercam 2019 continues to increase productivity and programming efficiency, while reducing overall production costs, with a series of automated 2D through 5-axis toolpath improvements. Re-engineered chamfering and holemaking strategies, plus the new Multiaxis deburring provide new levels of time-saving automation and simplicity. New milling toolpath strategies, like the high speed Equal Scallop toolpath, offer both machining performance and surface finish improvements. The new release includes additional support for the Sandvik Coromant PrimeTurning™ method, enhanced grooving, bar feed, and other features for turning and mill-turn applications, plus new lathe and Swiss-style machine support.

Job Preparation and Setup Mastercam 2019 increases

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MACHINE TOOLS WORLD JULY 2018

efficiency and reduces job setup time and the preparation needed for part machining and programming. This includes enhanced CAD functionality and 3D model import support, improved part preparation and fixture setup tools, additional PowerSurface capabilities, and expanded support for ModelBased Definition (MBD).

Tool Support Mastercam 2019’s expanded digital tool library capability delivers accurate, 3D tool assembly models, with access to the latest cutting tool technology and updates for Sandvik Coromant CoroPlus® and MachiningCloud™ platforms. Mastercam 2019 also expands Accelerated Finishing with support for taper and lens style tools aimed at 75% cycle time improvement for finishing operations with superior surface finish quality.

Validation With improvements to toolpath and machine simulation, toolpath

graphics, and other verification and analysis tools, Mastercam 2019 provides greater programming assurance and allows for better,

more informed decisions before a job is run. These improvements include support for block drilling multiple holes simultaneously and better axis control in simulation, allowing you to easily check machine limits or collision checking.

Job Management and Documentation Mastercam 2019 also improves job documentation and management, while helping to address quality and certification initiatives. New toolpath visualization capabilities and section view tools, improvements to view and setup sheets, and a wide array of system level enhancements improve efficiency in managing job workflow, as well as providing better tools for process documentation.

About Mastercam Developed by CNC Software, Inc., Mastercam is Windows®based CAD/CAM software for 2- through 5-axis routing, milling and turning, 2- and 4-axis wire EDM, 2D and 3D design, surface and solid modeling, and Swiss machining. Privately owned and founded in 1983, CNC Software provides CAD/CAM solutions to more than 224,000 installations in 75 countries in industries including moldmaking, prototyping, automotive, medical, aerospace, consumer products, and much more.

For more information, Website: www.mastercam.com.



BUSINESS NEWS

IMTMA Design Institute organizes alumni meet Indian Machine Tool Manufacturers’ Association (IMTMA) organized an alumni meet of machine tool designer talent pool at its head office in Bengaluru on 9 June 2018. The meet was hosted as part of IMTMA Design Institute’s 5 year celebrations. B.C. Rao, Managing Director, Kennametal and Executive Member, IMTMA was the Chief Guest. Other panelists included V. Anbu, Director General, IMTMA and BIEC, P.J. Mohanram, Senior Adviser, IMTMA, and H.V. Rajashekara, Senior Director, IMTMA. Around 75 delegates participated in the meet. Speaking on the occasion, B.C. Rao deliberated that young engineers are the backbone of manufacturing industry and their role is very important for the continuous growth of the industry. Industry scouts for higher skilled

workforce as an on-the-job training for a fresh engineer would affect their economics and day-to-day operations. Picking up an experienced or trained ‘industry ready’ engineers from institutions such as IMTMA Design institute will make the job easy for companies. Mr. Rao felicitated IMTMA for imparting design skills to young engineering job aspirants and getting them placed in various industries of

the manufacturing sector. The delegates were presented with the credentials of IMTMA Design Institute The faculty and delegates who attended the meet expressed that IMTMA’s Design Institute was the best platform to build the industry design skill sets to make fresh engineers “The Industry Ready Design Engineers”. All of them were very proud to be a part of these noble initiative.

Dormer Pramet explains the process of creating a new cutting tool gaps in the company’s current assortment. Karel Tiefenbach is the company’s product manager for indexable milling and he created a concept brief and clear objective for the development team. Dormer Pramet’s aim was to create an assortment of tools for its double-negative

Global manufacturer Dormer Pramet tasks its product management and development department with creating new tools every year. A member of the team is product and development engineer Jan Bittner. In January 2015, Jan joined Dormer Pramet and became part of the company’s project to develop an assortment of high feed milling tools. Almost three years later, a new range of SBN10 cutters and BNGX inserts were launched into the global market. The time taken to introduce a product is an indication of the investment a manufacturer makes to create a new product which will add value to customers for many years. This is Jan’s story. At Dormer Pramet, the process of creating a new tool begins with its product management department which identify the market needs and

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MACHINE TOOLS WORLD JULY 2018

cutters, which allowed high feed rates for increased productivity. The design needed to be for double-sided inserts to maximize the economic value (four-edges) and provide good chip-control, allowing for a higher ramping angle.

At the same time, the tool needed to offer process security and a versatile range for mold and die operations, covering roughing to finishing. Jan began the process with Jan Vlček from the company’s product design & information department, responsible for all aspects of tool development. This includes creating high quality data on every tool produced, the design of products and supporting manufacture. The department’s first task in designing a new high feed milling tool – later known as SBN10 - was to research what products were already available in the market from competitors and how Dormer Pramet could be different, while still meeting the needs of customers.



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BUSINESS NEWS

Elesa+Ganter receiving the IF DESIGN AWARD Industrial design not only makes products more appealing to the eye, it also enhances their value as a whole. Design optimizes ergonomics and functionality, which Elesa+Ganter shows with its GN 126 adjustable flat tension levers and its GN 328 cabinet „U“ handles and GN 428 machine handles. Thanks to their modern form, these standard elements are ideally suited to the appearance of modern machines and systems. In this way, details such as handles and levers can be implemented with the same high level of design as the machine itself, regardless of the batch size. The option of customizing size or color in a simple

yet cost-effective manner further enhances the possibilities for use. Internal recessed grips and exact edge rounding ensure noticeably

improved ergonomics. The fact that Elesa+Ganter, together with the design agency Corpus-C from Fürth, is taking the right design path, is un- derscored by the current awards received from two independent juries: The iF International Forum Design Jury honored the GN 328 and GN 428 cabinet “U” handles and machine handles as well as the GN 126 flat tension levers with an award. The aforementioned cabinet “U” handle and machine handles were also awarded the coveted Red Dot Award by the jurors. The GN 126 adjustable flat tension levers are characterized by their dynamic shape, produced

by zinc die-casting and finished with a plastic coating, and are ideal wherever pivoting ranges are limited. The integrated serration allows for the position of the handle to be adjusted without having to loosen it. If required, the same GN 126.1 shape is available with a completely stainless steel interior. The GN 328 and GN 428 cabinet “U” handles and machine handles are made of cast aluminum or a bent aluminum profile and are also available with different surface finishes. For applications in particularly corrosive environments, the GN 328.5 cabinet “U” handles are also available in stainless A4 precision cast stainless steel.

Mastercam announces New 4-Axis Mill Post Processor for the SINUMERIK CNC Software, Inc., producers of Mastercam CAD/CAM software, announced a 4-axis milling post processor that will unleash the highest productivity on SINUMERIKcontrolled machine tools. The new post processor was developed utilizing the technical expertise of Siemens CNC engineers. This post processor includes support for SINUMERIK 840D sl and 828D CNCs from Siemens. It features: • CYCLE 832 support for high-speed settings, now including the latest Top Surface functionality. • Drill cycles (CYCLES 82, 83, 84, 85, 86, 840), with full 4-axis support. • WORKPIECE output for graphical simulation, including rotary axis blank orientations.

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MACHINE TOOLS WORLD JULY 2018

• Tool call as tool name or tool number. • TOFFR option. • Siemens 4-axis application guide. • Optimized multiaxis toolpath utilizing the FGROUP and FGREF commands. • Streamlined program editing with the GROUPS functionality.

“The development of this new 4-axis post for Mastercam 2019 demonstrates our ongoing commitment and collaboration with Siemens, to bring the highest productivity gains to machine tools, that began more than two years ago with release of our 3-axis milling post processor for Mastercam 2017,” says Post Department

Manager Pedro Sanchez, Jr., of CNC Software, Inc. It is cooperation like this that provides Mastercam users the opportunity to truly complement their CAM investment and give their shops the best chance at a more efficient manufacturing solution, from design to part. Chris Pollack, Virtual Technical Application Center Manager, Siemens Industry, Inc. comments, “With a strong continued collaboration, we’re able to optimize product performance for both the Mastercam software as well as the SINUMERIK control. This allows our mutual customers to achieve the very best out of their resources.” Pollack continues, “Seeing what we’ve already been able to accomplish, Siemens looks forward to continuing to help Mastercam create more advanced post processors in the future.”


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BUSINESS NEWS

Pune Machine Tool Expo 2018: Spotlight on India’s Western Region 27 - 30 September, Auto Cluster, Pune Indian Machine Tool Manufacturers’ Association (IMTMA) is organizing the second edition of Pune Machine Tool Expo (PMTX 2018) in Pune. The expo spread over 4 days will feature exhibitors displaying technology and innovations in metal cutting and metal forming. Pune is known as the Detroit of western India. The city is base to a large number of industries in automotive, heavy engineering, aerospace, defence, ordnance and many other manufacturing segments. The presence of leading manufacturing companies makes the expo a significant one for western region.

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MACHINE TOOLS WORLD JULY 2018

Expressing his views on PMTX 2018, Mr. P. Ramadas, President, IMTMA said, “Automotive sector is the largest consumer of machine tools. We have substantial number of members from western region based in Pune as this is one of the major markets for them. A show like PMTX will be a great enabler for business development of machine tools in this region.” Supporting Mr. Ramadas’s views, Mr. V. Anbu, Director General and CEO, IMTMA added, “New and emerging technologies are the need of the hour for the development of any manufacturing industry. IMTMA will bring these

technologies closer to the door steps of manufacturing industries in this region through PMTX. The show will support not only the OEMs in automotive sector but also other major engineering industries in the region to upgrade their manufacturing capabilities.” The first edition of Pune Machine Tool Expo held at the same venue in 2016 had recorded an overall footfall of over 7000 visitors. IMTMA hopes to surpass this in the second edition. Visitors can log on to www.mtx.co.in to get more details on the second edition of the show and register for visiting the expo.

About IMTMA IMTMA is the apex body and single point of contact for machine tool industry in India. IMTMA plays a crucial role in the growth and development of metalworking industry in the country. IMTMA’s initiatives range from policy advocacy, export promotion, trade fairs, mega events, training, seminars, technology missions, publications, etc. IMTMA formed in 1946 has a membership of over 450 members and represents 90% of the organized machine tool and allied equipment manufacturers in the country.


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COVER STORY

MAC Group : Embracing technology innovation for excellence

An interface with: From left Mr. J. Vijayakumar, Director, Hoshi Tools, Mr. J. Nagarajan, Managing Director, MAC Group of Companies, Mr. C. J. Badrinath, Director, CNC India

Despite volatile market conditions and stiff competition, MAC Group has been clocking steady growth and positive turnover year-on-year over the last 25 years. Shweta Nanda from MTW spoke to three key leaders in the group: J Nagarajan, MD, MAC Group of Companies; C J Badrinath, Director, CNC India; and J Vijayakumar, Director, Hoshi Tools to know more about the group’s journey, achievements and success mantra. 34

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AC Group, established in 1991, with its flagship company MAC Machine Tools and Automation (formerly MACH Electronics) has traversed a long way since its humble beginnings. Following an excellent turnover in the first year itself, the group’s second company, CNC India Tools and Services, was introduced in


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1992, followed by Hoshi Tools in 1994. In the last 25 years, MAC Group has carved out a niche for itself and established itself as a solid player providing turnkey solutions to the machine tools, industrial automation, manufacturing, robotics & engineering verticals. Keeping up with the technological advancements and evolving customer requirements, the group has grown from strength to strength. One key thing that clearly stands out, and is perhaps the biggest strength of the group, is its focus on futuristic technology. We takes an extensive look at the evolution and future plans of the three companies that are the pillars of MAC Group and have helped it carve its success story.

Mac Machine Tools & Automation: Sharpening Focus on IIoT Solutions Started as a firm catering to computerized PCB repairing and servicing at the component level, Mac Machine Tools & Automation has today expanded its horizon and fulfills industrial automation and IIoT requirements of customers in Karnataka and Tamil Nadu. Under the leadership of its Managing Director J Nagarajan, the company has achieved various milestones. The company’s big breakthrough came in 1994 by being recognized as System Integrators of Rockwell Automation and in 2006 it got elevated to being authorized distributors of Rockwell Automation products for the region of Karnataka and Hosur & Krishnagiri Districts of Tamil Nadu. “This was a major milestone for us which set path for our 27 years long journey. From then on there was no looking back,” avers Nagarajan. From then on, the company has tied up with various OEMs as their authorized distributors. Today, the company provides IIoT solutions in partnership with Ewon, remote access solutions in partnership with ProSoft, data connectivity solutions in partnership with Softing, XL reports in partnership with SyTech, harmonic filters in partnership with MTE, electrical enclosures in

partnership with Pentair Hoffman, UPS and switches in partnership with Socomec and machine tools in partnership with leading machine tool manufacturers like Victor Taichung, Lymco, Adria, Flow, to name a few. A major milestone worth mentioning is the company’s partnership with Denmark-headquartered Universal Robots. “In 2018, we introduced Universal Robots’ Cobots into VIVO IPL 2018 with our solutions programming the Cobot to act as cheerleaders and bar tenders for the Team RCB. We are very proud of this milestone as it is for the first time in the world that robots have acted as cheerleaders,” Nagarajan shares. The company is focused on futuristic technology and constantly embraces technological advancements by evolving itself. A case in point is its emphasis on IIoT. “The Internet of Things is one of the more nebulous terms to have entered the digital lexicon. Say there is a robotic arm on the manufacturing shop floor. This robot not only performs rote tasks but also produces data that is automatically synced to enterprise software, giving users real-time, easy access to information regarding the shop floor’s machinery and efficiency. When devices are connected to the Internet, they can constantly compile data and automate tasks. That’s the power of the Internet of Things,” asserts Nagarajan. The company offers a range of IIoT solutions with its business partners. Updating about the company’s product range Nagarajan says, “‘Rockwell Automation’s Connected Enterprise’ allows for a Connected World on the shop floor that enables easy monitoring. ‘ProSoft Connect’ by ProSoft allows you to establish communications with your machines anywhere in the world. With Connect, automation programming tools can talk directly to automation devices without the need to setup IP routing or other complicated communications settings. ‘Ewon’ offers Industrial Remote Solutions that enables access to distant

machines and installations. It offers advanced Data Services for performance monitoring and proactive maintenance and gives turnkey solutions for endusers/facility managers to monitor and control industrial assets online and thereby making better operational decisions.” IIoT truly has the potential to transform the entire manufacturing process. In fact, the more the usage, the better the efficiency and productivity. Nagarajan believes that smart manufacturing can address some of the biggest challenges of Indian manufacturing. “In India, manufacturing sector is human intensive which makes productivity lesser, allowing products to have damages and exposing humans to high risk environments. ‘Smart Manufacturing’ would increase productivity and make growth more inclusive. It would also connect the entire shop floor allowing for constant monitoring of the production / manufacturing process,” he explains. The company is already seeing a positive response for IIoT solutions, with Indian market showing readiness for smart manufacturing. Looking ahead, the company plans to increase its thrust on IIoT solutions as the awareness increases and market becomes more mature.

CNC India: Betting Big on Robotics From a ‘service company’ catering to services of CNC Machines to providing turnkey solutions to robotic automation and manufacturing Special Purpose Machines (both metal and non-metal cutting machines which are combined with fixtures), CNC India has indeed come a long way. With Director C J Badrinath at the helm, CNC India has created a niche for itself where it offers Robotic Gantry Solutions, Pick & Place Automation and Robotic Welding Solutions to the leading automobile companies across the country. The company today primarily caters to the automotive industry with specific focus towards two-wheelers, commercial vehicles and the tractor industry, as well

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COVER STORY as the defense and space Industry by closely working with ISRO. CNC India is placing huge bets on robotics as it is transforming the automobile industry at a tremendous pace. “Robotics is a surging, multibillion-dollar market because it provides businesses incredible savings and efficiencies with robotic process automation for consumer and business applications, which are expected to become an $8.7 billion market by 2024. Being the sunrise sector for the ‘Make in India’ campaign and one of the key sectors contributing towards the GDP of the country, the automotive manufacturing segment has been making rapid strides in the industrial automation domain emerging as a role model for the other industries by showcasing how automation should be utilized to scale up the value chain and achieve zero-defects manufacturing,” informs Badrinath. While there is definitely a lot of interest around robotics, there are a few challenges related to mindset. “Human labour in India is very cheap compared to human labour abroad. When considering the operation costs, humans and robots are usually compared. What manufacturers are not looking at is, with robots in the manufacturing set up, the safety, efficiency and productivity of the product only increases,” explains Badrinath. The company is currently witnessing demand for robotics in the most popular applications, such as arc welding, plasma cutting, laser cutting, BIW welding lines, palletizing, tending robots on press machines, CNC machines, etc. And as manufacturing move towards smart manufacturing, robotics is slated to witness further traction. “Robots are already integrated with the computer network and hence are part of equipment in network. However, with the new sensors, information sharing tools and applications, robots can be a perfect role player in IoT based smart factory which is truly Industry 4.0 compliant,” opines Badrinath. The company is riding high on the

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wave of success with automobile sale seeing a double-digit growth in the last decade. “All the organizations catering to the automobile industry have also been growing at a steady pace,” Badrinath points out. Given its success story, CNC India has charted aggressive growth plans. The company is aims to be a 100 crore company and among the top three automation companies in India by 2019.

Hoshi Tools: Expertise in Custom Built Tools Starting out in the year 1994 with a single VMC – Makino make at Yeshwanthpur Industrial Estate, in a machine shop measuring 550 Sq Ft., Hoshi Tools is another company in the MAC Group umbrella that has played a huge role in the group’s success. Hoshi Tools today owns about 20 Vertical Machining Centers (VMC), 4 Turning Centers, Cylindrical Grinding, Micro Drilling and Laser Etching Machines. Under the leadership of Director J Vijayakumar, the company has achieved several milestones and has established itself as a major player in the South India market. “We claim about 25% of tooling requirements to South Indian industries for our category of tools. We also have our sales / marketing in North Indian sector, where we are slowly increasing our market share,” updates Vijayakumar. As the company manufactures custom designed cutting tools, mainly carbide oriented, it provides services to any metal cutting industry where there is an emphasis for productivity improvements by evolving from conventional ways of manufacturing to technologically advanced and improved ways of manufacturing. Thus, the company primarily caters to industries which involve high volume production such as automobile industries, machine tools, aerospace, ancillary units, valves industries, general engineering, etc., apart from special tools. The company also manufactures precision components for machine manufacturers. The company’s niche lies in its

ability to manufacture various types of custom built tools, as per the customer specification. “Our highly qualified design engineers are capable of producing designs as per customer requirements. Our expertise also lies in turnkey solutions where we take the manufacturing process from procurement of raw material to the dispatch of finished products. Adaptation of Computer Integrated Manufacturing (CIM) through advanced software of 3-dimensional Parametric CAD & CAM for fast interactive results, enables us to produce quality products of international standards,” asserts Vijayakumar. The company has huge focus on after-sales service and provides training to customers. It orients the customers on resolving machine related issues, thus enabling them to improve their productivity by fine tuning their processes. The company also sensitizes them on the new tools in the market for improved quality, productivity, cost reduction, etc. Hoshi Tools is further looking at expanding its offerings and business areas. “We want to be `One Stop Solution Provider’ for all the machining requirements of our customers. In line with this, we have already tied up with M/s AKKO – Turkey to offer their Standard Turning Tools & Milling Cutters in India and M/s C P T – Carbide Precision Tools – Germany to offer their Standard & Custom Threading Tools & Thread Mills in India,” says Vijayakumar. The company is also looking at further tapping into the fast-booming sector of aerospace and adding new products into its existing line of offerings. It is also in talks with reputed MNCs for adding more product categories of tooling such as PCBN and PCD. Clearly, with MAC Group companies’ eyes firmly set on the market demands and their drive to diversify and embrace new technological advancements, the group is ready to take the next big leap. As smart manufacturing continues to gain steam in India, MAC Group’s outlook looks extremely positive.


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IN FOCUS

World over the most successful firms are the ones that build their business on the foundation of quality in products as well as services: P.D. Pant, Metal Power

Mr. P.D. Pant, Managing Director, Metal Power Analytical (India) Pvt. Ltd.

Q. You are a name to reckon with in Analytical Instrumentation. What precisely is your niche? We specialize in the analysis of metals. In this field, we have two key areas of focus at present. The first is arc-spark optical emission spectrometry (OES), where we offer the world’s widest range of arc-spark OES. The other is the measurement of Hydrogen content in Molten Aluminium. In both the fields, we have patents to our credit, which we leverage to offer superior technical and economic performance.

Q. You have been in the business for over 25 years now. What are the technological advances that have impacted the industry? As with any industry, the last 25 years have seen a number of innovations and developments that have transformed the industry. In ours, quite definitely

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Metal Power Analytical (India) founded by Mr. P.D. Pant in 1987, provides a comprehensive range of products and services to meet the analytical needs of metal industries. The company’s product portfolio spans Laboratory Optical / Atomic Emission Spectrometers, Mobile Spectrometers, Hydrogen analyzers for molten Aluminium, Certified Reference Materials, Sample Preparation Machines for spectrometers as well as a wide range of accessories. Its Laboratory Division also offers services in Material Analyses and Proficiency Testing for other laboratories. The Company has over 25 years of experience serving the needs of ferrous and non-ferrous metal industries and has its presence in 35 countries across 5 continents including North and South America, Europe, Africa and Asia. Mr. P.K.Balasubbramaniian converses with Mr. Pant to understand Metal Power from close quarters and get more insights into the engineering acumen and inventive spirit of the company which is already known for its customer centricity. Excerpts: the most influential has been the advent of CCD (charge-coupled device) and CMOS (Complementary metal–oxide– semiconductor) detectors as the detectors of choice. Till the late 1990s, PMT (Photomultiplier Tube) detectors were accepted as the only type that could meet really high-end needs. The advancement in CCD and CMOS have led to a complete change. From ~5% of the market then, ~95% of the market today is dominated by CCD/CMOS detector spectrometers. Indeed, today these detectors offer the highest-end features and the lowest of detection limits. This has seen spectrometer performance improve rapidly across the board – while size and costs (acquisition and maintenance) have dropped dramatically. This has had another big impact, where vacuum optics are no longer used. Today, virtually all new OES use Argonoptics – which result in lower capital

costs, lower noise, lower energy and maintenance costs as well as improved stabilization times and reliability. This is not to discount other improvements of course. Some of these are the use of digital current-controlled power sources, FPGA technology and the capabilities that software systems offer. These have resulted in far smaller and lighter OES while also adding a host of analytical facilities that were earlier unthinkable. From a user standpoint, the biggest changes have been: • OES are much smaller, lighter and less expensive to acquire and maintain; • LODs are far lower, with even entrylevel OES now offering much lower limits; • Stability and precision are far superior today; • Add elements, bases & matrices


IN FOCUS www.mtwmag.com

without having to modify hardware – even post-purchase; • Analytical features include melt addition programs, master alloy calibrations etc.; • Thin foil analysis, fine wire analysis etc. • Last, but not least, the entry of Metal Power into this field in 2004 has made a huge impact in terms of much higher capability spectrometers even at entry-levels.

Q. What are the end-to-end solutions you offer to the metal industry? When it comes to metal industries, we offer end-to-end solutions for chemical analysis of metals. Firstly, our OES – the higher-end ones in particular – analyse every element possible – including the gaseous ones like Nitrogen, Oxygen& Hydrogen. This reduces the need for separate gas analyzers! Then, we

offer all the associated equipment that laboratories may need, including high-quality Sample Preparation Machines, Sampling Moulds, Argon Purifiers, adapters for various types of samples and most importantly, Certified Reference Materials (CRMs). Through our Laboratory division – which is NABL-accredited – we offer a wide range of CRMs, which are needed by OES users for validating instrument performance. Further, we also offer Proficiency Testing (PT) Services which are needed by Labs as part of their NABL requirements. We also offer services to Laboratories that wish to obtain NABL accreditation to assist them in setting up their infrastructure and processes in a compliant manner.

Q. What are the different value propositions you offer to the foundry segment? We offer the widest range of OES – with

Metavision 10008X: The first optical emission spectrometry (OES) in the world to be fully CCD-based and yet offers every single high-end feature available.

each tailored to meet specific needs. For the foundry sector, this means that we’ve designed tailored models that cater to the needs of: • Start-ups, where budget is scarce, and testing needs are limited; • Mid-range models – where testing needs have expanded, but budgets are tight; these models offer the analysis of 25 – 35 elements including all key alloying and trace elements – including Nitrogen and Boron, apart from the routine ones like C, S, P, etc. These feature lower detection limits too – going down to the region of 5 – 15 ppm for most elements • High-end models: These cater to large firms where quality is of paramount importance; these offer the analysis of 45+ elements including virtually every element on the periodic table! They also offer high-end features like single (1 ppm) and sub-ppm (<1 ppm) detection limits, time-resolved spectroscopy, soluble-insoluble analysis, etc. For all our customers, we also offer a unique value proposition as a vendor in that we are fully indigenous and have all our Research as well as Service fully in-house. All our Service engineers are fully on-roll and technically trained. They are accountable directly to the MD and the reporting tree ends with the MD, ensuring that each and every customer is assured of the highest level of service – and also direct access right up to our MD if he is dissatisfied in any way! Further, as our R&D-cum-Applications Lab is fully in-house, we also routinely offer custom developments to any customer that needs it. This ranges from the development of customized analytical programs to software applications and even linkage of our system to larger plant-management systems that clients may run. Our value proposition is to offer all our clients the lowest TCO (Total Cost of Ownership) in the world – through tailored products and service and support that not just meets, but exceeds every expectation!

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IN FOCUS Q. Does quality obsession help in enhancing the bottom-line? Absolutely. The world over, in every field you care to evaluate, the most successful firms are the ones that build their business on the foundation of quality – in products as well as services. From Tata to Patanjali to Bharat Forge to Menon Pistons, no business leader can be faulted as neglecting quality. This applies equally to foundries as well. Focusing on quality yields three direct benefits, all of which impact the bottom-line heavily: a) Reduce the cost of rejections and rework – Rejections and rework cause drop in productivity in all cases and if it’s an external rejection also cause a negative impact on customer and market reputation. Eliminating these directly improves bottom-line as you reduce the cost of labour and operations, while also increasing output! b) Save on expensive alloying elements – When you focus on quality with the right setup, you can control your melt far more precisely. Aiming for the lower limits on expensive alloying elements (like Ni, Cu) directly saves costs while not impacting price as customer / grade specifications will accept any value in the entire range! Thus, margins increase for the same product – all of which go straight to the bottom-line; c) One gets better customers! – This is self-evident. The best customers look for the best vendors – and the best products almost invariably command the better price! Furthermore, with the right Quality Control and Quality Assurance setup, one is better placed to develop high-end alloys which command a far higher unit price – while the raw material costs remain largely similar. This, again, directly improves the bottom-line All this is of course, without looking at the very basic fact that more and more buyers today conduct vendor audits and evaluations that do take a critical look at the quality infrastructure and capability of the vendor. If one is lacking on this of course, one misses out on business as a

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whole hitting not only the bottom-line, but also the top-line!

Q. Could you enlighten us on your range of products and offerings? Our range of offerings could be summarized as below: • OES:As mentioned earlier, we offer the world’s widest range, from the entrylevel Spartan models through the midrange N-series and Metavision-1008i and the high-end Metavision-1008i3 and Metavision-10008X; • H-Scan: This measures the Hydrogen content in Molten Aluminium. Fully traceable analysis is offered with classleading accuracy in <3 minutes! This makes the product truly invaluable to quality-focused Aluminium foundries; • CRMs: Certified Reference Materials (solid metal) for Spectrometers. Our NABL Accreditation makes us the only accredited solid metal CRM manufacturers in all of Asia! • Essential accessories: These include sample preparation machines, Argon purifiers, long-life sampling moulds, various kinds of adapters, safety modules for lab equipment and other items essential for running an OES laboratory.

advantages – including being compact, rugged and economical, while also offering features no CCD OES has ever offered before, such as Time Resolved Spectroscopy, Soluble-Insoluble analysis, sub-ppm detection limits and analysis of even “difficult to analyse” elements like Oxygen, Nitrogen, Carbon, Sulphur, etc. down to as low as 1 ppm! Covering the entire usable spectrum, this OES is technically capable of analyzing virtually every element on the periodic table.

Q. How do you contribute to and raise the standards of material analysis and proficiency testing in the industry? We continuously strive on two fronts in this matter:

Q. Could you single out a product from your range which can be named an ‘engineering marvel’? This is a lot like a parent being asked to name their favourite child! Each model we offer carries something unique. In fact, most of our models are only developed once we are clear that we have a patentable / patented idea that it is based on, making it capable of offering something that nobody else can offer or offering class-leading performance at a dramatically lower TCO! That said, if forced to choose one, I would probably highlight the Metavision-10008X. This is the first OES in the world to be fully CCD-based and yet offers every single high-end feature available. It features the best of the CCD

Metavision 108N+: A versatile model ideal for analyzing all types of metals and alloys


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IN FOCUS • We are constantly focused on assessing customer needs and making instruments, applications, software features and testing programs that meet stated and unstated customer needs; • We constantly interface with industry – through forums like IIF and ASM as well as our own seminars, etc. – with a focus on increasing industry awareness about the need for product quality, the benefits of quality improvement and the options available to users today to enhance the quality of their work.

Q. Who are your major customers? We have about 1,700 customers today and each is special in their own way. Several have multiple units we’ve supplied to them and it would take an age to list them all. Some of our more easily recognizable customers are Tata Steel, Sterlite, Godrej & Boyce, GIRDA, CMERI, Modern Malleables, Tekno Valves, Gestamp, Hyderabad Castings and others of this ilk.

Q. Please throw some light on your export performance. Exports have emerged as a focus area for us in the last few years and we’ve seen rapid growth on this front. Today, something like 30% of our production is exported and this proportion is increasing annually. Overall, we have now got a presence in something like 35 countries overseas spread across five continents – with just Australia and (rather obviously) Antarctica missing!

Q. How crucial is service in your business? What’s your marketing and service set-up? Service is mission-critical. What we offer is capital equipment – it lasts for decades and is mission-critical for production. As such, high uptime is a must – and high uptime can only be assured through high-class preventive maintenance and high-quality service. Moreover, nothing is “fail-proof”;

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therefore, regardless of the quality of product and maintenance, it is also critical for a vendor to offer easily accessible and rapid support in case of any kind of failures – and also to be able to afford rapid turnaround for spares / consumables when needed! Our setup is fully in-house. We have around 30 service personnel located strategically across the country (14 locations across all the Regions) to be able to ensure that each customer is assured of rapid support whenever needed.We have Regional Managers for each of the four regions of the country, to ensure more granular management of service, and the Central team based at our HO in Mumbai oversees nationwide operations. Additionally, we operate a Central Helpdesk for complaint logging, telephonic support and online support. All of this is also supported with the fact that our Service team has access to even our R&D personnel in specific instances where support may be needed to resolve unique demands.

Q. What are your major strengths? Our three most major strengths are: Research and innovation: we can support any and every kind of customer through any and every type of analytical need – pre-purchase as well as at any time through the product lifecycle; Quality of Products and Services: We are fully ISO-certified in our business – including for our Service setup! Our products are built to the most exacting standards and our service is tasked with achieving customer delight (not just satisfaction); Customer-proximity: We remain committed to our core values – the most fundamental of which is our commitment to customer delight. We leave no stone unturned in our quest to meet customer expectations – and often go well beyond even the written word to ensure that no customer is left wanting for lack of effort from our side.

Q. What are the dynamics of the industry, and the challenges ahead for you? The industry is continuing to evolve. in our field, innovation in our own country remains limited to us with the competition really coming only from overseas players. Among the international players, there’s been dramatic change. Our entry and our commitment to offering economic valueaddition with a great value proposition, has seen these players dramatically drop prices, thus displaying just how much they were ‘milking’ the market in the past! Now, faced with a product and value proposition that is superior to theirs, they’re resorting to the final bet – dropping price! Indeed, some have even used their deep pockets to try a strategy of under-cutting our prices! The market could therefore be classed as more competitive than ever before. Retaining our position as market-leaders has therefore required us to push the boundaries of innovation as never before – and is a challenge to which we’ve responded with gusto! Globally, the market has seen consolidation. There are now very few large players that remain committed to the market – and I’m pleased to say that we are one of them! Moving forward, the challenge for us will be to continue development apace – continuously delivering new offerings and setting new benchmarks in the market for what value an OES can add. Moreover, of course, we continue our research into newer areas of technology as well, something that will bear fruit in the second half of this financial.

Q. What’s your vision for Metal Power? Our vision remains that of being the partner of choice globally for firms looking for analytical instruments that we manufacture. We aim to be technology-leaders in each area we enter and to serve each of our customers in a manner that sets a new benchmark for the industry.


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INDUSTRY FOCUS

Ace Micromatic Group: A pioneer in the metal cutting industry The group comprises of six principal companies which come with more than five decades of rich engineering experience supported by leaders who are pioneers in the development of many technologically advanced products

A

ce Micromatic group, is known for its customer centric products and services, and is a forerunner in the metal cutting industry and the largest machine tool conglomerate in India. The group specializes in the manufacturing of CNC controlled turning, milling and grinding machines along with subsystems like tool turrets, ATC etc. It also offer products to enhance our customer’s productivity through real time machine monitoring. Ace Micromatic group comprises of six principal companies which come with more than five decades of rich engineering experience supported by leaders who are pioneers in the development of many technologically advanced products. The group has 42 offices across the globe providing sales and service support to customers and more than 700 employees. The group has been consistently working towards giving its customers the benefit of round-the-clock service to help them maintain high uptime of machines.

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Advanced products Some of its latest products include Twin spindle machine from AMS, the CMV-350 TS. The machine is compact yet can do the job of two machines. It is ideal for high-volume production requirements and drastically cuts down production cost by reducing cycle time per component, lowering power consumption thereby decreases the need for extra man power. From Ace Designers, The Vantage 800 M is a high precision machines with C and Y axes capability to cater to a wide variety of machining needs like milling, drilling, tapping and turning in a single setup. The machine has a max. spindle speed of 4000rpm and can hold up to 12 tools. The spindle is designed for heavy duty cutting and provides precise circular orientation for effective live tooling. A power up series motor is also offered for increased torque at lower spindle speeds. From MGT, the firm has the CNC

Mr. TK Ramesh, CEO, Micromatic Machine Tools Pvt. Ltd. production Centreless grinder CG-6030 (TG) with a grinding wheel spindle speed of 45 m/s and regulatory wheel dia x Width x bore of Ø350x250x Ø127(RBS)mm. The model is equipped with a ribbed structure bed that ensures better static, and dynamic rigidity, and vibration damping. The machine is also equipped with a heavy duty pre-loaded high-precision roller guideways for in-feed movement. The grinding wheel and regulating wheel spindles have undergone FEA analysis for maximum load in dynamic condition.



INDUSTRY FOCUS

SW’s Cloud Platform provides greatest transparency in manufacturing process Schwäbische Werkzeugmaschinen GmbH (SW) has developed an internal SW Cloud Platform to make customers’ machine data from their machining centers even more transparent, accessible and user-friendly

“An essential element for keeping the system availability of SW machining centers at maximum levels over the entire service cycle is carrying out preventive and status-dependent maintenance,” explains Jochen Heinz, Director of Industrial Data Services at SW. “The use of online services like the SW Cloud Platform is an important part of this.”

development and offers continuous performance monitoring, which ensures greater transparency over the entire manufacturing process. “A profile is saved for each of the machines connected worldwide that makes all the machine information and process data available via a dashboard. A map of the world and various production lines provide an initial overview of machine locations and states,” explains Jochen Heinz, Director of Industrial Data Services at SW. This ensures optimum conditions for customers for continuous performance monitoring and preventive maintenance. By 2020, all functionalities will be successively transferred from the previous Cloud solution to the new system. In addition, the design of the user interface including all graphics and statistics are arranged clearly and

concisely, which makes inconsistencies and problems in the operating sequence easy for the user to identify. Care was also taken to ensure intuitive operating guidance, which makes for easy error analysis. SW attaches special importance to data security: “The issue is given high priority at SW. Since a large amount of data in a system is saved in the SW Cloud Platform, we have paid special attention to this aspect,” explains Heinz. The Cloud solution is part of “life,” the complete uniform service concept, as part of the “life data” module: It expands the data services portfolio, which includes, in addition to online services, the components digitization, consulting, factory simulation and data analytics. These solution modules will be further expanded in the future to meet all the challenges of Industry 4.0 proactively.

S

W has already taken on a pioneering role in the industry, as it has been offering its customers access to machine data – via a portal since 2004. To be able to present this information more clearly and concisely and in a more modern format, SW has developed its own Cloud solution based on the Predix IIoT platform from GE, thereby making it even easier for customers to meet quality and production goals. With the existing platform, SW has already been evaluating machine data for more than 15 years with the consent of its customers. About 2000 machines are currently connected; 700 million data points and 25 million machine events have been collected. The new SW Cloud Platform is the result of advanced

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Schwäbische Werkzeugmaschinen GmbH (SW) has developed an internal SW Cloud Platform to make customers’ machine data from their machining centers even more transparent, accessible and user-friendly


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COMPANY PROFILE

Jay Shree Machines : Trusted for quality excellence

Mr. Rajendrabhai Harsora, Managing Director, Jay Shree Machines

J

ayshree Machines Manufacturer of Sheet Metal Forming Machine has products like Press Brake Shearing Machine, Power Press, Deep Draw Press in Mechanical and Hydraulic. For more than one decade, the company operates under the brand Name Jayson/ Kishan. The company earlier started as fabricator for more than 15 years. Simple design and quality with after sale service has ensured steady growth of the company. More than 1500 machine through out India are working satisfactorily. The machines are very useful to the steel furniture Industry, industrial storage system manufacturers, air conditioning and refrigeration firms, door frame and slotted angle manufacturers, utensil manufacturers, coach & body builders, control panel manufacturers and many more usage. Turnkey project for manufacturing water filter is supplied to the company which is financed by UNICEF. Our products are supplied to ISO:9000 companies. Also machines are exported to GULF & AFRICA.

48

MACHINE TOOLS WORLD JULY 2018

Mr. Nirav Harsora, Managing Director, Jay Shree Machines Our Aim

Company has an aim to reach at desired goal by expanding its business with overseas customers. Products Range

• Hydraulic Shearing HVR and EE Series • Rear Cylinder Hydraulic Press Brake • Mechanical Over Crank Shearing Machines • Mechanical Under Crank Shearing Machines • Piller Type Power Press • C Type Fix Body Power Press • 3 & 4 Roll Standard Piramide Type Mechanical & Hydro Mechanical Plate Bending Machine • Heavy Duty Hydraulic Press For more information Jay Shree Machines Pvt. Ltd. Plot No. G-1148, Road No.G-1, G.I.D.C. Metoda, Tal.: Lodhika, Dist.: Rajkot. (Gujarat-India) Telefax : 02827-287835 Ph.: 02827-287836 E-mail: jayshreemachines@ymail.com



COMPANY PROFILE

Gala Precision’s Forte: Precise Surface Engineering Solutions

G

ala Precision, serving the industry for over 25 years, is a one stop solutions provider for surface finishing needs such as de-burring, finishing, washing and cleaning of components and parts. The company offers the whole gamut of machines, processing media, compounds and services for surface finishing and parts. Gala has capability to build large finishing & cleaning equipment for challenging needs of defence, atomic and aerospace sectors. The finishing machines are capable of achieving Ra value of 0.05 microns while precision parts cleaning machines are capable of achieving a Millipore value of less than 1mg.

porcelain, steel or plastic materials. Compounds are used with water with concentration levels of 5 to 10%. Gala offers standard and customised products to suit specific customer needs. The finishing machines are of different types. These are:

• • • • •

Vibratory finishing Centrifugal Barrel Finishing Disc Finishing Customised finishing systems Complete automation of surface finishing processes is possible by using component loading system, conveyors, vibratory trolleys and dosing system using PLC based control panels.

Deburring and Finishing

Vibratory Finishing

The de-burring and surface finishing machines are used for mass finishing of metal, plastic, ceramic and rubber parts. Small parts weighing a few grams up to 25 Kg can be processed in a variety of machines available from Gala’s wide range of products. Use of de-burring and finishing machines is essential to achieve consistency and high production rates. In addition to finishing equipment, use of abrasive media and compounds is essential to achieve the desired process results. Abrasive media can be of ceramic,

The Vibratory finishing machine consists of a bowl lined with polyurethane material which is mounted on springs and uses vibratory motor and unbalanced weights to achieve gyroscopic motion to the workload. Vibratory finishing is used to achieve de-burring, edge radiusing, degreasing, de-scaling, polishing, mirror finishing and smoothening of a variety of components. This is the most common method used for de-burring and polishing of components which include sheet metal, machined, cast, forged & moulded parts.

Conveyorised Spray Cleaning System from Gala

50

MACHINE TOOLS WORLD JULY 2018

Gala’s Disc Finishing Machine

A wide range of components of Automotive, Aerospace, Defence and consumer products can be processed using vibratory finishing machines. Gala offers the following types of Vibratory machines based on the shape of the working bowl.

• Round Vibratory Finishing Machines are the most common type of machines used in manufacturing industry for a wide range of components. This machine can be used for small parts like rivets & screws to bigger parts like turbine blades. Gala offers machines from 70 to 1500 litre capacity. Standard and Auto Separation models are also available. • Spiral Machine is a modified version of Round vibratory finishing machine. This type of machine is used to ensure 100% separation of parts within a short time of 8 to 10 minutes. Due to the Spiral shape of bowl, the process efficiency is better as compared to round vibratory machine. Gala offers Spiral machines from 120 to 800 litre capacity. Spiral vibratory finishing machines are used for parts of bearing industry, brass valve bodies, furniture



COMPANY PROFILE industry, etc. • Elliptical Vibratory Finishing Machines are used where processing time is less than 10 minutes. This is used for removing light burrs and general finishing of small parts like bearing cages, ceramic insulation tiles, etc. Elliptical machines are available up to 250 litre capacity. • Trough Vibratory Finishing Machines are used for de-burring, degreasing and polishing of medium size parts like axles, shafts, rods, marble & granite tiles, turbine blades, aerospace parts, etc. Gala offers machines from 100 to 1200 litre capacity. • Segmented Machines are used for bigger parts to avoid part to part hitting while processing. Segments are provided to make compartments in working bowl where one or a few parts are loaded for finishing. Normally 3 to 8 compartments are provided. Gala offers segmented Round and trough vibratory finishing machines as per the customer needs. These machines are used for parts like machined aluminium die cast parts, parts of hydraulic industry and so on. Centrifugal Barrel Finishing

This is a more aggressive form of finishing

Multistage Ultrasonic Cleaning Equipment

as compared to Vibratory finishing. This machine uses 3 or 4 barrels mounted on turret assembly. The high rotation speed of turret results in high centrifugal forces which results in faster process. These machines are often used with variable frequency drives to adjust the rotational speed as per process need. The surface finish achieved with this process is more uniform and even. Such machines are used in various industry sectors like jewellery, bearing, compressor, automotive and aerospace. Centrifugal barrel finishing is capable of achieving high Ra values up to 0.06 microns for parts like textile rings, reed valves, bearing rollers, etc. Centrifugal Disc Finishing

This is the most aggressive form of surface finishing as compared to Vibratory finishing or Centrifugal barrel finishing.

The resulting forces are at least 10 times higher as compared to Vibratory finishing process. This machine consists of a tub or housing with a rotating disc at bottom driven by electric motor. Complete automation is possible with component loading, separation trolleys, and media reloading using PLC -based controls. These machines are popular in processing parts like coin blanks, medical implants, fine blanked components and precision components of automotive & aerospace sector. Customised Finishing Systems

Completely automated finishing systems can be offered along with Vibratory finishing and Disc finishing equipment. Automation results in achieving higher production rates and process consistency. Fully automatic finishing systems can be offered using component loading system, separation equipment, compound dosing system, conveyors and PLC- based control panel. Customised systems are popular in applications like processing of coin blanks, medical implants, fine blanked parts, drive chain components, bearing rollers & cages and so on. Parts Cleaning

Gala Vibratory Finishing Machine.

52

MACHINE TOOLS WORLD JULY 2018

Parts cleaning is an essential process of the manufacturing industry. Parts cleaning equipment are used to remove all types of contaminants from the surfaces of components. Parts cleaning machines are used for degreasing, de-scaling, removing


G-SERIES

Precision at the highest level GROB 5-axis universal machining centers stand out due to their absolute precision and reliability in the automotive, medical and mechanical engineering industries, in tool and mold making as well as in the aviation industry. The proven 5-axis simultaneous technology with horizontal spindle position enables you to machine parts of various sizes and materials in a flexible and failure-free way while offering maximum stability of the machine. Fast chip-to-chip times and the innovative further development of our spindle technology guarantee a high economic efficiency and productivity.

Contact: GROB MACHINE TOOLS INDIA Pvt. Ltd. I Hyderabad, INDIA Phone: +91 40 4202-3336 I E-mail: info@in.grobgroup.com

01_MTW_Monthly_Magazine_190x250mm.indd 1

www.grobgroup.com

15.02.2018 10:20:47


COMPANY PROFILE metallic burr or particles and other solid particles of contamination. Parts cleaning can be achieved by using Immersion, Spray and Ultrasonic Techniques or combination of these techniques. Gala offers complete range of aqueous parts cleaning equipment which includes Spray cleaning, Ultrasonic cleaning, Rotary screw, Single Chamber multi-process and customised machines. The company also builds customised machines which include Ultrasonic machines with material handling system, drying with centrifuge arrangement, Single piece flow and so on. It is capable of building large machines as big as 5000 iitre capacity Ultrasonic cleaning machine for very big parts and 60 feet long conveyorised washers. It offers machines suitable for batch & continuous production and also for Single piece flow lean production. Gala equipment are preferred for precision cleaning of parts of industries such as aerospace, automotive hydraulic, engineering, electronics and many others. Machines can be built to meet stringent requirements of achieving Gravimetric (Millipore or NAS standards) values of less than 1 mg and particle size as per class A for precision cleaning. Gala is indeed a one stop solutions provider for equipment and cleaning compounds.

4 bar and basket rotation speed is in the range of 3 to 6 RPM. Rotary basket machines are suitable for general cleaning of small components such as machines parts, sheet metal parts, fasteners, springs, etc.

of medium and heavy parts such as housings, axle box, brake drums, machined castings & forgings. Parts can be loaded in basket or can be placed on work table. Wash, Rinse and dry cycle can be offered.

Rotary Indexing

Conveyorised Washing

This is suitable for small and medium size parts. Component loading can be at the same or at different locations. A single part is indexed in cleaning, rinsing and drying zone and follows single piece flow. Component loading and unloading can be manual or automatic with pick & place device or with robots. Rotary indexing machines are suitable for cylinder liners, shells, and machined cast parts.

Conveyorised washers are popular as they support continuous production and easy to operate. Components travel on conveyor with or without trays and pass through enclosed chambers. Spray, rinse and dry sections can be customised based on the cleaning requirements. Conveyor can be made of steel wire mesh and chain & rod type. Conveyorised washers are suitable for parts like aluminium or brass shells of ammunition, connecting rods, containers, bins, housings, wheels, rifle scopes, gears & sprockets, machined castings & forgings and reflectors.

Rotary Screw

Rotary screw spray cleaning machines are suitable for continuous production. The cleaning and drying stages can be customised. Machines are available from 30 kg/hr to 1500 kg/hr capacity. These washers can be integrated with other production equipment to maintain production flow in a uniform manner. These washers are popular for components such as stamped washers, fasteners, small arms ammunition shells, etc. Cabinet Front Loading

Spray Cleaning

Gala’s comprehensive manufacturing range also includes spray cleaning machines up to 100 bar spray pressure. Spray cleaning machines are widely used for washing of components such as machined parts, stamped parts, cylinder heads, cylinder blocks, connecting rods, crank shafts, housings, bearing parts, fasteners, transmission parts, ammunition shells, containers, etc. The spray cleaning machines are offered in the following configurations: Rotary Basket

Rotary basket washers are compact machines suitable for small parts in batches. These machines are simple to use with wash, rinse and dry options. Spray pressure is in the range of 2 to

54

MACHINE TOOLS WORLD JULY 2018

These washers can have fixed or rotating work table. This is suitable for cleaning Gala’s Phosphating Plant

Ultrasonic Cleaning

Gala manufactures a whole range of Ultrasonic Cleaning Machines from 20 to 5000 litre capacity. The company can offer material handling system for multistage ultrasonic cleaning machines for ease of handling of parts. Multistage machines are customised to suit customer needs with options of multiple cleaning, rinsing and drying. Ultrasonic cleaning machines are


TNC 640 – The new High-End Control for Milling and Turning Operations The new TNC 640: for the first time, milling and turning are combined in one TNC. Now users can switch as desired between milling and turning—within the same NC program. Switchover is independent of the machine kinematics. It automatically takes the respective operating mode into account and without any additional action.This new simplicity is complemented by dialog-guided plain language programming, the optimized user interface, powerful programming aids as well as comprehensive cycle packets taken from amply field-proven HEIDENHAIN controls into the new TNC 640.

HEIDENHAIN OPTICS & ELECTRONICS INDIA PRIVATE LIMITED

Angle Encoders

Linear Encoders

Chennai 600031, India

Contouring Controls

phone +91 44 3023 4000

Position Displays

Length Gauges

www.heidenhain.in

Rotary Encoders


COMPANY PROFILE used for precision cleaning of parts which are complex in configuration and geometry and / or which require stringent gravimetric values and particle size count as per class A. Ultrasonic cleaning machines are widely used for cleaning of precision parts of aerospace and automotive sector like engine valves, pistons, turbine blades, fuel injection parts, coil springs, bearing cages etc. This technology is ideal for cleaning of electronic parts & PCB’s, moulds, optical parts and lenses. Gala can provide ultrasonic transducers of tank bonded, immersible box and rod type, based on application. Operating frequency can be 25 KHz or 30 KHz or 40 kHz to suit cleaning application. Ultrasonic cleaning machines offered are: Table top, Multistage and Multistage with material handling system.

Customised Solutions

Gala also offers customised cleaning solutions to meet customer’s special requirements. It can build machines for Single piece flow or Robotic washing. Phosphating Plants

Gala also offers pre-treatment, passivation and phosphating plants. These plants can be fully automatic with material handling system, PLC based control panel and SCADA system.These are offered with features like basket rotation, auto dosing, walking beam material handling arrangement, etc.

Single Chamber Multi-process Cleaning

Material Handling

Machines (SCMP)

Gala also builds and offers material systems for conveying components. The

Single chamber multi process cleaning

56

machines offered by Gala are compact in size. Spray, Immerse flood wash and Ultrasonic wash cycles are possible in this configuration. Vacuum drying also can be provided on customer request.

MACHINE TOOLS WORLD JULY 2018

range includes Belt Conveyors, Inclined Conveyors, Component Loading Systems and Vibratory trolleys. Industrial Dryers

Drying is a natural corollary in the process of components cleaning. Hence Gala also offers Industrial Dryers of various types. These are Vibratory, Belt type, Rotary Screw, and Centrifuge Dryers. Undoubtedly, Gala Precision is a One-stop-shop for Solutions for Surface Finishing, Cleaning, Washing and Drying of Precious Machine Parts and Components. Quantity, size or criticality doesn’t deter Gala from offering a solution to any industry to the utmost satisfaction of the ultimate customer. - P.K. Balasubbramaniian


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CASE STUDY

Efficient and ultra-dynamic: Simultaneous milling and 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 and now relocated to Breidenbach, Hessen, the milling services provider HETEC is now a loyal GROB customer.

H

ans Rink, Head GROB

a GROB 5-axis universal machining

discussions took place in Mindelheim

Representative for the Hessen

center was strong. Basic issues needed

and Breidenbach – with long phone

region, managed to persuade

to be clarified first as to whether HETEC

calls – and they finally hatched the idea

HETEC MD Friedhelm Herhaus to visit

actually wanted to implement the axis

of developing a “fantasy component”,

the GROB trade fair stand. Back then,

system (with rotated Y axis). An axis

for which the GROB machine concept

Friedhelm Herhaus was rather sceptical

system that was totally new territory to

minus re-clamping and multiple clamp-

about the size of GROB as a company, as

HETEC at the time. But as he traveled

ing would deliver rapid results. There

he couldn’t believe that he would really

back from the trade fair,Friedhelm

was also a requirement to create various

be taken seriously as a regional supplier

Herhaus called Hans Rink to discuss

contours on the GROB machine. Chip

of tool, die and machine manufacturing

the machine’s axis symmetry and the

removal with deep pockets was another

products from one of the world’s biggest

machining technology for workpieces

major issue on the check list. “We were

machine tool companies. But he soon

with long tools. He was increasingly

really impressed by the assistance we re-

knew better.

persuaded, recognizing that workpieces

ceived from the GROB technicians. Even

can be machined with long tools with

at an early stage of our collaboration,

world first from GROB – the first fully

the GROB machine and that the hori-

when we hadn’t even bought a machine

hydraulics-free, fully CNC controlled

zontal spindle position enables opti-

yet, we quickly realized that GROB

machining center. Back then, he wasn’t

mum chip removal for both drilling and

looked after new customers really well,

interested in all the arguments for and

deep cavities. The question of the extent

the aim being to find the best user solu-

against hydraulics-free machine tools.

to which the GROB machine would

tions”, Friedhelm Herhaus looks back to

He was much more interested in the

suit existing HETEC machine tools also

the time with fondness.

horizontal spindle position on the G550

needed to be clarified, and whether this

and that you could mill and drill with it

type of GROB machine with its specific

at the same time without having to re-

axis concept could be integrated in the

HETEC team impressed by GROB technology

clamp the workpiece or take it to a deep-

HETEC environment successfully. Fried-

The more Friedhelm Herhaus and

hole drilling machine. An important

helm Herhaus could instinctively see the

his technicians got to grips with the

factor for tool and die construction, but

potential of the GROB machine. Further

technology of the GROB machining

2010 saw him standing in front of a

for many mechanical engineers, too,

centers, the more they could see the

when they have to drill deep holes. The

strength of these machines. First the

highly experienced Friedhelm Herhaus

benefit that – thanks to the special axis

had never seen milling and drilling on a

concept – the entire length of the tool

single machine of this kind before. So it

can be used in each axis setting – even

initially got his interest, at any event. He

at maximum workpiece size. And the

found the travel and GROB kinematics

special tunnel concept means that the

– the whole machine concept in fact –

whole work area can be used, as the

very appealing.

motor spindle plus tool withdraws into the spindle shaft, meaning

Thorough preliminary research and intensive technical analysis And yet. The disinclination to opt for

58

MACHINE TOOLS WORLD JULY 2018

that the machine table can rotate and swivel with the workpiece and Grob 5-Axis Machining Center G-350

clamping mechanism without colliding


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• Ideal for all types of metals and alloys across a range of applications • 35+ elements in total • Master alloy calibrations available • Low level analysis for key elements like N, C, S, P etc. • High accuracy, precision and stability • On-site expandable to add elements, bases and matrices without hardware changes • Analysis of foils down to 0.05 mm (50 microns) • Economical to procure, operate and maintain

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CASE STUDY – a definite plus point. Something

companies from a wide range of sectors.

completely new to the die HETEC

With production plants in Mindelheim

technicians. In Mindelheim for training

(Germany), Bluffton, Ohio (USA), São

during the initial and test periods, the

Paulo (Brazil), Dalian (China) and Turin (Italy) as well as sales and service

machine operators soon appreciated another benefit provided by GROB

in greater flexibility and improved

offices around the world – GROB has

machines: The spindle is positioned

spindle running times.And then came

an international footprint. The GROB

almost at eye level, giving a good view

the GROB in-house trade show in 2015.

Group employs 6,600 employees around

of the machining tool.

The HETEC management team were

the world, generating a turnover of

impressed by the benefits of a G550 with

around 1.5 billion euros.

From the first G550 to the G550 with rotary pallet storage system (PSS-R)

a rotary pallet storage system (PSS-R), purchasing one soon afterwards with a

machining centers and ultra-complex

After successful testing at GROB in

master computer. A major plus point in

production systems with integral

Mindelheim, the HETEC management

their eyes was the fact that, even with

automation to manual assembly stations

team finally took the decision to buy

the GROB automation application, the

and fully automated assembly lines.

a G550. Particularly because the axis

machine operator still had a good view

Production facilities for electric motors

concept allows for machining deeper

and access to the work area.

and assembly facilities for battery and fuel cell technology also feature in the

cavities with good chip removal and drilling operations with deep hole

A solid partnership is formed

product range. Custom solutions are

drilling tools (Ø 8 x 650mm) went

At an early stage of discussions and

created for engine component coating

without a hitch.

the process of getting to know each

technology, machining turbine housings

The first GROB G550 was then

other, HETEC dismissed fears of a

and machining structural and chassis

installed as planned for machining

David and Goliath situation. Both

components. The company has taken

modelling components with complex

sides soon learned to value each other

a major step forward with its GROB-

contours, high surface requirements and

as they looked for the best solution.

NET4Industry software for future

parallel introduction of cooling bores in

The GROB philosophy of “nothing’s

digitalizing and networking production

a single clamp. Later on, HETEC soon

impossible” ultimately won the day.

processes.

saw the machine’s actual potential at

GROB acceded to nearly all of the

HETEC for machining used in tool and

customer’s wishes, developing special

die construction. The G550 was ideal for

solutions. The purchase of a G550

HETEC – good performance is no accident

machining the high-strength, hardened

seven years ago marked the beginning

HETEC – a service provider in the

steels typically used in this area. HETEC

of a solid collaboration based on trust

milling sector – has been assisting

technicians were amazed by the option

– something that HETEC had never

customers in the fields of model, mold

of full introduction of cooling and

before experienced in over twenty years

and machine manufacturing for over

ejector bore with tool lengths of up to

of existence. HETEC are also really

twenty years with great success.

650 mm in the same clamp.

impressed by the GROB Service hotline

Continuing close collaboration

The company’s success is built on the

and expert technical support. So it’s

efforts of a team of 22 highly motivated

between HETEC and GROB, allied with

no surprise that Friedhelm Herhaus

specialists in conjunction with twelve

a desire to introduce automation for

is really pleased with his Swabian

latest-generation production centers.

die- and tool-making processes with

Bavarian partners, buying more

Careful planning, extreme precision,

typically long running times, led to

machines in Mindelheim.

constant quality control and punctual

the purchase in 2014 of a G350 with a

delivery are further reasons behind

GROB-WERKE – The latest technology and expertise worldwide

the long-term relationships it has with

system that made it possible to set up workpieces outside of the machine.

This global family owned and managed

are built on fairness and reliability

Completed pallets were replaced by

company has been involved in the

– inside and out. Whether it’s CNC

newly fitted ones manually. But it

development and production of

milling machines, wire EDM or NC

was also clear that simultaneously

systems and machine tools for over

programming, HETEC – based in

setting up the workpieces while the

90 years. Customers include big-

Breidenbach – is ready and waiting for

machine was running would result

name automakers, their suppliers and

new customer projects.

zero point clamp system and a pallet

60

The portfolio extends from universal

MACHINE TOOLS WORLD JULY 2018

customers. And all of these features


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DRIVESYSTEMS


CASE STUDY

Renishaw conformal cooling solutions prove a boost to moulding productivity The use of cores incorporating conformal cooling in the moulds for its plastic casings has allowed Alfred Kärcher GmbH & Co.KG to reduce the cooling time for each part by 55%, giving a huge boost to the company’s moulding productivity. The special cores, which were designed by Renishaw, were produced using metal additive manufacturing technology

H

igh-pressure washers from Alfred

Renishaw GmbH in May 2013, to work on

Kärcher GmbH & Co.KG, with

improving the cooling time in the moulds.

their unmistakable bright yellow

casings, have become a permanent fixture

Solution

in many German homes and are growing

“The first stage of the project was to

in international popularity. The devices’

obtain data for the existing moulds to

power and reliability encourage people

determine whether Kärcher’s goal was

to use their “Kärcher” as part of their

feasible,” recalled Carlo Hüsken, who

daily cleaning routine, both inside and

coordinated the project for Renishaw.

outside the home. To meet the increasing

The existing injection moulding process

demand from around the world, Kärcher produces its compact washer by the

was mapped with thermographic images provided by Kärcher and simulated

million every year. More than two million

assembly lines, operating three shifts

using Cadmould® 3D-F simulation

K2 basic pressure washers alone leave

per day, to give a production capacity of

software. This revealed that, within the

the Obersontheim factory every year.

12,000 assembled and packed K2 high

52 second cycle time, cooling accounted

However, even this level of production is

pressure washers each day.

for 22 seconds, with melting at 220°C and

unable to meet the global demand.

62

K2 pressure washer casing in production.

Clearly, one option would be to add

de-moulding at 100°C. The mould tool

more moulding machines. However,

temperature was controlled with water at

Challenge

Leopold Hoffer, the coordinator

a temperature of 35°C and a throughput

One of the Kärcher washers’ most

for injection moulding at Kärcher’s

of 10 litres/minute. Hotspots, detected by

recognisable features is their bright yellow

Obersontheim factory, believed that it

the thermography, were also modelled,

casings. This was also one of the key

should be possible to generate more

as these areas were responsible for the

bottlenecks in the manufacturing process.

productivity from the existing equipment.

extended cycle time and needed to be

For example, the casings for the K2 series

“Our aim was to reduce the cycle time

analysed in more detail. With this data,

washer are produced on six injection

from the original 52 seconds to between

a simulation of 20 cycles was completed,

moulding machines, each capable of

40 and 42 seconds,” he explained. He

including an analysis of the wall

moulding 1,496 casings a day. This was

approached Pliezhausen-based LBC

temperature.

not enough for Kärcher, which has four

Engineering, which was acquired by

MACHINE TOOLS WORLD JULY 2018

Based on a suggestion from Mr


CASE STUDY www.mtwmag.com

Hüsken, the temperature control on the

that the new mould design, combined

nozzle side was improved for the second

with the re-alignment of some peripheral

simulation run. The beryllium copper,

components (material feed, handling

threaded fitting dome, for the body cover

systems, etc.), made it possible to reduce

was provided with additional cooling

the cycle time from 52 seconds to 37

by inserting two conventional cooling

seconds. As a result, the daily capacity

channels into the mould plate on the

on one machine could be increased from

nozzle side.

1,496 to 2,101 castings. Kärcher then implemented the design

Two simulations were then run to assess potential improvements

changes for the other moulds. The

through the use of conformal cooling.

additively manufactured hybrid inserts

Conventional mould cooling is made up

for these moulds were produced and

of a network of drilled channels. Drilling

Kärcher pressure washer.

the channels limits the geometries that can be produced so, while this is adequate

design in order to alleviate the problem. Based on the results of the simulations,

for simpler moulds, it cannot provide the

supplied by Renishaw, with Mr. Hüsken actively supporting the mould-maker during the manufacture of the tooling. Having been sceptical about the project

most efficient cooling in more complex

Renishaw presented a comprehensive

initially, Mr. Hoffer said, “At the end

examples. Conformal cooling is based on

improvement plan to Kärcher. This

of the day, the results were better than

the use of metal additive manufacturing

showed that conformal cooling could

expected. Renishaw sold us a complete

to produce the core of the mould.

be used to improve the temperature

improvement package, with a holistic

Additive manufacturing builds the cores

control of the mould hotspots, thereby

consideration and analysis of the mould

in a series of thin layers. The flexibility of

achieving a more uniform cooling rate

used to achieve the best results.”

this approach means that cooling channels

and a reduced cooling time. A modified

Renishaw always bases its client-

of almost unlimited complexity can be

mould design was proposed that would

specific solutions on a combination of

incorporated. Typically, conformal cooling

incorporate two additively manufactured

technology. “In our case, this meant a

is used to keep the channels at a more

cores to provide conformal cooling at the

mix of conventional cooling technology,

equal distance from the moulding, giving

identified hotspots.

project-specific cores produced using additive manufacturing, and vacuum-

more even cooling, or to focus on areas where hot spots are known to exist to give

Results

brazed cores” he added. “From these

more rapid cooling in those areas.

The results from the modified mould

ingredients, we created the right recipe for

design were checked by Renishaw, using

the application.”

The simulations showed that practically

From this project, Mr. Hoffer has

all of the hotspot areas could be improved

thermographic images supplied. These

through conformal cooling, with the

confirmed that the wall temperatures

gathered important knowledge and

wall temperatures reduced by up to

could be reduced by 40°C to 70°C. The

experience. “In future, we will give more

70°C. Finally, in one area where there

cooling time was reduced from 22 seconds

attention to cooling in the design phase,”

was insufficient space in the mould to

to 10 seconds, a 55% reduction. Volker

he stated. “Cooling calculations will be

incorporate conformal cooling, Kärcher

Neu, technology and Plastics group leader

an essential stage of each mould design at

made clever improvements to the product

at Kärcher, produced figures confirming

Kärcher. Using this information, we can

www.qviindia.com

The original OGP SmartScope® Flash CNC 200 video measuring machine.

JULY 2018

MACHINE TOOLS WORLD

63


CASE STUDY

Rollon Technology for Intralogistic Systems

Packaging and palleting phases are automated with the help of an industrial robot and the Actuator System Line.

Intralogistics is becoming more and more important in facilitating in-house processes at companies, and is also growing thanks to the constant increase in e-commerce. The degree of automation increases at the same rate as the need for personalized solutions, ranging from linear units, such as handling systems, to complete interlogistic systems. This may be followed by further development that can include collecting, packaging and palleting, often combined with wrapping machines.

L

64

inear technology is the core

of the product range and the Group’s

business of our Italian company,

capacity. For example, the acquisition

Expansion of production capacity for integrated solutions

with a branch in Bangalore, India.

of the Italian Company, TMT, in January

In November 2017, the Limburg

Its products cover a wide range of

2017 was aimed at extending the range

production plant that previously

functions in relation to handling, like

of self-supporting aluminum profiles.

belonged to Hegra Linear moved to

those that are part of intralogistics. The

Integration of the range of products

a new site. Expanding production

Rollon Group has maintained constant

allows the linear technology experts to

capacity to 1800 square meters makes

growth, increasing the number of

install light-weight “pick-and-place”

it possible to respond more quickly

orders, and developing new fields of

Cartesian systems. In October 2017,

to customers’ needs and to increase

application. In the last six months, it

the acquisition of the Italian company,

production while reducing delivery

has acquired at least five manufacturers

T-Race, which specializes in linear

times, implementing personalized

in the linear motion sector. These

and telescopic rails, followed the same

solutions, and optimizing production

acquisitions are based on an important

principle: in fact, T-Race systems extend

processes. Rollon is also busy extending

principle: they must be tailored to the

the choice of Rollon systems when it

its Vimercate branch in Lombardy,

company, with suitable integration

comes to intralogistics.

where the production processes will be

MACHINE TOOLS WORLD JULY 2018


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.

New Delhi, India July 25-28, 2018 Hall 11, Stand 11.42 ROLLON India Pvt. Ltd. - INDIA 1st oor Regus Gem Business Centre 26/1 Hosur road, Bommanahalli Bangalore 560068, INDIA www.rollonindia.in - info@rollonindia.in


CASE STUDY made more linear, with separation of production lines. The area set aside for actuators is combined in a new plant with a production area of 1800 square meters. Here too, there is an increase in capacity and a further reduction in delivery times. The aim of all the investments made is to offer the market the most extensive linear technology for intralogistics, and to enhance the product range with integrated solutions.

Rollon’s personalized intralogistic solutions Starting from individual handling systems that carry out physical logistical processes such as handling, separating, collecting, packaging, and storing, our company designs and constructs

When it comes to collecting and packaging, Rollon’s multi-axis systems are long-lasting and precise in terms of positioning.

complete handling and conveying lines, broken down for each area of

adverse ambient conditions. Shuttle

tempered sliding surfaces. There are

application. Thanks to our wide range

systems, on the other hand, favor a

systems suitable for use in demanding

of high quality products, personalized

high degree of rigidity, with the same

conditions, and other self-aligning

intralogistic solutions can be put

dynamics. Overall, all applications have

systems when adaptation of tolerances

together more quickly and easily, and

what the end client is looking for in

is required.

at lower costs than completely new

terms of long-life and reliability. Telescopic Line: includes telescopic rails

systems which are designed from scratch. For example, when it comes to

Tailor-made intralogistic systems by

with bearings or spheres, which Rollon

multi-axis portal systems, the designers

Rollon are obtained by combining four

makes in various construction forms

are able to choose from various drive

product lines:

and sizes, as well as special versions.

systems for the conveying units.

Linear Line: which includes linear and

The extractions can have tempered rails

Depending on its function, attention is

curved rails, with spheres or bearings,

able to handle large loads with reduced

focused on high dynamics, long strokes,

to carry out linear movements wherever

bending. They resist impacts and wear,

moving heavy loads, or use under

necessary. The rails have high-strength,

and can be extracted partially, totally or added to, and can be used for up to 200% of the sliding length. Actuator Line: the linear axes, with various rail and drive configurations, are available with a belt, screw, or rack and pinion transmission, and are suitable for the widest range of needs, when it comes to precision, speed, and the rails used. They come with rollers or recirculating ball bearing systems, to meet the most diverse needs in terms of load and ambient conditions.

Multi-axis systems are used to equip machine tools or for packaging systems.

66

MACHINE TOOLS WORLD JULY 2018

Actuator System Line: this is an evolution of the Actuator Line, and



CASE STUDY

You can find Rollon India Pvt. Ltd. and its solutions for linear motion systems at: PackPlus 2018 | Hall 11 - Stand 11.42 July 25-28 New Delhi, India

Rollon builds equipment for large load shelving, as well as for handling medicinal products in pharmacy storage spaces, where a high degree of precision and hygiene are called for. includes multi-axis systems for

combine high forces and torques, with

3°C, or at summer temperatures. Rollon

industrial automation. They are applied

precise positioning, which is standard

has proved to be the ideal partner

in numerous industrial systems: servo-

for Rollon. Linear systems are highly

when it comes to modern intralogistic

systems for machines, high-precision

durable, even in environments where

systems, thanks to its unload and stack

assembly systems, packaging systems,

abrasive dust is present and in condi-

systems that are easy to design using

and production lines with a high

tions of continuous use.

Linear Line rails, complex material flow and handling systems that involve

number of cycles and speeds.

Collecting, packaging, and palleting: some examples of intralogistic systems

68

Extraction mechanisms for horizontal and vertical storage systems

the use of industrial robots, and the Actuator System line.

Rollon products are applied to horizontal and vertical shelving, vertical

Collecting, packaging, and palleting are

warehouses, and automatic warehouses

important processes within the com-

for small parts, with personalized

pany, which often have to be combined

extraction systems suitable for large

with packaging machinery. Here, with

loads. Dynamics and large loads, along

For more information:

its Actuator System Line, Linear Line,

with limited bending, are guaranteed

ROLLON INDIA Pvt. Ltd.

and Actuator Line systems, Rollon is

even for long strokes or high forces and

1st floor, Regus Gem Business Centre

able to put together turnkey mechani-

torques. From large load warehouses

26/1 Hosur road, Bommanahalli

cal systems that are highly dynamic,

to automated handling systems for

Bangalore 560068, INDIA

with limited bending of the linear units,

medicinal products in pharmacies, all

Tel: +91 80 67027066,

even when dealing with large spans.

types of solutions are possible. The

Fax: +91 80 67027004

The portal and gantry systems, along

same applies to vertical systems and

Email: info@rollonindia.in

with Cartesian pick-and-place systems,

shuttle systems in refrigerated cells at

Website: www.rollonindia.in

MACHINE TOOLS WORLD JULY 2018



TECH TRENDS

Laser triangulation sensor sets new performance standards in industrial displacement & distance measurements

The innovative optoNCDT 1750 laser triangulation sensor from Micro-Epsilon enables new performance levels. Advanced sensor technology makes the compact and universal sensor best in its class.

The innovative optoNCDT 1750 laser triangulation sensor from Micro-Epsilon attains new levels of performance. Advanced sensor technology makes the compact and universal sensor best in its class. Default presets provide ease of use, high precision results and time savings. Therefore, the optoNCDT 1750 laser triangulation sensor is used in automation technology, electronics production, machine building and the automotive industry.

T

he new optoNCDT 1750 laser sensor from Micro-Epsilon, which is a high performance laser triangulation sensor, sets another milestone laser-optical measuring systems, while offering increased repeatability and linearity in displacement and distance measurements. Furthermore, many new software features are also included. High speed is one of its principle features. Based on a measuring rate of 7.5kHz, this model operates 3x faster than its predecessor. Its improved repeatability by a factor of two is another decisive advantage. Achieving 0.06% FSO means an increase in linearity of 25%. This laser triangulation sensor applies a surface compensation feature patented by Micro-

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MACHINE TOOLS WORLD JULY 2018

Epsilon, which ensures high accuracy and fast results in changing reflectivity conditions. In addition, another benefit is the peak selection feature that enables measurements on transparent, coated materials and objects behind glass. The high measurement frequency of the optoNCDT 1750 is required for the analysis of mechanical oscillations. For example, when shunting wagons where the impact of the buffers is to be determined or for measurement tasks of rotating parts, e.g. when determining shaft run out. Optimized lenses have increased the linearity. Together with increased repeatability, the user obtains results with higher stability and precision. This extends the fields of application

and even more solutions with high requirements of the measurement technology can now be implemented. The innovative web interface, which simplifies sensor setup, has a unique feature. User-friendly presets enable the user to easily optimize the sensor for difficult surfaces such as semi-transparent plastics and ceramics, PCB materials or carbon- and glass-fiber reinforced plastics. This is favorable for rapid commissioning and high precision results. Intuitive operation additionally provides the unique web interface with ease of use and the sensor can be easily configured. Integrated help texts accelerate parameter set up. Data output is analog or digital via an RS422 interface. Furthermore, the



TECH TRENDS optoNCDT 1750 provides two switching outputs and one input to control different functions. The optoNCDT 1750 laser triangulation sensor is used in numerous industries such as automation technology, electronics production, machine building and the automotive industry. For users who are already familiar with the optoNCDT 1700 laser sensor, the changeover is very easy. Both are compatible, accessories and appliances can still be used. Ease of use is a focus of attention. The default presets enable the user to optimize the sensor for various surfaces. In the menu, the user can choose between three presets. The first default preset is used for materials that the laser point cannot penetrate, e.g. for steels and plastics. The next preset is intended for use on materials that the laser is able to penetrate. It is used for ceramics and bright, semitransparent plastics and paper. The third preset is for changing surfaces, e.g. printed circuit boards where the laser beam penetrates the FR4 printed circuit board material while being strongly reflected by the shiny conducting paths. Due to the RTSC real-time surface compensation feature, the laser-optical

measuring system operates almost regardless of the target material and color. The RTSC system was developed by Micro-Epsilon more than 15 years ago. It reacts to rapidly changing surface characteristics. A typical application example is a barcode, which is a difficult target for a common, optical laser sensor as the quantity of reflected light continually changes. The frequent change between bright and dark also occurs on other surfaces and components where thickness or distance must to be measured. Conventional sensors solve this measurement task using the Micro-Epsilon controller, which however requires more time. The controller has to run through an entire loop in order to be able to restart at the starting point. This process requires four to five cycles until the detected exposure value is considered in the next exposure. The sensor must expose in the first cycle, read out the array in the second, evaluate the measured signal in the third and forward this result to the interface in the fourth cycle. Until the signal is evaluated, the sensor does not know if the exposure was correct. When the sensor recognizes during the evaluation

The default presets enable the user to optimize the optoNCDT 1750 laser triangulation sensor for various surfaces. In the menu, the user can choose between three presets.

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MACHINE TOOLS WORLD JULY 2018

that too much light has interfered with the measurement, the sensor starts to calculate and reduces the value with a delay in the next loop. Consequently, the sensor is readjusted several loops after the current measurement. However, with RTSC the exposure control feature is directly integrated in the array where the light is controlled via an analog circuit during the actual exposure. The filling level of the pixel is measured, and during the current exposure of the image the analog circuit registers if there is sufficient light and if the laser needs to be switched off. The measurement is performed as soon as the exposure starts which leads to the designation Real Time Surface Compensation. Another unique feature of MicroEpsilon sensors is their integrated electronics, which is inside the sensor. In most cases, competitors use external controllers. Integral controllers simplify the sensor development as the temperature of the sensor is no longer a critical aspect. Components that warm up, e.g. with controllers, are outsourced and in most cases not installed at the point of measurement. However, disadvantages for the user are the limited cable length and the need to install a second device. It then often becomes crowded. Laser triangulation sensors from Micro-Epsilon accommodate the electronics in the sensor head. This means the user can freely select the cable length of up to 50m in industrial environments without restriction. This is particularly favorable with installation on robots. Here, only minimum space is available. Here, only minimum space is available. Due to the integrated electronics, no supplementary device is required and space can be saved. The optoNCDT 1750 offers numerous new and enhanced features, which make this laser sensor the best in its class. Among other industry sectors, measurements can also be carried out in the food industry. For example, in meat processing the sensor is used during the slicing of meat and sausages. This ensures that the blister packs always contain the same number of slices. This means the


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TECH TRENDS

Due to the RTSC real-time surface compensation feature, the laser-optical measuring system operates almost regardless of material and color.

machine must provide extremely high cutting accuracy in order to ensure that there are always five slices that weigh precisely 100g in a single pack. The sensor measures the required volume and weight of the meat, which

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MACHINE TOOLS WORLD JULY 2018

is then transported onto a conveyor belt. The sensor is turned and detects the surface of the meat. After this, it is cut. The information about volume and weight enables the exact calculation of the required slice thickness.

Measuring Principle 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 CCD/CMOS array. The distance to the measurement object is determined by the three-point relationship between the laser diode, the measuring point on the target object, and the projection on the CCD 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. This large measurement distance in turn enables measurements to be taken against difficult target surfaces such as hot metals. The non-contact principle 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.





TECH TRENDS

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.

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.

• 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.

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:

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

Figure 1: Classic HEIDENHAIN rotary encoder for motor feedback

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MACHINE TOOLS WORLD JULY 2018

repeatability, the absolute position accuracy that can be achieved within 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.



TECH TRENDS Step 2: secondary encoders for highly accurate position measurement Robotics manufacturers can significantly improve the absolute position accuracy of their robots by using additional, high-accuracy angle encoders or rotary encoders at every robot axis. These socalled secondary encoders, which are

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

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 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

ECA 4000

ECI 4000

WMR

Scanning principle

Absolute, Optical

Absolute, Inductive

Incremental, inductive

Inside diameter

70 mm to 512 mm

90 mm / 180 mm 60 mm to 10 000 mm

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

+

++

+

Table 1: Comparison of the most important specifications for typical secondary encoders

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MACHINE TOOLS WORLD JULY 2018

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.

Figure 4 : HEIDENHAIN linear encoders

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.

For more information Web: www.heidenhain.com


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TECH TRENDS

Maximising the productivity of your ANCA CNC machine

Top Tips on setting up your facility to achieve premium flower

F

ollowing some basic principles can make a significant difference in your grinding performance. For example finding the right coolant system – including chiller, filtration and oil can save money and improve performance. Andrew Ritchie, ANCA Product Manager said: “Our goal is for customers to get maximum performance from our machines and we have a range of support to help them achieve that. For example, our machine maintenance tasks can be found in the User Manual which identifies regular routine activities that customers should carry out on the machine. ANCA

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MACHINE TOOLS WORLD JULY 2018

can also offer customers a scheduled maintenance contract to arrange planned service visits and carry out preventative maintenance to minimise machine breakdowns.” “If you have any concerns with the infrastructure of your facility, contact your relevant services supplier - whether it’s your electricity provider, your air compressor or coolant system and coolant,” Andrew concluded. 1) How to achieve premium power • It is important no matter what brand machine you have that the electrical earthing, quality of power

circuit components (including RF filters), transformers, etc. meet the requirements of the machine. • Don’t have the machine power connected to a power board where any noise-generating equipment is attached, such as electric welders or electric discharge machines, as a lowquality power supply can negatively impact a machines performance. • A qualified electrician should wire the electrical circuit for the machine and make all electrical connections to the machines, factoring in the overall equipment and building power demands.


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TECH TRENDS 2) The importance of compressed air • Compressed air must be clean and free of any impurities. Low-pressure air purge is used on ANCA machines to keep coolant out of the grind spindle, work head spindle, servo motors and their encoders to avoid contamination. The compressed air supply must not contain gross liquid or contaminants (NO oil and water!). • ANCA strongly recommends the air compressor to have an air dryer fitted and meet the air quality standard of ISO 8573-1 Class 4. In locations where it is humid for only a few weeks of the year, unless there is an air dryer, condensation can find its way into motor windings and encoder surfaces creating expensive and untimely failures. • The air supply must meet the air pressure and consumption needs depending on the machine configuration, including any other machines in the facility. A facility with many machines and insufficient compressed air, not only operates

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MACHINE TOOLS WORLD JULY 2018

continuously and uneconomically, but usually has problems with a lack of air supply on the last machine furthest from the compressor. • Regular air compressor servicing to ensure the quality of air is maintained and does not become contaminated. Finding the right coolant system including chiller, filtration if fitted and coolant oil • The height of the coolant system must be lower than the machine coolant outlet to allow gravity return of the coolant to the coolant system. Raising the machine height may overcome coolant drainage issues, however the raised height affects the operators’ ability to use the machine interface. • ANCA strongly recommends levelling the machine as low as possible to the floor, for machine stability under higher acceleration. • ANCA machines are designed to use oil based filtered coolant, water based coolant is not recommended and using this may affect your factory warranty. For a list of recommended

coolant oils please contact your ANCA representative. 3) Getting your Fire System in order • Fire systems provide insurance and peace of mind against serious fire damage inside a machine. • An automatic fire extinguishing system is highly recommended when using oil based coolants, especially during unmanned operation. • An optional Pyrogen fire system is available on ANCA machines. If customers want to fit an alternative fire system, then consult your ANCA representative for support. • The optional coolant mist extractor shut-off prevents a fire spreading into the factory duct work which prevents a catastrophe beyond just the machine.



TECH TRENDS

Inter-stage Membrane Dryer: Lower Life Cycle Costs, Zero Maintenance

H

ow a submarine dives into the deep sea and re-surfaces is a question of simple physics. And aiding in this function is air compression technology. The vessel floats on the surface when the weight of water it displaces equals its own weight. This displacement of water creates an upward force called buoyancy that opposes the downward acting gravity. Since a submarine can control its buoyancy, it can submerge and re-surface. A submarine controls its buoyancy with the help of its ballast tanks; these tanks are filled with water to increase the overall weight of the submarine, thus allowing it to submerge. And when that water is pumped out by displacing it with compressed air, its weight is reduced and the submarine re-surfaces. So by either flooding the ballast tanks or venting it, the submarine can dive or rise. But compressed air is required not just for charging ballast tanks to change buoyancy but also for life support. A constant supply of compressed air is therefore maintained on board in large steel pressure vessels called air flasks. Clearly, the air compressor is a critical piece of equipment on board a submarine. However, storing a large amount of compressed air alone is not enough; that air also needs to be dry in order to ensure safe operation. Compressed air at a high

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pressure enters ballast tanks through a blowing valve. And since the air gets throttled in the process, its temperature drops substantially. If there is moisture in the air, there are chances of that moisture freezing in air passages or in the blowing valve itself. Hence in the humid marine environment, maintaining air quality is crucial not just for diving and rising but also for engine controls, weaponry and various other control systems. Compressed air is therefore maintained at a minimum of -20o C at atmospheric dew point. Failure to do this resulted in the sinking of the USS Thresher, a US navy nuclear submarine in 1963. The vessel sank as the presence of moisture in the compressed air led to icing in the blowing valve. Following this disaster, the usage of air dryers on all submarines has been made mandatory the world over. However, the traditional absorption technology that is widely used in air dryers has its disadvantages. The desiccant granules in dryers turn into clay or become powdery over time that need to be replaced periodically. J.P. Sauer took up this challenge and developed a high pressure dryer with a membrane that efficiently separates water vapour from an air stream. The membrane consists of thousands of hollow fibres bundled together. As moisture-laden air flows through the membrane, it travels

through and around the hollow fibres. The fibre bundle is enclosed in a long tubular container that ensures efficient flow of air. Moisture is removed by selective permeation and dry air exits at the opposite end. The dryer is fitted before the final stage of the compressor and hence the name Inter-stage Membrane Dehydrator (IMD). It improves the life of final stage valves and piston rings. This new technology is also cost effective. Another big advantage of IMD is that it is maintenance free throughout its service life, except for periodic replacement of the pre-filter element. These coalescing pre-filters installed before the membrane dryer remove the bulk of the water vapour and any trapped compressor oil. Since the IMD does not need electricity, it is ideal for use in remote applications. Moreover, since it has no moving parts, it is also ideal for heavy duty installations and work efficiently in harsh environments including shipboard systems and power plants. Its initial cost is higher than a desiccant dryer but its overall life cycle cost is far below other dryers that offer the same air quality.


MGM-Pubblicità(210x297)_Layout 1 08/04/13 10.33 Pagina 1

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• 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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TECH TRENDS

Ceramic coatings for refurbishing machine tool parts

M

achine Tool Industry has undergone major developments in providing enhanced service life to spindles, arbors, bearings, etc. Ceramic Coatings by Plasma Spray have been in use in many industries since 1960. Since last decade, this process and ceramic coatings are being used to provide surfaces to seal areas of spindles, contact faces of arbors and electrical and heat insulation to bearings. Apart from OEM level coatings, many user industries are using ceramic coating for refurbishing of spindles and other machine tool parts. Typical Spray Materials used with Plasma Spray Metals and its alloys: Steels, Ni alloys, Co alloys, Moy, bronze, copper, Babbit, etc. Ceramics: Chromium Oxide, Aluminium Oxide, Al Oxide + TiO2, ZrO2, etc. Carbides: Tungsten carbide, Cromium carbide, TiC Hardness range of coatings: From SOFT 60Rb (Bronze) to HARD 70 Rc (ungsten carbide) Benefits of Plasma Sprayed Ceramic over Hard Chrome Environmental: Less hazardous as there

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is no Hexavalent chrome involved dust disposal; easier than bath liquid. Performance: 3-4 Times more wear resistant than Hard-chrome; Micro porosity holds lubrication; Selective area coating is possible; Higher thickness up to 300 microns per side is possible. Limitations: Ceramics are brittle and are to be handled carefully. The process is not as widely available as hard-chrome. Spraymet Surface Technologies Bangalore-based Spraymet Surface Technologies Pvt. Ltd., headed by Mr. P.T. Bindagi, Technical Director and a veteran metallurgist, is engaged in thermal spray, ENP plating and weld surfacing. While their main plant is in Bangalore, the second plant is located in Pune, to stay closer to its customers especially from the automobile sector which is demanding technical excellence, proximity and

service all at the same time. Spraymet has the distinction of having pioneered the carbide coatings in the steel mills and galvanizing line roll coating. Spraymet owns a few proprietary coatings like Moly bend (Spraymet MoB) for metal-to-metal wear, and Ductile matrix carbide (Spraymet DMC) for plastic process feed screws. Mr. Bindagi is working towards expanding applications in turbine industry, medical implants, and other frontiers. In his quest to spread knowledge, Mr. Bindagi also picks students from universities for project work related to tribology and wear metallurgy. Spraymet has helped the industry save a lot of money and helped conserve its scarce resources.

– P.K. Balasubbramaniian



TECH TRENDS

Precise profile bending with Faccin’s Angle Rolls

F

accin S.p.A. designs, manufactures and supplies a range of profile bending machines designed to support extreme rolling performances. The company’s angle rolls are technologically advanced, reliable and precise machines able to assure excellent bending quality and maximum productivity over time. The profile bending machines are suitable for bending steel, stainless steel & aluminium profiles and beams of various shapes and sizes. With the aim to efficiently satisfy the most diverse processing requirements, Faccin constructs and markets various types of angle rolls. The range includes two high performance models: • RCMI, double pinch angle rolls with special modular roll system, specifically designed for bending profiles with high flexion strength modulus • Taurus is the variable geometry angle roll suitable for bending aluminium profiles as well as heavy metal fabrication work Angle Roll RCMI The double pinch angle rolls of the RCMI series are precise and reliable, designed and constructed to assure high

bending performance. They feature a quality certified steel structure, electrowelded and thermally treated in order to eliminate residual internal tensions which combined with high strength forged steel modular rolls make every model in the RCMI range the ideal angle rolls for bending profiles with high flexion strength modulus. RCMIs are able to operate on all standard profiles, including beams and curved ducts in the direction of greater inertia. Large series of rolls are supplied as standard equipment which allows all kind of different types of profiles to be rolled (including beams, columns and channels rolled on edge) ensuring a superior rolling precision. The adaptability of the special modular system of bending rolls guarantees the best possible guide for the profile during the complete rolling process. The four lateral guide rolls are, as standard, independently adjustable in 6 directions to guarantee the best control of the planarity of rolling, to calibrate diameters and to prevent twisting of asymmetrical sections. Angle Roll Taurus The variable geometry angle rolls of

the Taurus series offer excellent rolling quality, versatility in bending steel and aluminium profiles achieving maximum productivity. The special design with variable geometry and 3 motorized rolls not only assures maximized precision in bending small profiles (closed roll configuration) but also, has the ability to bend large and high resistance modulus profiles (open roll configuration). Taurus series machines are ideal for heavy metal fabrication work up to 17,000 cm3 (1,000 in3) capacity. One of the main features of the Taurus series are their three independently motorized rolls: the side rolls move horizontally while the central one moves vertically. This all adds up to the reduction of waste of material to be removed on both ends of the profiles. Profiles bent with the Taurus series machines are widely used in the construction sector for works such as bridges, stadiums, airports and metal structures in general.

The Trusted Partner in Metal Forming Machines

For more information, Web: www.faccin.com

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TECH TRENDS

Networking as the Basis for Smart Tool Production

Well positioned for Industry 4.0 with network-capable production stations

ZOLLER customers are well positioned for the future when it comes to networking, a task there is no way around against the background of increasing digitalization and Industry 4.0. All ZOLLER solutions, including the proven ÂťgeniusÂŤ universal measuring machine and the new Smart Cabinets tool storage cabinets, operate on the basis of a common database and are connected via a central database.

T

he smart factory operates with the data that is available. With respect to tool management this means that the goal is to have the right tool with the right data, at the right place at the right time. The aim is to link real and virtual tool data over the entire production process and to allocate it to the physical tool, and to provide this information regardless of location. ZOLLER offers a combination of tool management software and software-

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supported tool storage cabinets for the transparent and efficient storage of individual components, complete tools, consumables and accessories in order to quickly find the right tool or grinding wheel with the corresponding data for incoming production or the grinding order. The tool storage cabinets, so-called Smart Cabinets, are structured and transparently displayed in the software interface. The user is guided quickly and

easily to the exact storage location of the tool via the intuitive software interface. On customer request, the individual components can only be removed once the tool has been digitally checked out from the software in order to keep the stock constantly up-to-date and accurate. Grinder Special: Grinding Wheel Management Package ZOLLER offers the grinding wheel management package in its software



TECH TRENDS

Software module for systematic storage and management of grinding disc packages

range especially for grinders. This package offers everything that grinders need for measuring and managing grinding wheels. Thanks to the connection to the new, software-supported tool storage cabinets from ZOLLER, long search times are no longer necessary. The single components required for grinding wheel packages can be stored and managed safely and systematically. Having the right grinding wheel in the right configuration saves costs and lets your machines grind more efficiently. Once the user has all components together, the “Tool Assembly Assistant” software module in the tool management software ensures that the grinding disc package is correctly assembled. The software module can be called directly at the ZOLLER workbench and displays the parts list, a drawing and a 3D model of the assembled tool. Well Equipped for the Future with ZOLLER Measuring Machines Once the tool has been manufactured, it can be measured directly on the ZOLLER measuring machine next to the grinding machine. In an increasingly complex world of networking, ZOLLER attaches great importance to one thing: the simplicity of the operation of all software and hardware solutions. The intuitive software interface of the »pilot« measuring instrument software and the TMS Tool Management Solutions tool management software guides the user simply, quickly and precisely to the (measuring) result.

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A further requirement for the measurement technology of the future: Impeccable tools including digital twin. After measuring the real tool with proven ZOLLER measuring technology, the tool data can be created and managed as individual components directly on the ZOLLER measuring machine on the basis of the characteristic structure DIN 4000 / ISO 13399. That is how tool grinder customers benefit not only from the real, high-precision ground tool but also from the “digital twin”. The characteristic data, including 2D and 3D models, can be easily and quickly output as XML or CSV files to almost any tool management system. “Automation is the future of tool preparation” says Alexander Zoller, at the EMO 2017. Ideal for tool manufacturers and grinders with very high tool throughput and a claim to 100% control and logging is the ZOLLER »roboSet 2« automation solution for tool measurement. When networked directly with the ZOLLER universal measuring machine, »roboSet 2« can load tools around the clock, completely autonomously. Thanks to a multi-pallet system and double gripper, it can process and document large numbers of tools fully automatically. Smart storage cabinets for efficient storage of complete tools and individual components

Smooth Data Transfer to the Grinding Machine ZOLLER offers numerous interfaces to make the transmission path of the measured actual data from the machine tool measuring machine to the grinding machine as efficient as possible. They form the basis for smooth processes and open up major potential savings. With the grinding program, the data set for the measuring device is generated at the same time and the fully automatic measuring sequence is generated from it. Depending on the type of interface, the measured data is transferred back to the programming system or the grinding machine and the grinding program is temporarily corrected for this tool. This reduces programming effort and machine downtimes to a minimum. Users save time and money - and also avoid errors during data entry and the creation of a new grinding program.



TECH TRENDS

Teamwork between humans and robots in the electronics industry SCHUNK Electronic Solutions is showing how depanelling machines can be made collaborative for the electronics industry

A

t SCHUNK, everything is moving at such a rapid pace when it comes to collaboration. Following an initial pilot application in its own gripper assembly, the innovative family-owned company is now showcasing on a demo system from its subsidiary SCHUNK Electronic Solutions, how depanelling machines can be made collaborative for the electronics industry and the benefits resulting from this. Depanelling machine with robot arm The automated system consists of the SAR 1700 depanelling machine and a UR5 six-axis robot arm from Universal Robots equipped with a SCHUNK Co-act EGP-C gripper. While employees used to have to manually load stand-alone machines such as the SAR 1700 with electrical assemblies, now they only have to manually refill the panel storage rack for the robot. The machine takes care of everything else. The robot reaches into the storage rack, takes a panel, places it in the machine, closes the door, and presses the start button.

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Once the depanelling machine has cut the circuit boards, the robot arm places the parts on a conveyor belt and the process starts over again. The storage rack can fit up to 32 panels. If necessary, the employees can take over and load the machine manually at any time. “By applying the collaborative concept, efficiency in electronics production can be significantly increased,” explains Henrik A. Schunk. “Instead of just one or two machines, operators can now operate up to five depanelling machines simultaneously for example. That means that the solution pays for itself within a very short period of time.” Since the SAR 1700 is specially designed for smaller companies and represents a comparatively low investment, electronics production can be expanded gradually with additional machines. Each has the option of being equipped either manually or automatically based on individual requirements. DGUV-certified gripper fits all cobots The SCHUNK EGP-C Co-act gripper

used in the application is the world’s first inherently safe industrial gripper that has been certified, and approved by the German Social Accident Insurance (DGUV) for collaborative operations. The 2-finger parallel gripper that is controlled via digital I/O, covers a wide range of applications – from small parts assembly in the electronics and consumer goods industry to assembly applications in the automotive sector. It satisfies the requirements of ISO/ TS 15066 and is designed in a way that humans cannot be injured. It includes a protective cover as well as safe current limiting. In order to make the collaboration with the operator as smooth and as intuitive as possible, the 24 V gripper is fitted with LED lighting in traffic light colors. The user can use this to signal the status for each module. It is delivered as a completely pre-assembled unit that includes the right interface for the cobots from KUKA, FANUC or Universal Robots. Moreover, interfaces for other robot manufacturers are available upon request. The entire regulation and power electronics are fitted in the interior of the gripper, meaning they do not take up any space in the control cabinet. In order to further minimize commissioning efforts, SCHUNK is planning programming modules for all conventional cobots.



TECH TRENDS

HAAS is unstoppable on the Indian shop floor Phillips brings cuttingedge HAAS machine tool technology to India helping transform Indian manufacturing with worldclass products, proven solutions and a warranty scheme like no other. Terrence Miranda, Managing Director, Phillips Machine Tools India and Rupesh Ranjan, Sales Director, Phillips Machine Tools India, tell us what has made the company accelerate in a highly competitive market Q. HAAS made history with record sales during 2017. Can you please tell us about this magical achievement? TERRENCE: 2017 was phenomenal. We received orders for more than 1,150 HAAS machines surpassing our earlier projections. There are several reasons for this but if I was to pick one it would have to be the special India Value Package that HAAS introduced on the popular VF-2 and VF-4 machines packed with options that enhance productivity at an incredible 43% discount. The Indian industry has prospered in the last couple of years. The introduction of GST and other policies has driven Indian manufacturers to invest in the future. RUPESH: Indian SMEs have always dreamt of owning a HAAS machine, a global machine builder that in the previous 30 years has sold more than 225,000 machines worldwide. Price was a hurdle in the fulfilment of this dream.

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Terrence Miranda, Managing Director, Phillips Machine Tools India

Rupesh Ranjan, Sales Director, Phillips Machine Tools India

HAAS made these dreams come true in April 2017 with the India Value Package on its popular VF-2. This move was astounding with bookings of 114 machines in April 2017 alone! Sensing the customer response, HAAS extended this offer month-wise till June 2017. In July 2017, HAAS offered an India Value Package offer for the larger VF-4 as well. VF- 4 is one of the top-selling models across the world for HAAS. The HFO PHILLIPS team: sales, service and back office put in an outstanding effort. The team that booked 300 machines in 2016, booked 1,150 machines in 2017. Presales, After-Sales and the Office Support worked in unison and left no stone unturned to fulfil our promise to our customers: QUALITY and LEGENDARY SERVICE above all else. The same year saw the PHILLIPS EPD Engineered Products Division also record 450 other CNC product sales, which took PHILLIPS total CNC orders in 2017 to over 1,600 machines.

Q. Is the India Value Price still applicable for both the VF models of HAAS? RUPESH: In the past 30 years, HAAS has not increased the prices of its models in the US. Features and unique innovations in CNC technology have become the hallmark of the HAAS VF series. This value-based pricing strategy for its high-tech, high-accuracy products has made all the difference. In India, from 2012 onwards, price to the end user increased on account of the INRUSD exchange rate. HAAS presented the India Value Package for our popular VF-2 for April 2017 only. Indian manufacturers grabbed this opportunity, and new customers approached us immediately. The stupendous response led HAAS to renew this month-by-month and to also include the VF-4 in this offer, which is valid till 30 July 2018. HAAS USA will then decide whether to extend it further.



TECH TRENDS Q. What are your sales objectives for this year, and what plans have you made to achieve them? TERRENCE: Our objective is simple: We will introduce HAAS and our INDIA VALUE PACKAGE to every CNC machine shop in India through an expanded sales, service and marketing presence. We will revolutionize Indian manufacturing particularly SMEs by delivering world-class products and services that will enable our customers Make in India and compete on the world stage. RUPESH: We will focus on 2 initiatives: 1. An exclusive, comprehensive 1+3 years warranty for each HAAS machine. No machine tools manufacturer has offered such a scheme in Indian Manufacturing history. Our confidence in this scheme stems from our assurance about HAAS machines, parts and processes.

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2. A 2-year deferred payment plan offered exclusively by PHILLIPS at industry leading rates. We believe that finance must not be an impediment in making world-class technology available to an Indian manufacturer. Q. How is HAAS catering to the growing demand of a 5-axis model machine? RUPESH: HAAS machines have a unique plug-n-play feature and transforming from 3-axes to a 4- or 5-axes machine is seamless. A VF-2 or VF-4 machine can be upgraded to a 5-axes configuration by adding a trunnion 2-axes HAAS CNC rotary. A HAAS machines owner can upgrade at any time and do not need to purchase an expensive stand-alone 5-axis machining center. Another example of HAAS SIMPLICITY and VALUE.

Q. What value does HAAS add to the customers and how is Phillips extending those values in the market? RUPESH: HAAS is differentiated by our legendary HAAS CONTROL and IN-HOUSE manufacturing of all critical assemblies, which ensures optimal synchronization and compatibility. HaasCNC.com and AtYourService.com provide manuals, FAQs and much more to HAAS machine owners. In India, our unique HFO advantage ensures that parts and service are available in every major industrial area within 24 hours. TERRENCE: HFO Phillips proudly represents HAAS and offers a variety of solutions in tune with HAAS objectives. The trust that our Indian customers shower on HAAS and Phillips invigorates us as we play our role in transforming India into a manufacturing powerhouse.



TECH TRENDS

TBD HS: Programmable System for noncontact high speed tool breakage detection

I

ndustrial realities, where productivity represents the priority to achieve, aim to implement tool measurement solutions, which prove to be quick, accurate and reliable. Aware of such need and willing to develop an application that could avoid affecting production efficiency, Marposs presented TBD, the Tool Breakage Detector, a time-saving laser-based solution for broken tool detection on machine. TBD on milling machines and machining centres permits to keep under control the process, thanks to a very short tool checking cycle. Fast and reliable detection achievable by the TBD allows to reduce production time and to avoid expensive work-pieces scrap due to wrong cutting process by damaged or broken tools. All functionality is contained within the TBD unit compact housing, which can be mounted outside the machine area, saving space on the table. It is possible to choose among different working modes, which endow TBD with a great flexibility. Switching the power to the maximum gives TBD the chance to recognize a tool placed at a longer distance (up to 2 meters), with a standard capability to check the breakage. If a smaller tolerance is required, the reduced power can be set obtaining a smaller beam. Furthermore, an user can choose the filtering level of the signal. In fact, during the checking cycle, some coolant drops could interrupt the beam or coolant stuck on the tool could create variation in the signal received. Setting “Hi Filter” makes the software of the TBD more restrictive in order to give the more reliable response. On the other hand, choosing “Low Filter” TBD responds in a faster way, as the filter is less severe. Lastly, it is possible to choose the appropriate range of spindle speed, up to 5000 rpm.

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The new TBD HS Marposs S.p.A. has recently introduced the new TBD HS, High Speed, on its wide range of products for tool checking on milling machines and machining centers. The new TBD HS is a programmable system for non-contact checking hi-speed tools, particularly committed to those applications where there is the need for hi-speed spindles, up to 80.000 rpm. Thanks to its rotary switch selector, the TBD HS is able to recognize the tool in two different ways, depending on the actual rotational speed, thus minimizing cycle times, generally crucial in this kind of process. Selecting “Quick Recognition”, the tool checking is performed for 10.000 rpm spindle speed and its multiples; on the other hand, it is possible to choose “Hybrid Recognition” if the speed is 1.000 rpm and its multiples or 10.000 rpm and its multiples. With a reflective, clean tool an impressive 150 msec checking time is achieved, approximately half the time compared to the standard TBD. High spindle speeds and small tool dimensions lead to the need for a fine adjustment for positioning the TBD HS in a very precise way: that is the

reason why an effective system has been designed to make accurate and easy the searching procedure of the tool verification position. Once TBD installed and tool approximately pointed, now is even more quick and simple to optimize the laser beam and to find the checking position. The tool breakage detection performed by the TBD HS is improved by the presence (upon request) of a blower for cleaning the receiver glass: taking advantage of the usual standard inlet, both in terms of air flow and pressure, it has been developed a solution able to protect the glass from swarf and scraps without increasing the air consumption. Moreover, when the conditions are particularly harsh because of the aggressive presence of shavings, there is the chance to substitute the standard protection glass with one in sapphire crystal: being 9 out of 10 its hardness degree on the Mohs scale, this kind of protection lets the receiver performance always at its maximum, no more damaged by the extreme machine conditions. For more information: Website: www.marposs.com


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TECH TRENDS

The benefits of the New Renishaw Equator 500

This has an intelligent process control for larger parts with all the benefits of the proven Equator 300 gauging system

E

quator gauging systems have helped to improve yield and increase process capabilities of production lines around the world, by providing high accuracy dimensional inspection data next to turning and machining centres, at the point of manufacture. The new larger Equator 500 system now enables the gauging of larger parts, with a working volume of 500 mm in diameter and up to 400 mm in height. Both Equator 300 and 500 systems are accurate between 5 ยบC and 50 ยบC at any rate of temperature change, and are capable of scanning speeds in excess of 200 mm/s. Every system is compatible with simple-to-use Organiser operator software, EZ-IO software for automation, and IPC (intelligent process control) software for updating tool offsets on CNC machine tools.

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Larger measuring volume The Equator 500 has a gauging volume of 500 mm diameter in the X/Y plane and 250 mm in Z when used with the SM25-2 scanning module. This can be expanded to 400 mm in Z with the SM253 scanning module, which allows styli up to 200 mm in length to reach many more features. The base of Equator 500 supports workpiece and fixturing with a total weight limit of 100 kg. The ratio of gauging volume to footprint means that the machine is extremely space efficient, with a footprint of just 920 mm by 924 mm. This allows manufacturers of larger parts to easily fit Equator 500 onto the shop floor alongside their production machines. Typical applications include the manufacture of car and truck transmission and engine casings, drive-train parts

like conrods and differential housings, suspension castings, pressed parts, valves and pumps. High speed gauging of size, position or geometry Most users of Equator systems need short cycle times to maximise throughput from their manufacturing processes. Both Equator 300 and 500 systems, while maintaining high levels of repeatability, are capable of rapid scans and high speed touch points on a wide variety of features. Years of customer experience with Equator systems have proven the capability to gauge size, position and geometry on a single device. This can eliminate the need to stabilise parts to the temperature of the quality room prior to measuring geometry and form of critical features.


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.

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TECH TRENDS Accuracy with rapid temperature changes Climatic conditions can result in variable daily and seasonal temperature cycles. For example, early in the morning a cold machine shop can increase in temperature due to both external conditions and machinery heating up. The system has been proven to cope with this by remastering, meaning that accurate gauging can start as soon as the first part has been produced and continue regardless of how conditions change. Automatic update of tool offsets directly from Equator 300 and 500 systems The Equator range is compatible with new IPC software which allows constant monitoring and automatic adjustment of a machining operation, keeping part dimensions close to nominal and well within process control limits. This correction of process drift improves part quality and manufacturing capability, and reduces scrap. The proximity of the Equator gauge to the CNC process allows adjustment at the point of manufacture, avoiding time delays or reliance on finished part (tailgate) inspection. An Equator gauging system can be connected

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to one or multiple CNC machine tool controllers. Process control configured to specific manufacturing operations IPC software can average results from several parts to determine the true process mean for adjustment of critical cutting tools. For process control purposes, often only one machined feature per cutting tool will require gauging, in contrast with the many features inspected for typical Quality Assurance (QA) applications. The frequency and magnitude of offset updates can be configured on a featureby-feature basis depending on design tolerances, process variation and tool wear rates. IPC is an integral function of Equator Process Monitor software, using recent historical gauging data to determine process corrections. Connection to a compatible machine tool can be as simple as connecting an Ethernet cable from the Equator controller to a CNC machine. Reduce dependence on skilled operators The ability to correct a process automatically with IPC software

eliminates the potential for manual data entry errors, and removes the requirement for an expert to decipher traditional measurement reports into a process correction value at the CNC machine. Available with new automatic part loading system The new EQ-ATS Equator Automatic Transfer Systems, for Equator 300 and Equator 500, allow parts to be loaded on to a fixture plate in front of the gauge, and transferred in and out of the measuring volume under automatic program control. They can be used for either manual loading by operators, cranes or fork-lifts, or robot loading in an automated cell, protecting the Equator gauge from accidental damage. EQ-ATS is easily integrated, bolting directly on to the base of the Equator gauge. The versatile gauge The Equator gauging system is unique in its design and method of operation. The speed and temperature range benefits of the Equator 300 system are now available for larger parts with the Equator 500, further expanding the capability of Renishaw’s flexible gauging range.



International Machine Tools & Industrial Trade Fair

INTEC 2019

th

18 Edition

(An Event of CODISSIA Intec Technology Centre)

2019

2019

INDUSTRIAL

EXPO 2019

th

AUTOMATION INSTRUMENTATION IT SYSTEMS

th

6 to 10 JUNE 2019

CODISSIA Trade Fair Complex Coimbatore, INDIA

Exhibitors Profile Industrial Electrical & Electronics General Engineering Machinery for Process Industry Metallurgical Plant & Equipments Textile Machinery & Equipments Fabrication Machinery & Equipments IT Consulting & Service Providers Machine Tools & Accessories Hydraulics & Pneumatics Material Handling Equipments & Machinery Foundry Equipments Pumps & Fittings Precision Tools, Cutting Tools, Dies & Moulds Instrumentations Automation

Factory Cleaning & Pollution Control Equipments Industrial Consumables

Platinum Supporter

Diamond Supporter

Silver Supporter

Conference Partner

E-magazine Partner

STALL BOOKINGS OPEN

Mobile : 99655 15182 / 75025 22000 / 75029 22000 / 85080 22000 E-mail : intec@codissia.com Web : www.intec.codissia.com



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 and one head for flame cutting of sheet metal with a dual side longitudinal drive with AC motors. The standard equipment comes with a basic machine package with CNC controller, one torch, central gas diffusion with manometers and a remote flame ignition.

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

The CNC Controller – Phantom: The Phantom brings you the performance of a

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

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MACHINE TOOLS WORLD JULY 2018

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


PRODUCTS SHOWCASE www.mtwmag.com

MVX DRILL - New Chipbreakers and Grade for Hardened Steels and Aluminium Smart thinking has led to simple solutions for some old problems associated with indexable insert drilling. Difficulties such as chip clogging on deep holes, dissimilar rates of wear on inner and outer inserts due to differing peripheral speeds, plus flexing and wear of the drill body itself have all been resolved with a new and innovative design.

New UH breaker for hardened steels and UN breaker for aluminium

New UN breaker for aluminium

The existing range of inserts for steels, stainless and cast iron has been complemented with 2 new chip breakers and a new insert grade. The latest PVD coating technology has been applied to the new DP8020 grade to supplement its durable carbide substrate. This makes it the ideal grade to combine with the new UH chip breaker. The strengthened edge of this chip breaker provides the properties for reliable drilling of harder New UH breaker for materials up to 45HRC. hardened steel For aluminium machining, the uncoated TF15 grade now comes equipped with the new UN chipbreaker. With a sharp ground edge, it provides outstanding chip disposal and helps to prevent chip welding for increased reliability.

Different grades for inner and outer inserts The outer insert in this type of drill naturally runs at a higher speed than the inner, thereby leading to higher levels of wear. Consequently the inner insert needs to have a higher level of stability and resistance to fracturing at lower speeds. This anomaly has been negated by using a CVD coated outer insert that has higher abrasion resistance, in tandem with a PVD coated inner insert that can cope better with fracturing forces and resistance to welding. This combination means improved reliability and fewer changes of insert for increased levels of productivity.

Interchangeable inserts with 4 cutting edges The SOMX type inserts are interchangeable from inner to outer position, have 4 cutting edges and a unique wavy chip breaker design for improved chip control. The peripheral edge also has a wiper type geometry for excellent hole wall accuracy and surface finishes. The inserts are also positioned in such a way that when cutting, they are both equally in contact with the workpiece, thereby reducing drill body flex to provide a more consistent performance.

Tool body For Product Enquiry Contact MMC Hardmetal India Pvt. Ltd. R.O.: 4th Floor, Nirmal Plaza, Survey No. 148, Hissa No. 4A/4B, Paud Road, Kothrud, Pune - 411 038, Maharashtra, India. Tel : +91 20 6520 8430, 2539 6824, Cell : +91 9890595858 E-mail: mayur.kulkarni@mmci.co.in Web: www.mitsubishicarbide.com

The tool body is designed with through coolant holes and an optimum sweep of the flutes that provides extra metal thickness behind the direction of the principal cutting force. This controls tool body deflection and helps to achieve reliable deep hole drilling up to 6 x D. Additionally the body surface is heat treated to prevent wear from chip evacuation. The sizes available are Ø17mm-Ø43mm in L/D=2, 3, 4, 5 and 6. And Ø17mm-Ø63mm in L/D=2, 3, 4 and 5.

JULY 2018

Up to 6 x D

MACHINE TOOLS WORLD

111


PRODUCTS SHOWCASE

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

Designed to performs

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

“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.

New transmission elements

For Product Enquiry Contact Elesa and Ganter India Pvt. Ltd. A-54, Sector - 83, Noida 201 305 (U.P.) INDIA Tel. +91 120 472 6666, Fax +91 120 472 6600 info@elesaganter-india.com www.elesa-ganter.in

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MACHINE TOOLS WORLD JULY 2018

The brand-new transmission elements are now online included in the wide group of machine elements. Glass-fibre reinforced polyamide-based technopolymer and grey colour. Transmission elements count two families: cylindrical spur gears (pressure angle 20°) with straight teeth (ZCL) and racks (pressure angle 20°) with straight teeth (ZCR). Spur gears modules are from 0.5 to 3.0 and racks from 0.5 to 4.0. Racks are available in square section, with or without metal core, with mounting bracket or “T” shaped. Main function of transmission elements is the transfer of a speed and torque in a mechanical system. Over the last few decades, the evolution in engineering plastics and technopolymers has led to the availability of spur gears in plastic material featuring high mechanical strengths in addition to providing all the advantages of plastics: • corrosion and chemical agents resistance • high resistance to torsion and tensile strength; • noise reduction; • low friction coefficient, which allows the use of gears even in sectors where lubrication is not recommended or even prohibited. A further advantage of these elements, but no less important, is the low specific weight, offering a saving over metal gears, making them ideal where a general weight reduction is required. Elesa+Ganter transmission elements can be coupled to both technopolymer and metal gears. This is an excellent solution for all those applications where it is necessary to obtain a faster dissipation of the heat accumulated during the operation.


PRODUCTS SHOWCASE www.mtwmag.com

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

Following are some of its unique features:

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

• • • • • • •

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

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

Nexgen Refrigerated Air Dryers

For Product Enquiry Contact GEM Equipments (P) Ltd. SF No.103, Avinashi Road, Arasur, Coimbatore 641 407 Phone: 0422-2363800 / Email: sales@gemindia.com

The Nexgen Refrigerated Air Dryers from Gem Equipment are known for engineering excellence, innovation and reliability.The heat exchangers are designed to provide worry-free, highly efficient heat transfer whether you are processing simple fluids, viscous solu8tions, or particulates. They feature honey comb construction of aluminium fins, true cross-flow for greater effective temperature differences, non-clogging larger cross-sectional area for air flow, integral air-air and air-refrigerant exchanges, with stainless steel demister moisture separator, robust non-corrosive grade aluminium, and larger heat transfer area for higher efficiency. The rugged electronic panels display both inlet and dew point temperatures. They incorporate a Tripper module with alarm for compressed high discharge pressure, compressed low suction pressure, expansion valve malfunction, auto drain valve function and fan motor cycling. Introduction of speed control is one of the major developments towards the optimization of refrigeration systems based on average load. For periods of high cooling demand, the compressor speed can be increased which results in a higher refrigerant flow and thus higher cooling capacity and vice versa during periods of low cooling demand. Compressed air purification equipment must deliver uncompromising performance and reliability while providing the right balance of air quality with the lowest cost of operation. As a quality-centric group, Gem ensures that its dryers are test at each stage of assembly as per ISO 7183 or relevant standards. It maintains stringent engineering practices throughout the production process to achieve higher reliability. Gem’s state-of-theart ISO 9001-23008 certified facility is equipped with dedicated men and machines to chisel out products of impeccable quality and reliability.

JULY 2018

MACHINE TOOLS WORLD

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PRODUCTS SHOWCASE

FLIR C3 - Powerful, Compact Thermal Imaging System The FLIR C3 is a full-featured, pocket-sized thermal camera designed to be your go-to tool for electrical / mechanical and building applications. Keep it on you so you’re ready anytime to find hidden hotspots, structural defects, plumbing issues, and more. The C3’s must-have features include MSX® real time image enhancement, area maximum or minimum temperature measurement, and Wi-Fi connectivity – so you can quickly get to the job of finding hidden problems, sharing images, and documenting repairs.

For Product Enquiry Contact FLIR Systems India Pvt. Ltd 1111, D Mall, Netaji Subhash Place, Pitampura, New Delhi – 110034, INDIA Tel: +91-11-4560 3555 | Fax: +91-11-4721 2006 Email: flirindia@flir.com.hk Webiste: www.flir.in

• Light, slim profile fits comfortably in any work pocket • Brilliant 3” intuitive touch screen with auto orientation for easy viewing • Radiometric image stores 4800 pixels capable of capturing thermal measurements from -10°C to 150°C • Accuracy ±2°C • Focus Free • Thermal sensitivity < 0.10°C • 2-10 years warranty.

Ground Ballscrews with Rotary Nut- FSWT Series Features • Our high slenderness ratio ballscrew can be used at high feed speed without causing inertia. • In the past with long ballscrew assemblies, the nuts couldn’t react immediately. A rotary nut can have a high feed speed with high lead and still achieve accuracy. • The design of the screw shaft journal can be simpli¬ed because it does not need support bearings.

Structure

For Product Enquiry Contact Precision Motion Industries, INC. (PMI) No.71, PRECISION Ln. 20, Dafu MOTION Rd., Shengang INDUSTRIES, Dist., INC. Taichung City 42946, Taiwan TEL: +886-4-25282984, FAX: +886-4-25120834 Email: sales@pmi-amt.com.tw / sales@superslides.in Websit: www.pmi-amt.com

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MACHINE TOOLS WORLD JULY 2018

• Roller thrust bearings must be installed on rotary nuts because the support bearing is larger than the regular bearing, therefore the rigidity in the shaft direction has been increased. • It is possible to lubricate the ballscrew and the bearing installed on rotary nuts at the same time. • Lubrication for rotary nuts is complicated since rotating unions are necessary to feed lubricant directly into the nut, and centrifugal forces push all lubricant away from the balls and groove. • The design of the nuts end face can be directly secured by the use of the timing pulley.

Application • Gantry Type Machining Center/ Bridge Type Machining Center/ Double Column Surface Grinder.


PRODUCT INDEX A

Drive Systems

AC / DC Geared Motor

101

AC Linear Servo Motor

101

61

O Oil/ Coolant Mist Cleaner

E

101

Oxy-Fuel CNC Cutting Machines

93

Actuator

85

End Mills

Actuator Line

65

Endmills

49

After Coolers

69

Energy Absorption & Vibration Isolation

95

Planetary Gear Boxes

Agro Files

89

Engineering Files

89

Plasma CNC Cutting Machines

93

Air Compressors

25

Plunge Shaving Machine

33

Air Tank

69

Allied Equipments

59

Filters

69

Position Displays

55

Alloy Wheel Machining Solutions

45

Flex Clamps

81

Aluminium Profiles

101

Angle Encoders

55

Angle Rolls

19

Auto Cables

FRONT GATEFOLD

F

Flexible Couplings

101

G

103

Gas Flow Products

95

69

Gas Management

95

Automation Products

93

Gear Boxes

87

Gears, Racks & Pinions

101

Ground Resistance Testers

Ball Transfer Units

81

101

Ballscrews

85

Bending Rolls

19

Bevel Gear Boxes

76, 77

Power Analyzers

Harmonic Filters

105

High Pressure Filtration

95

87

Hydraulic Press

79

Burnishing Tools

99

Hydrogen analyzers

59

Hypid Gear Boxes

105

Power Press

107

76, 77

C

101

Press Brake

107

Pressure Control Solutions

95

Project Engineering Solutions

93

Pump Solutions

31

I

Real Time Power Factor System

55

S Saw Files

89

Screwiacks

101

Shearing Machines

107

Sheet Straightener

107 101

37 67

Inserts

Casting

71

Instrumentation Fittings & Valves

95

Slewing Ring

Circuit Identifiers

81

IOT

43

Spectrometers

Clamp Meters

81

FRONT GATEFOLD

59

SPMs L

59, 75

Stabilizers

105

CNC Control System

21

Laser Sensors

57

Static Elimination Solutions

CNC Grinding Machines

51

Lathe Machines

17

Stepper & BLDC Motor

CNC Horizontal Boring Machine

45

Length Gauges

55

Surface Cleaning

CNC Lathe

45

Light Energy Management Systems

105

7, 75, BACK PAGE

Linear Actuators

101

CNC Smart Mills

45

Linear Encoders

55

CNC Solutions

11

Linear Guideway

85

CNC Turning Center

41

Linear Line

65

CNC Vertical Machining Center

41, 45

Coatings

91

Consumables

93

Linear Motion Guides Lubricants

101 23

M

81

Contouring Controls

55

Machining Centers

CRMs

59

Mass Flow Controllers

95

Current Testers

81

Megohmmeters

81

101

Cycloidal Gear Boxes

76, 77

D

Metal Working Fluids Milling Cutters

97

9, 29

23 FALSE COVER

Tool Holders

IFC

FRONT GATEFOLD, FALSE COVER

T-Slot Cutters

FALSE COVER

Turning Solutions

IFC

U U-Drills

FALSE COVER

69

53

Motion Toolpaths Motor Rotation Testers

FRONT GATEFOLD, IFC, 73

Thermal Spray Coatings

105

89

Drills

81

Universal Machining Centers

63

45

47

Thermal Imaging Cameras

Ultra Isolation Transformers

Dimond Files

IFC

65

Test & Measurement Tools

81

Dimensional Measurement Systems

Drilling Solutions

FRONT GATEFOLD

Telescopic Line

Moisture Meters Moisture Separator

Drill Tap Center

T Taps

IFC

13

45

95

Milling Solutions Digital Inverter technology

Double Column Machining Centers

95 101

Threading & Grooving Solutions

Continuity Testers

Curvic Coupling

105

Rotary Encoders

Cam Driven Systems

CNC Machines

95

Precision Ball Screws

Calibration Systems

101

81

Power Conditioners

R

H

Brake Motors

Clamps for Linear Guides

76, 77

Precision Air Moving Products

Auto Drain Valves

B

P

Multimeters

IBC 81 81

89

Welding Equipments

81

W

N Needle Files

V Voltage Detector

JULY 2018

93

MACHINE TOOLS WORLD

115


ADVERTISERS INDEX COMPANY NAME

PG. NO.

A ACE MICROMATIC GROUP

BACK PAGE

ADOR WELDING LIMITED

93

ANCA MACHINE TOOLS PRIVATE LTD

7

APEX PRECISION MECHATRONIX PVT. LTD.

101

BETTINELLI AUTOMATION COMPONENTS PVT. LTD.

67

BIRLA PRECISION TECHNOLOGIES LIMITED

89

BRIGHT BURNISHING TOOLS PRIVATE LIMITED

99

C INSIDE BACK COVER

COMPANY NAME

PG. NO.

GLEASON WORKS (INDIA) PRIVATE LIMITED

33

MMC HARDMETAL INDIA PVT. LTD.

INSIDE FRONT COVER

GLOBAL CNC AUTOMATION

75

N

GLOBE-TECH ENGINEERING EXPO - 2018

109

DELTA ELECTRONICS INDIA PVT. LTD.

21

DOWEL ENGINEERING WORKS

79

DUTCH TECH TOOLS PVT. LTD

49

E ELECTROTHERM (INDIA) LTD.

13

ELGI EQUIPMENTS LTD.

25

EPPINGER TOOLING ASIA PVT. LTD.

76-77

F FACCIN S. P. A.

19

FATTY TUNA INDIA PVT. LTD.

45

FLIR SYSTEMS INDIA PVT. LTD.

81

G

NORD DRIVESYSTEMS PVT. LTD.

23

GROB MACHINE TOOLS INDIA PVT. LTD.

53

GRUNDFOS PUMPS INDIA PRIVATE LTD.

31

OERLIKON BALZERS COATING INDIA PVT. LTD.

91

P

H HEIDENHAIN OPTICS & ELECTRONICS INDIA PRAIVATE LIMITED

55

HOSABETTU HEAVY MACHINERY LLP

29

HYUNDAI WIA INDIA PVT. LTD.

9

PARAGON MACHINERY CO. LTD.

51

PRECISION MOTION INDUSTRIES, INC. ( PMI )

85

Q

IMTEX - 2019

83

IMTOS - 2019

27

INTEC - 2019

108

J

QVI INDIA PVT. LTD.

63

R RAJKOT MACHINE TOOLS SHOW - 2018

15

RENISHAW PLC

37

ROLLON INDIA PVT. LTD. - INDIA

65

RR KABEL LIMITED

103

JAY-SHREE MACHINES PVT. LTD.

107

S

JYOTI CNC AUTOMATION LTD.

41

SECO TOOLS INDIA (P) LTD.

73

SHAVO TECHNOLOGIES PVT. LTD.

95

97

M MAC MACHINE TOOLS AND AUTOMATION

43

MARPOSS INDIA PVT. LTD.

47

SPRAYMET SURFACE TECHNOLOGIES PVT. LTD.

MEERA CASTING

71

T

METAL POWER ANALYTICAL (INDIA) PVT. LTD.

59

TRUCUT PRECISION TOOLS PVT. LTD.

MGM-VARVEL POWER TRANSMISSION PVT LTD

87 57 11

GEDEE WEILER PRIVATE LIMITED

17

GEM EQUIPMENTS (P) LTD.

69

MITSUBISHI ELECTRIC INDIA PVT. LTD.

FALSE COVER

U UNITY CONTROLS PVT. LTD.

MICRO-EPSILON INDIA PRIVATE LIMITED

MACHINE TOOLS WORLD JULY 2018

61

O

I

D

116

PG. NO.

GP PETROLEUMS LTD.

B

CNC SOFTWARE, INC.

COMPANY NAME

105

Y YG-1 INDUSTRIES INDIA PVT. LTD.

FRONT GATEFOLD


WE’RE SHAPING THE FUTURE OF MANUFACTURING®

Toolpath strategies for the biggest innovation in turning…since turning.

2X

Double the speed and feed

Longer lasting inserts

>50% Productivity increase

Stay tuned! This June, for an interesting contest in India

Or see PrimeTurning in action at: www.sandvik.coromant.com/primeturning To learn more, visit: www.mastercam.com/primeturning

Contact Us On : +91 7378 55 2000

Technical Support : +919325628101 Contest Support : +918007979966


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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