Volume 05 No. 06 | November 2019 | ` 150
Pages 138 | RNI No. MAHENG/2015/64267
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DUSTRY 4.0
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Website: www.iscar.in
Whatever industry sector you’re in? Aerospace, Automotive, Electronics, Medical or woodworking
ANCA Machine Tools Private Ltd 8/1 , Dr. M H Marigowda Road, Arekempanahalli , (Wilson Garden ), Bangalore - 560027, Karnataka, India T: +91 (80) 6759 2100, M: +91 96637 6991 E: indiainfo@anca.com
anca.com
linkedin.com/company/anca
CEO CORNER
Publisher & Printer Shirish Dongre
CEO Shekhar D.
Editor
The growing trends of machine tools industry
Shilpa Dongre
Assistant Editor Shweta Nanda
Process automation, additive manufacturing and the rise of electric vehicles are the three core trends that are changing the dimensions of the machine tool industry , Automation and smart will be the buzzwords going forward and the trend will move towards machines being interfaced with automation systems and smart controls.
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MACHINE TOOLS WORLD
Stating that the industry is growing at an exponential rate and is presently estimated at around Rs 6,000 crore, he said the manufacturers will need to develop capabilities to cater to the demand and investments in this area could yield long-term benefits. industry has advanced significantly in hardware and software applications. The future includes automation of processes into manufacturing and engineering sectors. Reduced manual intervention in process control using machine tool control system and smart tooling would be the key to optimise cost, reduce scrap and improved machine utilisation. Even if there are many positives, the machine tools industry must continually innovate to improve quality, enhance productivity by maximum machine utilisation and improved costs savings by better part control utilising automation and other smart techniques.
Rajkot (Saurashtra) Swapnil Bhatia: 09227909005
6
Reduced manual intervention in process control using the machine tool control system and smart tooling will be the key to optimising costs, scrap reduction and improved machine utilisation. Globally, many advanced manufacturing markets have adopted these technologies and the trend is set for the Indian machine tool industry to address the technology-gap and drive innovation in this direction. In addition to this, the improved quality, capabilities for machining high precision components, and improved productivity will be the key factors to stay ahead of competing markets like China.
NOVEMBER 2019
With the interest rates forecasted to be tending lower in the medium term, increasing domestic consumption, and the government capital spending expected to increase, the machine tool market should grow at about 13% to 15% CAGR going forward for the next few years. One should be looking at a total machine tool market size of about $3 billion by the year 2020.
CEO
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Automation for a Changing World
Smarter Solution, Better Tomorrow Delta Industrial Automation offers comprehensive green manufacturing solutions for smart machines, production lines and factories to meet the rapid market changes and ensure our customers an outstanding future together. Find out more at ENGIMACH 2019 and get an overview of Delta India Industrial Automation business in specific and discuss in detail about its CNC, AC Drives, Servo Motors & Drives, PLC, HMI, SMPS, Power Quality, Smart Sensors, Temperature Controllers, Energy Management and Robotics Solution offerings complimenting the machine tool applications.
Meet us at ENGIMACH 2019 Venue: The Exhibition Centre, Gandhinagar, Gujarat Hall no. 12, Stall No. 40 Date: 4th to 8th Dec 2019
www.deltaelectronicsindia.com automation@deltaww.com
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Contents
NOVEMBER 2019
COVER STORY
GEDEE WEILER: Coherent INNOVATION with CUSTOMER centric approach
44
Mr. K. Ganapathi Subramanian Vice President Gedee Weiler Private Limited
BUSINESS NEWS
COMPANY PROFILE
18 LMW to make latest VMC for Japan’s
Surya Manufacturing Company: Commited to ‘Lighting’ Excellence
machine tool major DMG Mori
22 Elgi Equipments launches Oil Free Piston Compressors at the 13th IREE
50
24 Nicolás Correa presents its new machine
CASE STUDY
line at EMO
30 Schmersal Group establishes subsidiary in Thailand New branch opened in Bangkok
34 Concord make molybdenum wire re-
usable technology CNC wire cut EDM machines
36 Oerlikon Balzers celebrates 25-year
anniversary, inaugurates forming tools facility
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MACHINE TOOLS WORLD
NOVEMBER 2019
56 Renishaw Equator™ gauge enables production growth at major aerospace manufacturer
AMT SECTION
59 www.mtwmag.com
Ultra-compact: the versatile AX8000 multi-axis servo system. Safe: 17 drive-integrated TwinSAFE functions
Highly flexible: ■ Free combination of modules as required: ■ Power supply module, 20 A, 40 A ■ 1-channel axis module, 1 x 8 A, 1 x 18 A ■ 2-channel axis module, 2x6A
High performance: Current controller response time of 1 µs ■ Current controller cycle time of 62.5 µs (down to 16 µs) ■ Position controller cycle time of 62.5 µs ■ EtherCAT cycle time of 62.5 µs ■
Simple installation: Fast, fail-safe and tool-free assembly
Highly scalable: AM8000 synchronous servomotors with One Cable Technology
www.beckhoff.co.in/AX8000 The modular AX8000 system complements the highly scalable Beckhoff Drive Technology portfolio: In addition to the TwinCAT software motion control solutions and scalable motor series, a wide range of drive controllers is available, from compact drive technology in I/O terminal format to powerful AX5000 Servo Drives. With freely combinable drive modules, the AX8000 multi-axis servo system can be scaled to demand. It delivers high-performance drive technology and enables optimised space utilisation in any control cabinet.
Beckhoff Automation Pvt. Ltd. Pune – 411 001, India Phone: +91 (20) 6706 4800 info@beckhoff.co.in
Contents
NOVEMBER 2019
TECH TRENDS
70 FACCIN, making Remote Service Management Less Remote
74
76
82
‘How lubricants can help in improving Machine Shop’s performance’
New concepts in graphite milling: SEAGULL® tools have impressively high life cycles
80
88 86
90
Integrated drive technology reduces machine footprint and control cabinet space requirements
PRODUCTS SHOWCASE
131
Electronic position indicators: new wireless system
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132
Marvel : Criss Cross Gloves
NOVEMBER 2019
133
Effortless cleaning of oily machinery, factory floors and plastic bins by the use of O-CLEAN3
134
FLIR TG297
www.mtwmag.com
Editorial Board
Editorial Index A
M
ADOR Welding
124, 133
ANCA
42
B 86
AMT- The Association For Manufacturing Technology
Walchandnagar Industries Ltd
Nicolรกs Correa
Birla Precision
74
O Oerlikon Balzers
Concord
34
D 90
Renishaw Metrology Systems Ltd.
Mr. Rupesh Paparaju Director, Bettinelli Automation Components Pvt. Ltd.
Rocklin Manufacturing 68
Elesa and Ganter
131
Elgi Equipments
22
S Schmersal
30, 32, 114
SolutionBuggy
F
Spraymet Surface
FACCIN S.p.A.
70
Technologies
FIBRO
88
Steel Plant
134
Specialities
FLIR Systems India
24 130 133
Superslides & 44
Ballscrews
92
Surya Manufacturing 134
Company
50
U
ISCAR
Sanjay Tools & Adhesives
98
ExxonMobil Lubricants 76
I
Association of Ludhiana Machine Tool Industries
56
Rollon India
Hoffmann Group
Machine Tools Manufacturers Association - Rajkot
R Renishaw
80
H
Mr. Suhas Belapurkar Director - Sales & Marketing ( Industrial Products)
110
Drake
GEDEE WEILER
Mr. Sushil Kumar General Secretary
36
DP Technology - Esprit 63
G
Mr. Yogin Chhaniara President
24
P PILZ India
DOLD Electric
Ms. Samina Khalid Marketing Manager
Millenia Technologies 52
30
E
Mr. Mukund Pant Director Metal Power Analytical (India) Pvt. Ltd.
67 106
Components C Mr. GK Pillai Managing Director & CEO
Mastercam
N
Bettinelli Automation
Mr. A.P. Jayanthram Ex-Managing Director, Heidenhain India
132
Micro-Epsilon
Beckhoff
Mr. Arun Mahajan General Manager
Marvel Gloves
102
United Grinding
L
W
Lakshmi Electro Controls
Wohlhaupter India
& Automation
Z
96
61
ZECHA Precision
Lakshmi Machine Works
34
18
Tools
82
Contact : For editorial contribution E-mail: shweta@divyamediaonline.com For advertising material E-mail: advt@divyamediaonline.com
Mr. P.K. Balasubbramaniian President VBS Corporate Support
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MACHINE TOOLS WORLD
Mr. B.P. Poddar Vice President - Sales & Marketing FEMCO Fatty Tuna India Pvt. Ltd.
NOVEMBER 2019
Mr. Jayant Vaidyanathan VP - Sales & Application Tsugami Precision Engineering India Pvt. Ltd.
For accounts E-mail: accounts@divyamediaonline.com For online advertising E-mail: ganesh@divyamediaonline.com
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"The most preferred Steel Plant maker up to 1 Million Ton / Annum”
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BUSINESS NEWS
LMW to make latest VMC for Japan’s machine tool major DMG Mori The dominant name in the Indian machine too scene, Lakshmi Machine Works has commenced manufacture of a Vertical Machine Center of special design, CMX 600 Vi for Japan’s machine tool major, DMG Mori. To start with, LMW will produce 10 units a month for DMG Mori for the Indian market. The production volume will increase in stages. Outsourcing to LMW in India would reduce the lead time for delivery as compared to supplies from Japan. “India is a market with great potential for DMG Mori,” Masahiko Mori, President, DMG Mori said. The company has a capacity to produce 12,000 machines a year and it has 14 factories spread across 7 countries. “We want to expand the customer base in India in collaboration with LMW,” he added.
Sanjay Jayavarthanavelu, Chairman & Managing Director, LMW said the entire machine will be assembled here and supplied. While the critical components will be imported from Japan, gradually the import content will be reduced to 80%. LMW would do value addition. The existing facilities have been upgraded in some areas.” “We have the capability to increase the volumes,” he said. The demand came from a product gap which is filled by the competitors. We realized we could fill it together with the product CMX 600 Vi. So we came together to provide the latest technology to the Indian customer,” he elucidated. CMX 600 Vi is a standard vertical milling machine for a broad range of manufacture. High rigidity and largest Y-axis travel in
Dr Masahiko Mori & Mr. Sanjay Jayavarthanavelu shaking hands during the ceremony
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MACHINE TOOLS WORLD
NOVEMBER 2019
Dr. Masahiko Mori, President, DMG Mori and Mr. Sanjay Jayavarthanavelu, Chairman & Managing Director, LMW Machine Works, cutting the ribbon at the launch ceremony of CMX 600 Vi at LMW on 29th Oct. 2019.
its class of 560 mm, and a highly reliable spindle for a variety of machining applications are some of its unique features. The machine is highly versatile and it can handle a wide range of workpieces including round-shaped large workpieces such as gear box housings which are difficult to cut on the machines in the same class. Because of its wide work envelope, interference can be reduced even when workpieces are rotated on the rotary table during manufacturing. CMX 600 Vi is meticulously designed for details with a thorough focus on workability, maintainability and reliability from the operator’s perspective. LMW makes a wide range of CNC turning centres, machining centres and machine subsystems like toolposts and a
variety of spindles for the domestic and export markets. It makes 3,200 machines a year. “The entire machining shop is supported with AHUs with positive pressure system. All castings for building machines come from LMW’s own foundry. We have a wide array of precision production machines which are world’s best brands. We make our own spindles. The assembly cell is fully temperature controlled. And every component going into the machines is tested for process capability,” explains K.S. Murthy, President – Operations, LMW. The Machine Tool Division of LMW was started in 1988. It has a total workforce of 3,250 employees. LMW is exporting its products to 23 countries and has a global presence. - P. K. Balasubbramaniian
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Hard-fine machining centre
ML 235
Higher precision, lower costs • Complete machining with reduced unit costs • Freely configurable work chamber for combined hard-fine or simultaneous machining • Integrated bore hole honing for maximum surface requirements • Optimised accessibility for simple tool changing and easy cleaning
Curious to learn more?
CONTACT US: NEMADE ENGINEERS PVT. LTD. Plot 16, Gat 605/2, Mukaiwadi Road, Pirangut, PUNE - 412115 INDIA Phone: +91-20-679-20500 Email: mail@nemade.in
Hard-fine machining in the BUDERUS combined process
INTERNAL GRINDING
THREAD GRINDING
EXTERNAL GRINDING
SHAFT GRINDING
BORE HONING
HARD TURNING
Combination processing – a key to efficient production
Modular automation cells – compact, productive The loading options of the ML235 are modular, too. Standardised automation cells with rotary magazine, cage stacking magazine or linear automation for manual loading or process supply of up to two production cells with components. Raw parts and machined parts are always completely separated without a risk of mix-up. Traceability through consistent batch management is a matter, of course.
BUDERUS solves complex tasks such as gear wheels from passenger car gearboxes, the functional surfaces of which have to be machined to precise dimensions as quickly as possible, using the modular principle. Thus external and internal grinding can take place simultaneously. The front and rear faces are turned and, if necessary, the bore hole can also be honed in the same clamping.
Configuration examples
Find out more: www.buderus-schleiftechnik.de
BUSINESS NEWS
Elgi Equipments launches Oil Free Piston Compressors at the 13th IREE Elgi Equipments, one of the world’s leading aircompressor manufacturers, exhibited its oil free range of piston compressors for the railway segment at the 13th International Railway Equipment Exhibition (IREE), Asia’s largest rail transportation event. Also on display at the ELGi stall No. 54 in Hall 2, were ELGi’s encapsulated screw air compressor (EN series) and underslung auxiliary compressors. Organised by the Confederation of Indian Industry (CII), in association with the Ministry of Railways, Government of India, the IREE, held from the 22nd to the 24th of October 2019, at Aerocity, New Delhi attracted exhibitors and delegates from across the globe with a focus on continuous modernisation and expansion of the Indian Railways. “The Indian Railways has been ELGi’s important customer for over four decades. Increasing urbanization and rising incomes have contributed to a significant growth in the passenger segment while freight traffic also saw a marked increase due to dedicated freight corridor investments. We’re confident that our oil free air compressors, which are renowned for reliability, performance
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MACHINE TOOLS WORLD
and energy efficiency, will further revolutionize the way compressed air is used in the railway industry’’ said Dr. Jairam Varadaraj, Managing Director, Elgi Equipments. Speaking at IREE 2019, Ramesh Ponnuswami, Executive Director, Elgi Equipments, said “We’re proud to introduce our Oil free air compressors for the Metro/EMU segment. Indigenously developed and bearing a lighter construction tag with noiseless operation at less than 66 dbA, this product is testament to our focus on continuous innovation and delivering sustainable and efficient compressed air solutions for our customers, in line with our brand promise of being Always Better.” ELGi’s Oil free piston series (RR10100 OF/ RR20100 OF) offers railway customers clean, oil free air, enabling ease of operations, reduced maintenance
NOVEMBER 2019
costs of up to 50% and improved maintenance schedules. This will eliminate the need for routine maintenance checks bringing significant savings. As a CLASS ‘0’ certified product, the ELGi oil free compressor also ensures reduced CO2 emissions and a greener environment. ELGi’s oil free piston compressor provides bestin-class output, durable parts and a minimum number of service points, thereby offering a lower life cycle cost to the customer. Also on display, the ELGi EN (Encapsulated) series compressor addresses customer’s varying air flow demands with high energy efficiency. The EN series is a compact, silent and energy efficient screw compressor with an encapsulated air end and air oil separation tank assembly. The EN series models also come equipped with enclosures and smart controllers that monitor,
control and protect the compressor. The ELGi U/S CRC auxiliary compressor provides customers with a convertible solution (on board/underslung) for pantograph lifting applications. This direct drive piston compressor is compact, silent and ensures superior performance on account of the unique integrated motor and top block design. ELGi, is a pioneer in cutting edge compressed air technology, offering a complete range of compressed air solutions from oil-lubricated and oil-free rotary screw compressors, oil-lubricated and oil-free reciprocating compressors and centrifugal compressors to dryers, filters and downstream accessories. With state-ofthe-art manufacturing units and a product portfolio of 400+ compressed air systems, ELGi redefines reliability, efficiency and cost-effectiveness across installations all over the world.
For further information on the organisation and its products, please visit http://www.elgi.com
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BUSINESS NEWS
Nicolás Correa presents its new machine line at EMO At EMO 2019 held in Hannover, Germany, Nicolás Correa presented as a world presentation, its machines of the future with an innovative design. The global launch of the new milling machines line took place on the Nicolás Correa’s stand at the EMO, on the first day of exhibition. The President of the company, Mr. Correa introduced the main features of the new product line to the hundreds of attendees. The new line of milling machines is designed considering future of machining of components and has an innovative design that combines the precision and robustness of the Correa machines with the most advanced technology. At the EMO, the attendees could see two machines of the new line carrying out machining operations; one NORMA MG fixed bed and rotary table milling machine and one FOX bridge-type milling
machine with the UDX mechanical transmission head that allows continuous rotation at 10,000 rpm. As a part of Nicolás Correa’s commitment to innovation and continuous improvement, new materials have been introduced into the structural design for increased thermal stability and damping capacity. Thus, the new “Correa” of the future keeps its mechanical soul and introduces unique mechanical innovations
to the market in the most complex part of the machine; the head. Moreover, temperature measuring and control systems have been introduced on the machine structure of the new Correa milling machines, which provide stable & long-lasting geometrical precision levels. This new structure also provides better ergonomics and improves the maintainability of the machines. The new milling
machines incorporate the latest connected machine advances and the PLC 5.0, which allow more efficient production management by providing data in real-time & monitoring of the most important parameters of the milling machine. Furthermore, the connected machine system allows intelligent maintenance to be carried out by detecting possible problems quickly and reducing machine downtime. The global launch of the new milling machines line has been the most important event of a very positive year 2019 for Nicolás Correa; with a growth of 16% in consolidated turnover in the first six months of the year. For more information www.nicolascorrea.com
SolutionBuggy expands its footprints The innovative, Bangalore based startup SolutionBuggy, recently expanded its footprints in Noida with inauguration of the new office. The online platform was wellrecognized at multiple forums for its uniqueness and support to MSMEs in the manufacturing sector across India. Claiming to be the
24
MACHINE TOOLS WORLD
only platform in India dedicated to MSMEs in the manufacturing sector, the startup is today benefiting 50,000+ MSMEs by connecting them with 5,000+ Subject Matter Experts to find best solutions. As per the founder Director & CEO Mr Arjun N, “The idea behind establishing an office in
NOVEMBER 2019
North India, is to teamup with manufacturing organizations in this region and help them grow and become more efficient. Access to a different set of talent pool is an additional advantage.” “The market size is humongous and we need to be present locally in order to connect to every nook & cranny of India to address
the need of the most inaccessible manufacturing organizations,” said Vikas Manral, Head- Strategy & Marketing functions, SolutionBuggy.
For more information, Website: solutionbuggy.com
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BUSINESS NEWS
Schmersal Group establishes subsidiary in Thailand New branch opened in Bangkok The Schmersal Group, a globally recognized specialist in machine safety, is further expanding its business in Asia and has founded a new subsidiary, the Schmersal Thailand Co. Ltd., based in Bangkok. “For Schmersal, the Thai market and the entire region of Southeast Asia offers great potential,” explains Prasad Kulkarni, Managing Director of Schmersal Thailand Co. Ltd. The countries of the Association of Southeast Asian Nations (ASEAN) are one of the fastest growing economies in the world. The Bangkok office will
The team of Schmersal Thailand Co. Ltd. in Bangkok.
support Schmersal’s sales partners in the ASEAN region and supply the markets in Thailand, Vietnam, Malaysia, Singapore, Indonesia, the Philippines and South Korea with machine safety products and innovative system solutions. In addition, certified
functional safety engineers from tec.nicum are also working on the new site. tec. nicum is a business division of Schmersal, which offers a comprehensive range of safety services. The customers of Schmersal Thailand Co. Ltd. include companies from the food and beverage industry,
pharmacy, personal care industry, robotics and automation technology, steel and automotive industry. “With the new company in Thailand, we will meet even better the strong growth and we are now able to respond even more flexibly to the rapidly developing Southeast Asian markets,” says Prasad Kulkarni. “Our customers benefit from shorter delivery times and better service.”
Website: www.schmersal.com www.tecnicum.com
Bettinelli’s high precison link conveyors: A range in constant evolution Cam Driven Systems (CDS), a division of the Bettinelli S.p.A. group, has come up with the widest range of positioners, rotary tables and cam mechanisms for the automation processes. CDS Precision Link Conveyors TSL, TL and TXL provide the industry’s highest accuracy and repeatability for automated assembly and manufacturing machinery platforms combined with the highest dynamic performance available on the market. The precision link conveyor TL series has been designed to meet the requirements of high productivity and reliability of modern automation, combined
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MACHINE TOOLS WORLD
NOVEMBER 2019
allowing great flexibility and a more accurate choice during the designing phase.
with excellent precision and speed, with a high degree of versatility to offer customers the most suitable solution. They are used on machines that require stability, precision, high speeds and low maintenance. They are different in terms of body width,
The need of the market and customer orientation, added to the desire of CDS to expand & improve its product range has brought new innovations to the TL series: TSL 200 : In TL 200, the depth of the body has been reduced, with the same stroke, with a consequent reduction of the gearwheel diameter and a better ratio with the driver unit and a better positional accuracy. This makes the machine far more compact and it is a great advantage to the machine builder.
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BUSINESS NEWS Plastic Protections: In the TL range, the plastic protections have been studied to be applied on pallets in order to guarantee an anti-intrusion covering for the components being processed. These covers are printed in 3D. Special Links Chain: Together with the plastic protections a new links chain has been developed. The latter is equipped with special seals to reduce the
accumulation of powders or abrasive material during the process and increase the protection of leads and bushes. In a nutshell, following are the salient features of these conveyors: • Versatile and compact modularcomponent design • Precision machined cast iron chemical-nickel plated links • Precision chordal compensation cams
• Cam Driven for fixed indexing motion or servo driven for flexible positioning The competitive price and fast lead time together with CDS quality and reliability make this series very attractive for the market, says Rupesh Paparaju, Director, Bettinelli Automation Components Pvt. Ltd., based in Pune. For more information, Website: www.bettinelli.in
Schmersal launches first ex-proof RFID safety sensor EX-RSS16 can be used in gas zone 2 & dust zone 22 At Motek 2019, the Schmersal Group is showcasing the first RFID-based safety sensor which has been designed in accordance with ATEX Directive 2014/34/EU and can be used in EX zones 2 (gas EX, category 3G) and 22 (dust EX, category 3D). This means that the EXRSS16 combines two important properties for system safety: functional safety in accordance with ISO 13849 and explosion protection. At the same time, the sensor features ignition protection classes Ex ec and Ex tc, covering the explosion protection function without requiring another energylimiting device. Schmersal launched this new development this year. The wear-free safety sensor is perfect for position monitoring of various kinds of safety equipment, including the monitoring of doors, position monitoring of machine axles or other
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MACHINE TOOLS WORLD
The EX-RSS16 safety sensor can be used in gas zone 2 and dust zone 22
rotating, lateral shifting or removable safety equipment. Three different actuation directions also allow a flexible choice of installation position. The EX-RSS16 is available with or without latching. For example, the variant with a magnetic latching ensures that a door is held closed even when there is no voltage. Because of the built-in RFID technology, the EXRSS16 enables individually coded variants with a coding level of high in accordance with ISO 14119,
NOVEMBER 2019
thus offering excellent tamper protection. The EX-RSS16 safety sensors have an optional diagnostic output or SD interface (Serial Diagnostics). Up to 31 safety switchgear devices with serial diagnostics can be connected in series. This means that the diagnostics data from the individual devices connected in series can be transferred via the SD gateway and a fieldbus (e.g. PROFIBUS) to a controller, e.g. status data or error messages. This means problems can be resolved
more quickly. Advanced diagnostics data supports predictive maintenance and helps prevent machine downtime. Control commands can be issued by the PLC to the devices connected in series. “The new EX version for gas and dust applications considerably extends the potential applications of the RFID safety sensor, which is already in strong demand because of its performance and cost-effectiveness,” explains Marlies GerstkämperOevermann, Product Manager at the Schmersal Group. “The EX-RSS16 is suitable for many industrial areas in which the requirements of explosion protection apply.”
For more information Website: www.schmersal.com www.tecnicum.com
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BUSINESS NEWS
Concord make molybdenum wire re-usable technology CNC wire cut EDM machines Concord was one of the first companies to introduce machines with Re-usable Molybdenum wire technology in India in the year 2000. The main advantage of this technology is the ability to reuse the wire, low power consumption and relatively easier operation. In addition, the cost of ownership was so low that, many small companies started using WEDM machines in their own shop. The speed, surface finish and accuracies of these machines, though
Concord has installed over 1000 machines of various sizes all over India for various Industrial applications like Defence, Aerospace, Tool Rooms, Automobile, Medical Equipment, General Engineering, Job Workshops and Educational Institutions.
not in the same league as the Brass Wire Machines, was acceptable for many applications and the added
advantage of very low running costs made these machines popular in the last 20 years.
For more information, Web: www.concordunited.com
Automatic detection and alignment of tools and blanks with the TOOL VISION SYSTEM from WALTER For correct pre-positioning of tools and blanks prior to machining, WALTER now offers a new TOOL VISION SYSTEM for all its tool grinding / eroding machines with robot loader. This system detects contact free, the orientation of the tool or blank, with e.g. brazed PCD plates on the front, sintered PCD veins or with cooling channels. The detecting is done automatically and during idle time. This means significant timesaving compared to the manual measurement method,
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MACHINE TOOLS WORLD
TOOL VISION SYSTEM from WALTER
Blanks viewed from the camera perspective
eliminates human errors and avoids damage to the
NOVEMBER 2019
tool due to the non-contact method.
The TOOL VISION SYSTEM is permanently installed in the robot cell and available with two lenses. The one lens for tool diameter from 1.7 mm to 12 mm, the other lens for tool diameter from 6 mm to 32 mm.
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DMU 50 3rd Generation with PH 150
ECONOMICAL PRODUCTION STARTING WITH THE FIRST BATCH
16 m COMPACT AUTOMATION
2
loading capacity up to 250 kg (incl. pallet)
THE FIRST CHOICE IN 5-AXIS UNIVERSALMILLING
36 -MONTH WARRANTY ON
speedMASTER SPINDLE
warranty without unlimited spindle hours
Exclusive Technology Cycle
MPC 2.0 – MACHINE PROTECTION CONTROL
Vibration and torque monitoring of the process
Find out more about DMU 50 3rd Generation dmu.dmgmori.com
ANZ_DMU50_3rd_PH150_2019_A4_EN_PRINT.indd 1
22.10.19 10:5
BUSINESS NEWS
Oerlikon Balzers celebrates 25-year anniversary, inaugurates forming tools facility Oerlikon Balzers, a leading supplier of surface solutions, recently celebrated 25 years of operations in Pune, India. Around 150 customers, 25 guests of honour and 150 employees gathered in Pune to celebrate the 25th anniversary, which also marked the inauguration of the new forming tools centre, a demonstration of Oerlikon Balzers’ continued commitment to the growing Indian market. The existing customer centre has been substantially expanded, enabling Oerlikon Balzers to respond to the increased demand for high-quality coatings and to offer an even wider range of services for forming tools in the Pune region and throughout India. The new dedicated production line features state-of-the-art pre- and post-treatment and can
Production officially begins as the invited guests of honour and Oerlikon Balzers management cut the ribbon (from L to R): L. Krishnan (Managing Director, TaeguTec), Vidhu Nevatia (Managing Director, Zecha Precision Tools Ltd.), Anton Angehrn (former Managing Director, Oerlikon Balzers India), Andreas Reiter (Head of Forming Tools, Oerlikon Balzers), Wolfgang Kalss (Head of Cutting Tools, Oerlikon Balzers), Dayanand Reddy (Managing Director, Vasantha Tool Crafts Pvt. Ltd), Michel Maeusli (Director Sales & Operations, Oerlikon Balzers Thailand), Cdr. Anand Badve (Chairman Oerlikon Balzers India), Othmar Hardegger (Consul General of Switzerland in Mumbai) and Pravin Shirse (Managing Director & Regional Executive SE Asia, Oerlikon Balzers)
handle large forming tools and low-pressure nitriding for metal, plastic and aluminium die casting tools. The event was hosted by Oerlikon Balzers management, who were joined by L. Krishnan, Managing Director at TaeguTec; Vidhu Nevatia,
As well as celebrating its 25-year anniversary in India, Oerlikon Balzers inaugurated the new customer centre in Pune for forming tools. The existing building has been enlarged by 30% in order to meet the demand from customers for coating solutions for forming tools.
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Managing Director at Zecha Precision Tools Ltd.; Anton Angehrn, former Managing Director at Oerlikon Balzers; Dayanand Reddy, Managing Director at Vasantha Tool Crafts Pvt. Ltd; and Othmar Hardegger, Consul General of Switzerland in Mumbai. In his speech, Dr Wolfgang Kalss, Head of Cutting Tools at Oerlikon Balzers said, “After beginning operations in 1994, continuous investment in the form of new coating centres throughout India and consistently high-quality customer service have enabled Oerlikon Balzers to build a strong reputation and position itself as a leader in the coating industry in India, where we have always deployed our latest coating technology
and equipment to offer outstanding products and services to our customers.” Dr Andreas Reiter, Head of Forming Tools said: “In the last 10 years Oerlikon Balzers’ coating business for forming tools has grown considerably. The existing coating centre has been enlarged by 30% and the new production space is exclusively dedicated to forming tools. Equipped with the latest technology, including pre- and posttreatment, it will allow Oerlikon Balzers to further expand this business by meeting the demands of our customers for innovative coating service solutions with short lead times.” For more information, www.oerlikon.com/balzers
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Overcome the low machinability issues of today’s stainless steels with Duratomic® TM1501, M2501 and TM3501 insert grades from Seco Tools
WWW.SECOTOOLS.COM
Gain better chip control and achieve dimensional part accuracy and surface finish perfection, especially when it comes to today’s more difficult-to-cut alloys and more complex workpieces.
OVERCOME THE CHALLENGES OF TURNING IN STAINLESS STEELS
BUSINESS NEWS
ANCA launches the latest generation of ToolRoom RN34 software package ToolRoom RN34 is the latest generation of ANCA’s successful software package that has been specially designed for the aerospace, die mould, general machining and power generation industries. Thomson Mathew, ANCA Software Product Manager said, “ToolRoom RN34 is aimed to be the differentiator among many suppliers of endmill manufactures in the industry by allowing customers to design complex geometries through software to achieve increased tool life, productivity, cutting volume and increased quality and precision of the workpiece.” “The constant helix ballnose option, for example, is replaced by a graphical drag-and-drop designer. This ballnose type of tool, with optimized irregular helix curves to reduce vibration, and with near-instant visualization easily achieved by switching from the 2D
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projection of the cutting edge to the 3D.” The new software promises benefits of: • Improved productivity through the intuitive creation of complex endmill geometries. • Tool balancing to increase tool life, cutting volume, quality and precision of the workpieces. • Minimizing chatter through the simple design of high performance, complex tools.
NOVEMBER 2019
Leading cutting tool manufacture Fraisa has been able to reduce set up from hours to five minutes through the new tool balancing feature in ANCA’s new ToolRoom RN34. Douglas Franke, Fraisa Production Manager said, “With ANCA’s balancing software, we have a tool balanced generally within five minutes. Some of our more complex tooling can take a little longer – up to 20 minutes. This drastically decreased our time in setup
on the machine which could take several hours. Our biggest success story has been an aerospace customer who is running our 1” aluminium roughing tool at 25k rpm.” ANCA’s ToolRoom software provides industry renowned tool design flexibility, from the simplest to the most challenging tasks. With the benefit of over 40 years of grinding knowledge, ToolRoom supports both manufacturing or regrinding applications. Flexibility is further enhanced by the fact that ANCA develops all aspects of the machine in house - from the CNC control system & application software to the machine and its accessories.
For more information, Website: www.anca.com
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COVER STORY
GEDEE WEILER: Coherent INNOVATION with CUSTOMER centric approach Q. Please brief us about recent initiatives undertaken in machine tools space? Which are your focus areas? As part of our continuous process of product development and to help our customers to increase the production and reduce the cost as a prime moto, we have recently launched new products with Turnmill and Automation capabilities. Our latest product Versaturn combines flexibility and productivity by incorporating Zero point clamping system on the cross slide of the CNC lathe which is a unique concept launched by Gedee Weiler probably for the first time in the world. Our other new products that we launched in IMTEX with different options like Servo Gantry loader and Robotic Automation have been
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received well in the market and created lot of interest. It is observed that the Indian manufacturing industry is gearing up to produce not only mass volume but be able to change over to new products very quickly. So the production facility should cater to a variety of products and at the same time should be able to combine multiple operations or processes in the same setting. Recognizing the need, we are focusing on expanding the range of our turnmill machines to provide Y-axis and sub spindles. Further, we are focusing on developing specific configuration of machines that cater to a particular family of parts in mass volume production to achieve maximum productivity at the least cost per piece.
Q. What are the market opportunities for your products in India? How do you plan to position these products? As a player in the CNC lathe business focused on small, precision and large volume parts, we have abundant opportunity in the Indian market especially in automobile components, general engineering, consumable durables, etc.. As a Leader in precision lathe segment, we enjoy a dominant position in tool rooms, aerospace industry, training centres and leading premier institutions. Our competitive turnmill machines launched about 2 years ago have found wide acceptance throughout India especially in small component segment in different industries. By offering a choice of live tool turrets,
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COVER STORY
Mr. K. Ganapathi Subramanian Vice President Gedee Weiler Private Limited
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COVER STORY
controllers, a bit of customization and strong application support, we position ourselves as a solution provider for turnmill applications. In IMTEX, we launched a larger turnmill center which has helped us consolidate our presence in this segment. Our Versaturn with zero point clamping system that enables set up change over in near zero time is ideally suited for medium volume production for a variety of parts.
Q. What is your marketing strategy for India? Gedee Weiler is a well-known brand in the machine tool field throughout India for several decades now. In order to improve the reach we have expanded our sales service network in the past several years by adding direct sales / service as well as dealers in different territories across the country. We set up a corporate technical center at our Coimbatore plant where customers can experience our latest products and technologies including live demos. We also have a resource center setup in Faridabad where we have a demo machine along with fully equipped application capabilities as well as after sales service spare parts back up. We contemplate to set up such resource centers in other potential markets as well in the coming years. We have increased our participation in national and regional and international exhibitions in the last few years which has surely improved our visibility.
Q. According you what are the factors affecting to your business? The factor that affect our business
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the most today is technology. Technology is changing and developing at lightning speed changing the way we live almost every day. The change in the preference of consumer in every walk of life like transportation, communication, etc.. brought in by this technology change is radically changing the demand pattern for different products. This throws a challenge to machine tool builders to develop products that can cater to the fast changing needs of industry in terms of productivity, flexibility and ability to change very quick, all at an affordable cost. while on one hand, the consumer preference is bringing in new demands, on the other hand change in skills required and / or the lack of it is a major factor that throws challenge to the machine tool industry. As always the economic conditions, the cyclical changes and the availability of finance at the hands of the customers especially the MSME sector are other constant factors that influences machine tool business.
Q. What are the key technological trends that are driving machine tools industry? The internet has changed greatly all our lives, has brought in change in various walks of life and the industry and the machine tool sector is no exception, to this. The latest concept of ‘Industry 4.0’ and internet of things are becoming the order of the day in manufacturing industry and the need of the hour is smart machine tools that can be part of the smart factory. Intelligent
machines that can easily adapt to the quick change in production processes with ease that can combine multiple operations in a single setting, facilitate monitoring of various parameters of machining, tooling, safety as well maximize productivity and at the same time be cost effective is the current trend in the machine tool industry.
Q. What is your vision for your company? As one of the pioneers in machine tool industry in India who has brought in many firsts to the Country, we always strive to maintain our leadership in Technology and Innovation. Our vision is to develop innovative products that help our customers produce their parts to the required quality at a competitive price thus maximizing their profits. We will continue to focus on bringing out products that combines multiple processes that are capable of adapting to automation and customization where possible to meet the specific needs of the customers. We are the largest exporters of machine tool to Germany from India and we are confident to maintain this position and further expand our export business in Asian markets as well. We are contemplating not only expanding our product lines but also are looking at opportunities to strategic tie ups with global machine tool builders and we foresee our Company to be a name to recon with in the global machine tools arena for precision and innovative machine tool solutions, for years to come.
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COVER STORY
VERSATURN
V
ersaturn slant bed turning machines are based on a revolutionary new concept of integrating zero point clamping system onto the saddle of the slant bed CNC lathe for the first time in India. Versaturn is essentially a CNC chucking machine available with two different X-strokes. The unique feature of this machine is that in the long stroke version (X-300mm) the machine can accommodate larger diameter components upto 180mm with 4 linear tools facilitating high productivity. Optionally this is offered with a combination of Linear tooling and Turret enabling the customer to use more than 8 tools if called for which is a unique feature. As another variant, the machine is offered with a Stark zero point clamping system with interchangeable T-slot tables mounted with different combination of linear tool blocks for different components which can be changed within few minutes. This unique innovation of Gedee weiler is the first of its kind in India that combines high productivity of linear tools and high flexibility to accommodate different components which call for medium batch production with near zero change over time. L.M.Roller guideways on both X & Z axis ensures rigidity and make it suitable for machining different materials like Steel, Cast iron and
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Aluminium. Needless to mention here that the machine is equipped with the spindle that delivers matchless precision (Spindle R/O ≤ 0.003mm) which is a hall mark of Gedee Weiler. Furthermore, these machines are offered with wide range of spindles (A2-4, A2-5, A2-5 LB, A2-6) and controllers (Fanuc, Siemens
& Mitsubishi) choices. Our live demonstration of hard turning, hard burnishing, thread cutting using dies and the heavy metal removal capability test in Imtex which attracted the attention of all customers stands testimony to the capability of the machine and its versatility for different applications justifying the name VERSATURN.
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Shaping the future. Together.
Two world leaders in industrial process fluids, Quaker Chemical and Houghton International, have come together as one company to keep our metalworking customers ahead in a changing world. As Quaker Houghton, we are proud to partner with metalworking industries around the world that are driving a sustainable, more prosperous future. We work with your teams to deliver expertise, service, and advanced technology related to industrial process fluids.
quakerhoughton.com ©2019 Quaker Houghton. All rights reserved.
COMPANY PROFILE
Surya Manufacturing Company: Commited to ‘Lighting’ Excellence Through its extensive product portfolio and impeccable customer service, Surya Manufacturing Company has solidified its position as a reliable brand providing perfect lighting solutions.
S
urya Manufacturing Company is a premier manufacturer and trader of electrical equipment offering a wide array of products to meet the diverse and unique requirement of customers. The company has established itself as a market leader and a reliable brand providing world class products, accessories related to CNC, SPM machines and automation. Its extensive product portfolio includes LED Machine lamps, relay modules, LED Tower lamps, LED Hand lamps, digital counters, electrical industrial connectors, batteries, ABS enclosures, proximity switches and sensors. The company is focused on understanding and meeting its client’s illumination requirements. In order to implement the right lighting solutions for its clients, its team of experts relies on a number of proprietary tools and approaches. In over two decades of existence, Surya Manufacturing Company has established itself as one of India’s leader in machine tool manufacturing. The company offers the highest standards of quality, service and technical expertise necessary to accomplish even the most complex precision machining. Surya Manufacturing Company offers specialized solutions for machine lighting, which is one of the most important areas in the industry. Glare, Reflection & inadequate illumination causes operator fatigue, which in turn adversely affects the quality and efficiency. Surya Manufacturing
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Company offers a wide range of glare free, long lasting and energy efficient lamps for the textile, automobile, engineering, automation, process, pharmaceutical, packaging, jewellery, electrical, electronics and most of other industries. Over the years, the company has solidified its position as a market leader in the national and international market for manufacturing and exporting machine lamps. Focus on Quality and Service A part of prestigious Surya Group of Companies, the company is deeply committed towards ensuring the quality of products. One of the pillars of the company’s success and growth over the years has been its goal to offer customers world-class products backed by unparalleled service. Its focus on adhering to high quality standards
can be gauged from the fact that Surya Manufacturing Company has been assessed by international certifications, such as ISO 9001:2015. It also constantly strives to ensure on-time delivery and rapid customer support. Further, competitive prices for these superior quality products has given an edge to the company, which has helped it to bag several key projects and customers. A testimony to its high-quality solutions and service is an award that the company received for the conversion of regular lighting to LED.
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EMAG GROUP TECHNOLOGIES Turning
Milling
Grinding
Gear Hobbing
Skiving
Heat Shrink Assembly
ECM / PECM
Laser Welding
Induction Hardening
The EMAG Group is one of the few manufacturing system suppliers that cover the entire process chain – from soft to hard machining. Access to a wide range of technologies (turning, drilling, milling, gear cutting, grinding, laser welding, ECM/PECM machining, induction hardening and automation) allows EMAG to implement complete process chains, not only for the manufacture of gear box, engine and chassis components, but also for components in the non-automotive sector including oil field, power generation, aerospace and large equipment.
EMAG India Private Limited “Technology Centre” I No. 17/G/46-3 · Industrial Suburb I 2nd Stage · Yeshwanthpur I Bangalore · 560022 I Karnataka · India Phone Sale: +91 80500 50163 I Phone Service: +91 80500 50165 I E-mail: sales.India@emag.com I www.emag.com
TECHNO FOCUS
ENGINE BLADES FOR THE AEROSPACE INDUSTRY TURBINE AND COMPRESSOR BLADES - SAFER AND MORE EFFICIENT WITH AN OTEC FINISH
O
ne of the most crucial components of a working engine system is its engine blades, such as turbine or compressor blades. A turbofan engine, for example, has many parts: at the front, the fan draws in the air and directs it into the compressor, which is composed of several blades arranged in a row and decreasing in size towards the end of a narrowing tube. Using a rotational movement, the suction air is compressed to up to a thirtieth of its volume, which in turns compresses and heats the gas. The air is then fed into the combustion chamber where it is mixed with injected kerosene and burned. The resulting energy propels the highpressure turbine where the turbine blades driving the compressor are installed. The downstream lowpressure turbine is also set in motion using this energy. The low-pressure turbine consists of longer turbine blades and is directly connected to
A turbine blade pre- and post-processing the fan. The turbine ensures that the fan rotates. The fan not only sucks the air into the interior, but past the compressor and the turbine. The cold air, which is fed past the interior, generates the greatest propulsive force. The process inside the engine merely ensures that the engine remains running. So the exhaust gas
flow produces 20% of the propulsion and the fan, 80%. Both the turbines and compressor blades are subject to high temperatures and pressures. Manufacturers have therefore implemented strict regulations for the production and processing methods used. The engine blades used in the aerospace industry are usually made of materials that are difficult to machine and have a low tolerance that must be met to obtain the ideal air flow and maximum wear resistance. These components are exposed to extreme temperatures of up to 1,000°C. This means that the blade surfaces also have to be of the highest quality and optimally adapted to the conditions in the engine. OTEC has developed a special process to improve the efficiency and safety of engine blades and produce fewer defects. Smoothing the air foil, i.e. the blade body, has a positive impact;
Results after rounding the blade edges in the stream finishing process
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depending on the required result, the surface can be smoothed to values of up to Ra < 0.2 µm in a few minutes, increasing blade efficiency. The material is removed evenly and only a minute amount is taken from the surface. Repairing the leading and trailing edges with precision rounding can reduce the quantity of rejected parts. The upstream machining process, e.g. blasting, can damage these edges. OTEC’s method enables them to be rounded to a given radius and hence repaired. The rounding process is very precise and involves minimal material removal. Deburring the root helps to improve safety by preventing the blade from becoming caught in the disc. Surface treatment not only prolongs the service life of the blades but increases their efficiency. This is also the ideal preparation for coating the components. Smoothing and rounding the engine blades is possible in a single operation thanks to OTEC’s innovative stream finishing process. In the stream finishing process, the blades are clamped into the machine and lowered into a container of abrasive. Processing is carried out by both the rotation of the container and the movement of the workpiece in the media flow. The flow to the blades in the machine is clocked, i.e.
the alignment angle of the workpiece changes at frequent intervals. This means processing can be precisely aligned to specific points on the workpiece, achieving a smooth surface and precise rounding without altering the shape of the blade. An important benefit of OTEC’s process is the ultrashort machining times compared to conventional processes. Depending on the size and initial condition of the workpiece, the surface treatment of engine blades takes between 2 and 20 minutes. As the blades are clamped individually, no damage will occur to the workpiece surface. All processing steps can be carried out in one machine. The SF-5 stream finishing system can process up to five engine blades at once, ensuring high output and cost efficiency. Tests conducted after OTEC processing show positive
SF – Series
TECHNO FOCUS
Stream Finishing Machine results for residual stress, fatigue strength and fluorescence control. Engine blades are not only used in the aerospace industry, but also in the power sector. The surface treatment of blades from energy turbines can also be carried out in OTEC machines.
www.otec.de
OTEC finish: for smooth surfaces and rounded edges
Video link of SF (Turbines blades process) https://youtu.be/o2g_Vo2jDV8
Millenia Technologies 311, Options Primo, Plot No. X-21, CTS-31, Near Passport Office, Kondivita, MIDC, Andheri (E), Mumbai - 400093, Maharashtra, India. | Tel: +91-22-28316101 / 28320401 Email: sales@millenia-technologies.com | URL: www.millenia-technologies.com
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â&#x20AC;&#x153;The open gate to the world of toolsâ&#x20AC;?
Features of the TOOLBOX software
Advanced system for manufacturing and re-sharpening standard and special high precision tools on 5-axis tool grinding machine. LECA
Graphical software for cutting tools building - can be adapted to any type of CNC tool grinding machine with at least five axes, regardless of the level of development and type of NC controller. The user can familiarize himself with the software in a few training days. Our team offers online Internet training and tool development support, including direct remote assistance
The structure The application has a tree structure in which the composite elements open and close according to user intent to introduce or track information. The corresponding parameters of the tool are assigned to the individual processes and allow quick access to the desired information. For each operation, we have attached the following information groups: specific machining options, geometry, kinematics, technology, the definition of grinding cycles, corrections and changes, specific technological parameters, different flags for changing the original machining. For fluting operations, there is an additional function to calculate the shape of the grinding wheel based on the theoretical flute form and the defined parameters. The composite elements of the tool are dynamically assigned according to the selected configuration of the tool. In addition to the tree structure there are other lists with the possibility to select the operations for the simulation and for the grinding on the machine.
SOLIDpro For a good preparation of the machining, each operation can be simulated in tool system axis (2D or 3D), whereby the user has the possibility to fix the shape and the parameters of the tool before its real machining on the CNC grinding machine tool. The process simulation based on complex mathematical algorithms reproduce 100% the real cutting process. The simulation process can be realized at any point of the tool shape, in radial and in cross section. The position of the simulation view can be freely defined by the user. The graphical representation includes zoom tools and additional functions for linear and angular measurements in real values.
The tool definition The modular structure of the application allows the definition of different tool configuration: - Forehead area (straight/flat milling head, drill point, deep hole drill, bull nose, corner radius, corner chamfer, annular cutter) - Tools area (standard cylindrical or conical cutters, step drills, butt tools, form cutters, taps, hobs, burrs). All forehead and tool types can be combined to define special tools. The resulting tools can be left or right spiral and left or right cut in any combination. The tooth pitch can be the same or different. For each tool can be performed different types and numbers of flute operations - one or more for each tooth - "FluteDEF" For each tooth can be assigned a different external profile drawing. The simulation can be generated continuously or sequentially, the colors, the type and the accuracy of the simulated operations can be defined.
The grinding wheels It can be defined as a standardized and / or profiled grinding wheel. The geometrical definition of the shape and dimensions of grinding wheels or disc packages as well as the selection of a specific disc with a special profile shape for each machining operation are accompanied by a graphic 2D and 3D representation. All grinding wheels, packages, spindle blocks are defined as objects and can be adapted to any configuration.
CNC controller interface The TOOLBOX application enables bidirectional data communication between the computer and the CNC control of the grinding tool machine. This data communication allows the user to track the machine's work process while programming other tools. The process can be extended to internal networks and the Internet.
Delivery TOOLBOX HARDLOCK SUPPORT
- CD documentation and demos. - USB-dongle, configured. - performance, upgrade, training
Hardware configuration For installation and optimal running of TOOLBOX software, the following are necessary: PC with a multicore processor, 8 GB RAM, 10 GB free HDD space, 2 GB video memory, operating system Windows 7/10, screen resolution 1280x1024
Tools Wizard GmbH Switzerland
office@tools-wizard.com www.tools-wizard.com
Lakshmi Electro Controls and Automation Bengaluru +91 9880282775 www.leca.in
CASE STUDY
Renishaw Equatorâ&#x201E;˘ gauge enables production growth at major aerospace manufacturer 56
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Background Senior Aerospace Weston is a leading supplier of a wide range of complex precision machined components and sub-assemblies, predominantly for the commercial aviation market. At the companyâ&#x20AC;&#x2122;s machine shop in Earby, UK, 95% of output is for use in Airbus aircraft, mainly A320 and A321, but also A330, A380 and A350 models. Most of the components are aerostructure (wing and mainframe) components; everything from small items measuring 50 mm, up to large engine pylon brackets and landing gear fittings.
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Hobbing and Shaving – the Complete Package Gleason Genesis® Hobbing Machines and the new 200SVP Plunge Shaving Machine are built in India to Gleason global standards, delivering worldclass performance for medium and high volume gear production. Both feature compact, rigid designs and the latest Siemens CNC for easy operation. All supported locally with application expertise, cutting tools and workholding. www.gleason.com/Genesis www.gleason.com/SVP
Gleason Works (India) Bangalore, Karnataka sales-india@gleason.com +91 80 7136-5000 © Gleason Corporation. All rights reserved.
CASE STUDY Challenge Some of the more complex aerostructure parts were taking up to 10 minutes to inspect using Senior Aerospace Weston’s existing coordinate measuring machines (CMMs). This would often cause bottlenecks and capacity limitations around the CMMs. To address the problem, the company introduced various manual inspection methods using traditional measuring equipment and hard gauging, but to limited effect. With build-rates increasing, Senior Aerospace Weston recognised its responsibility to become even more efficient with in-cycle measurement without compromising quality. Solution “We spoke with Renishaw and they proposed the Equator gauge, which
is another level up from a traditional 3-axis CMM in terms of speed,” explains CMM Programmer Andy Wright. The thermally-insensitive Equator system is a flexible gauge that is designed to provide speed, repeatability and ease-of-use. Installed at Earby during January 2018, Senior Aerospace Weston has already programmed eight parts. “We have 70 parts that could fit on the gauging system, so there is high potential,” states Mr Wright, who is also impressed with the system’s ease of use. “No special skills are required; the operator simply loads the part into the fixture, lets the cycle run and receives an easy-to-read report.” Another factor behind the success of the project has been the sales and applications support from Renishaw:
“The support we receive is first class,” says Mr Wright. “Renishaw is very quick to answer any queries, and it almost feels like we’ve been assigned our own special support team.” A key part of the support team for Senior Aerospace Weston is Renishaw Applications Engineer, Ed Clarke, who comments: “For any customer with a turnkey project we will provide ongoing support for all stages of their project. If there are any queries, the customer can come directly to us for the support they require.” Results Among the parts inspected at Senior Aerospace Weston using the Equator gauge is a titanium wing flap track component for Airbus aircraft. “Over the years we have gone through several process iterations and various equipment solutions trying to measure this part quicker with the required accuracy, but inspection would regularly fail due to component complexity and tight datum tolerances,” concedes Mr Wright. “However, using the Equator gauge we have been able to achieve a process that delivers accurate gauging and repeatability. The Equator gauge measures around 25 different features on this particular part, taking just 90 seconds in total.” “The in-cycle measurement time has been significantly reduced, with our operators now just reviewing an electronic report,” says Mr Wright. “Inspection cycle time has been cut by 75%. Previously a manual measurement would be taken and recorded on paper; now, we have fully electronic reports with every dimension recorded. We can also use trend data to help identify potential areas for improvement in our manufacturing process.” For more information Website: www.renishaw.com
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AMT SECTION
TECH TRENDS
AMT SECTION LEARN MORE ABOUT AMT’S CHENNAI TECHNOLOGY CENTRE AMT’s Chennai Tech Centre (CTC) is located in the MEPZ duty free zone just 7 km from the Chennai airport. It encompasses an area of 1,500 sq.m., including a 650 sq.m. technology demonstration area. Operational since May 2011, CTC has successfully served as a bridge between the Indian manufacturing sector and American advanced manufacturing technology. To learn more, please contact or visit CTC: AMT - Chennai Technology & Service Centre A 44 - Phase 1, MEPZ, SEZ Unit Tambaran, NH 45, Chennai - 600 045 Tamilnadu, India Phone: (+91) 44-22622690-92 Fax: (+91) 44-22622693 Arun Mahajan General Manager AMahajan@amtonline.org Cell Phone: (+91) 9790887032
WWW.AMTINDIA.ORG
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NOVEMBER 2019
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AMT SECTION
TECH TRENDS
WHEN QUALITY MEETS INNOVATION ®
T-A Drilling System The T-A continues to evolve with innovative coatings, holder designs, and insert geometries. Experience the power and customization for yourself.
Find your perfect geometry. Give us a call today. SOLUTION HUB APP All of Allied All the time. DOWNLOAD NOW
BORING
REAMING
BURNISHING
THREADING
DRILLING
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SPECIALS
Email: info.in@wohlhaupter.com | Phone: +91 11 41827044 Holemaking Solutions for Today’s Manufacturing
MACHINE TOOLS WORLD
NOVEMBER 2019
www.wohlhaupterindia.in
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AMT SECTION
TECH TRENDS
Newest 4TEX IC Drill Achieves Premium Hole Concentricity in Interrupted Cut Applications Improve hole quality, reduce insert change out time and extend tool life with interchangeable 4-sided inserts and superior holder rigidity. Written by Deborah A. Froelich
W
ohlhaupter India Pvt. Ltd. provides engineering, technical support, and onsite application services within India for Wohlhaupter GmbH and Allied Machine and Engineering Corp., leading manufacturers of holemaking and finishing tooling systems. Together, they are excited to promote their newest IC drill, 4TEX. According to the company, 4TEX excels in drilling operations that include interrupted cuts, inclined work surfaces, and angled breakouts, as well as high-temperature alloys and stainless steels. The indexable carbide drill is engineered to create optimal chip formation for efficient evacuation in holemaking processes and it outperforms other standard drills by delivering higher penetration rates in
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light-duty machines. 4TEX is ideal for applications that include shallow 2xD, 3xD, and 4xD holes in the 0.472” – 1.850” (12mm - 47mm) range. Allied Machine has optimized 4TEX’s insert geometries for wear resistance and offers them in geometry/coating combinations for all ISO materials including steel, stainless steel, high-temperature alloys, nonferrous and iron. Another benefit of its design is that the same insert can be used in either drill pocket, simplifying insert change out. The distinctive insert shape improves surface finish, hole quality, and penetration rates while eliminating issues from chips winding around the tool. The drill’s design touts increased core strength, improving hole size and straightness. The flute space of the
internal cutting-edge side, where chips often cluster, is 1.6 times larger than typical IC drills. Dual-twisted coolant outlets, coupled with the increased flute space, improve penetration rates by enhancing coolant flow and generating optimal chip extraction. Global leaders in holemaking and finishing systems, Allied Machine and Wohlhaupter have over 168 years of combined industry experience troubleshooting unique and challenging holemaking applications. For more details on GEN3SYS XT Pro high-penetration drilling systems or to schedule a free tooling consultation with a local tooling specialist. For more information, Email: info.in@wohlhaupter.com Website: www.wohlhaupterindia.in.
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TECH TRENDS
Harness the full potential of Swiss-Type Machining
Swiss-type CNC turning centers are commonly used to machine complex parts, in small lots, with many cutting tools, in a single setup. To provide programming, optimization, and simulation specifically tuned for these machines, ESPRIT combines a comprehensive suite of milling, turning, and inspection cycles with support for Swiss-specific machine components
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rom 3D CAD file to machineoptimized G-code, ESPRIT unlocks the full potential of the Swiss-type turning center. It meets the demands of Swiss programming with a natural workflow powered by a full suite of milling and turning cycles, high-speed machining, and FreeForm cycles for simultaneous 3- and 5-axis milling. Fine-tune cutting paths with extensive control, minimize cycle times with multichannel process synchronization, and reduce on-machine setup time
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with full simulation of the machine and the program. ESPRIT is the right choice for an all-in-one programming solution that produces edit-free G-code for all classes Swiss-type CNC turning centers. Swiss-type CNC turning centers are commonly used to machine complex parts, in small lots, with many cutting tools, in a single setup. To provide programming, optimization, and simulation specifically tuned for these machines, ESPRIT combines a comprehensive suite of milling,
turning, and inspection cycles with support for Swiss-specific machine components â&#x20AC;&#x201D; sliding headstocks, guide bushings, gang slides and posts for tooling, secondary spindles, and collinear axes. ESPRIT SwissTurn meets the unique challenges of Swiss-type turning with versatile support for turning and C-, Y-, and B-axis milling, all in the same G-code program. Full-Spectrum Milling & Turning As a full-spectrum CAM system,
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AMT SECTION ESPRIT delivers powerful programming, accurate simulation, and machine-optimized G-code for any class of CNC machine, limited only by the machine’s physical capabilities. ESPRIT employs a single user interface to program, optimize, and simulate machining tasks for milling, turning, wire EDM, and additive operations. To further reduce cycle times and extend tool life, ESPRIT offers patented highspeed machining strategies for Swiss turning centers and beyond. Synchronized & Optimized With SwissTurn, complete all machining on the part in one setup — even for parts that previously required multiple setups or even multiple machines. Process optimization strategies include segmentation of the program to take advantage of the guide bushing’s support for greater stability and more aggressive cuts, and specialized cutting cycles such as pinch turning and pinch milling that use multiple tools simultaneously within a single operation. Use machining patterns for synchronized and superimposed motion to optimize the cycle time for the overall process. Simulation, Verification, & Analysis With ESPRIT, use the built-in machine simulation and verification to prove out programs beforehand
TECH TRENDS and save valuable machine time. Based upon a digital twin of the Swiss machine, the simulation displays all the machining action in real time. This provides a highly accurate, animated view of the entire process, including the Swiss-specific cycles, motions, and components. Validate the program with collision detection between the tool, part, and all the components of the machine.
SwissTurn Machining cycles supporting any configuration of Swiss-type machine tool: SolidMill • All traditional milling, 2.5-axis milling, ProfitMilling, plus optionally: • C-axis index and rotary milling • Y-axis, 3+1, index milling • B-axis, 3+2, index milling • 3rd rotary axis, 3+3, index milling
Beyond the G-Code ESPRIT delivers much more than just edit-free G-code for each channel, ready to run on the CNC, including the Swiss-specific functions. To help with costing and quoting, ESPRIT can provide time studies based on cycle times. Use the report generator to produce setup sheets designed to provide shop floor operators with an overview of the job, processes, and tooling. Tailor the format of this report to the preferences of each individual shop.
SolidTurn • All traditional 2-axis turning cycles, including: • ProfitTurning • Barfeeder, part catcher, and part handling cycles • Collet and jaw chuck, modular and soft jaws • Modular cutting tool assemblies with turret blocks and adaptive items • Multiple spindles
Machine-Optimized Solutions ESPRIT offers individual solutions, built-in cooperation with each machine manufacturer, and tuned for each Swiss-type turning center. With ESPRIT, quickly move with confidence from design to finished part while minimizing programming and setup time, cycle times, and operator supervision.
FreeForm 3-axis, 4-axis, or 5-axis • Simultaneous multi-axis milling • Swiss-Type Machining • Sliding headstock and collets • Optional guide bushings • Gang slides, front, back, and opposite tool posts • Collinear axes • Program segmentation • Multiple programming channels with synchronization • Machining modes enabling synchronized or superimposed motion
For more information, DP Technology Corp. www.espritcam.com esprit@dptechnology.com
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AMT SECTION
TECH TRENDS
Make Better Parts Faster with Mastercam® 2020
M
astercam 2020 is now available for purchase. This software was developed to help you make better parts faster with more efficient CNC programming and process improvements for the digital age. This CAD/CAM software is developed to streamline your entire manufacturing process from job setup to job completion with enhancements based on feedback and requests from the world’s largest CAM community. Some of the new features and areas of improvement you will find in Mastercam 2020 include: • Enhanced Accelerated Finishing™
• Skip Drill Cycle Pecking
• Improved Dynamic Motion™
• And much more!
• Streamlined hole making
You can make better parts faster.
• Advanced Toolpath Display • Model-Based Definition • New Mill-Turn Component Library • Thread milling enhancements • Analyze associativity • Updated rotary axis positioning • Machine Configuration Workflow advances • More realistic simulation
Contact info@mastercamapac.com to
• Faster, easier chaining
learn how Mastercam 2020 can help improve your productivity.
• Associativity tracking
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www.Mastercam.com
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GE T A G RI P
With The Rocklinizer Carbide Application Equipment
Deliver a long-lasting and robust gripping surface. Just “Rocklinize,” or deposit a precisely controlled amount of our tungsten carbide, Rockhard, or Griptite electrodes onto any ferrous metal, to “get a grip” on: • • • • • • • • •
TUBE/PIPE BENDING DIES COLLETS C H U C K J AW S CL AMP BLOC KS FEED FINGERS NON-SLIP FLOORING FORKLIFT FORKS SURGICAL INSTRUMENTS MANY MORE!
110 South Jennings St. Sioux City, IA 51101 USA rocklinmfg.com | (800) 255-6046
National Distributors Sanjay Tools & Adhesives X20, MIDC Ambad, Nashik 422010 Suhas Belapurkar - Mobile : +91 9892516810, Email: sbelapurkar@sanjaytoolsnsk.com Mr. Mandar Gokarn - Mobile: +91 9822028518, Email: mandar@sanjaytoolsnsk.com
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cklinizer Carbide Application Equipment
lasting and robust gripping surface. Just “Rocklinize,” or deposit
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TECH TRENDS
FACCIN, making Remote Service Management Less Remote
Written by: Mr Virginio Paratico Sales Area Manager
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he world is always getting more digitally interconnected, there is a growing expectation regarding the speed of receiving service and assistance. At FACCIN, we understand this necessity and we are all fully prepared for meeting this expectation. We use state of the art technology not only to exceed customerâ&#x20AC;&#x2122;s production requirements but also to provide aftersales service fit for a modern production plant, our dedicated engineers make sure that FACCIN and all our customers are always on the threshold of technology.
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In order to provide a super-fast and professional service to all our customers around the world we have incorporated a special function in FACCIN CNC consoles called RSM (Remote service management) securely connected to the FACCIN Cloud Service. So How does it work? Long gone are the days of phone calls and endless emails to solve one small issue. A special router is connected to the PLC of the machine, the status of the
machine is converted into bits of data that is sent to the FACCIN database called FACCIN Cloud. Thanks to this router, data can flow in and out of the machine where it can all be monitored by the CNC display. All the service provided thanks to this router is called FACCIN Remote Service Management (RSM), FACCIN RSM monitors the machine while providing systematic and planned maintenance which drastically speeds up troubleshooting and problem solving. The software collects operation history, logs data of component
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Increase machine accuracy from the foundation up Ensure machine tool build accuracy with the XK10 alignment laser system Measure – straightness, squareness, flatness, level, spindle direction and coaxiality Single digital solution – replace the need for traditional artefacts Intuitive software – reduce reliance on highly skilled operators
For more information visit www.renishaw.com/xk10
Renishaw plc New Mills, Wotton-under-Edge, Gloucestershire, GL12 8JR, United Kingdom T +44 (0)1453 524524 F +44 (0)1453 524901 E uk@renishaw.com
www.renishaw.com
TECH TRENDS usage, idle time, machine condition and alarms all stored in the FACCIN Cloud. How is this useful for you? Most importantly, FACCIN RSM allows the end user to receive immediate assistance directly from our customer service department using live video feed and an easy to use interface so that real-time assistance is provided whenever needed. Upon request, the service department can also see the screen of the console which can help the user run diagnostics or trouble shoot at the spot and our experts can analyze the collected data and provide solutions for improving efficiency. What’s more, if you already have a FACCIN machine, it is possible to retrofit this timesaving feature, all you need is a stable internet connection and a FACCIN CNC console!
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Is your information safe? Security and privacy is very important to us, that is why the connection is made through a VPN connection to FACCIN Cloud is based on Amazon Web Services (AWS), it’s backed by a deep set of security and compliance. It’s already being used by many wellknown companies such as BP p.l.c, General Electric, Siemens, & many more. How is RSM different from others on the market? To further enhance the synergy between hardware and software, our dedicated FACCIN engineers have developed a special electronic radius measuring device that can measure the radius of a rolled product and send this data to the CNC where it can be stored and revised when needed. This device can connect to the CNC console wirelessly or with a simple
USB key, it feeds data that can be used to monitor the quality of the series of rolled products. This way, at the end of the month the operator can share the quality of the production with the foreman directly on the console or saved in a computer for presentation. The Company More than 200 years combined experience, forming today’s future. Faccin S.p.A. is a very powerful group which combines the best brands – Faccin, Boldrini and Roundo – in plate rolling, profile bending and dished-heads manufacturing, all united under one roof and offering the widest range of high-quality options available in the metal forming market. Should you be interested in this technology, do not hesitate to contact us and book a demonstration. www.faccin.com
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TECH TRENDS
Ensure consistent grip and accurate work piece holding with high-quality BPT Diaphragm Chucks
D
iaphragm chucks are increasingly becoming popular for a wide range of applications courtesy their accuracy and repeatability. Diaphragm chucks for grinding & turning centres functions similar to a human’s diaphragm that contracts and retracts. They offer many advantages as compared to standard chucks. Unlike standard chucks that rely on the wedge and master jaw linkage for clamping, a diaphragm chuck applies the principle of elastic deformation in expanding, contracting and using resistance to hold work pieces in place. Because diaphragm chucks don’t have sliding components, they don’t require lubrication and offer a more consistent grip force repeating to within 10 microns. Diaphragm chucks are primarily used for secondary operations, eg., grinding, boring, facing and light turning. Preferably, the locating surface should be a pre-machines or precision cast surface. Similar chuck locating diameter tolerances should be held to a total of 0.15 mm; on the larger chucks a total of 0.38 mm can be maintained. Standard diaphragm range is available in 160 mm, 200 mm, 250 mm, 315 mm and 400 mm sizes. How Diaphragm Chucks work Diaphragm chuck utilizes the inherent strength and accuracy of spring steel to achieve the required pressure for external and internal surfaces. When the drawbar is actuated (air introduced via the spindle and adaptor plate in the case of pneumatic version), the piston moves forward 0.45mm. The movement is transmitted
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cluster gears in automobile industries. Liner Industries: For Precision bore grinding / Precision boring operation in thin wall section component with respect to O.D clamping by Diaphragm Chuck. Thin Wall Component: Precision Bearing Cover, Precision Thin Section Flanges. to the diaphragm by a pusher sleeve. The chuck jaws are fixed open through this movement and the component can be loaded. To chuck (i.e. to clamp the component), the drawbar is reacted (or air turned off) and the jaws move toward the clamping diameter until contact is made with the component. Advantages of Diaphragm Chucks • Accurate holding of work piece • Error averaged out • Two level, double diaphragm effect chucking possible with standard chuck • Cages, locating pins and end stops are interchangeable • Cages can be furnished for other chucks • Easy loading & unloading of work piece / component. Industrial Application Gear Industries: All types of Gear Industries: To clamp the pitch circle diameter of various types of gears i.e. Spur and Bevel Gears for bore grinding applications to achieve concentricity/ runout of the bore with respect to PCD of the gear. Double Diaphragm Chuck / Two-Level Diaphragm Chuck are applied for
Aircraft Industries: For clamping lightweight and Thin-Walled components of Aircraft i.e. Cover, Flanges, Gears..etc. Application uses of Diaphragm chuck • To clamp external diameter • Grinding of bore and taper • Boring, facing and light turning • Extremely tight axial tolerances • Highest concentricity. Birla Precision Technologies, the first Tool Holder manufacturer in India since 1986, is at the forefront in delivering high-quality Diaphragm Chucks. The company is empowered by a strong team of designers regularly bringing new technology and products to the market. With its world-class facility, established through its Joint Venture with Kennametal (USA), the company exports its products to more than 20 countries globally.
For more information, Website: www.birlaprecision.com
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TECH TRENDS
‘How lubricants can help in improving Machine Shop’s performance’
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Mr. Rupinder Paintal, Director of Market Development, ExxonMobil Lubricants Pvt. Ltd.
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ith manufacturing activities taking a centre stage in India over the past few years, the sector is on a strong growth trajectory. Extensive use of technology and modern machinery form the base for these manufacturing set-ups. However, optimization of productivity and reduction of downtime still remain a concern for the sector. In order to attain advanced productivity, manufacturing set-ups should consider solutions which focus on improving the performance of the machine tools. We at ExxonMobilTM, are committed to offer a range of lubricants that are reliable and ensure optimal operational benefits for our customers, thus driving increased productivity & profitability for them.
In this milieu, ExxonMobil recently participated in AMTEX 2018, an annual machine tool exhibition that prompts innovation and networking in the manufacturing industry. During this 4 day event held in Delhi, ExxonMobil displayed an array of products ranging from Metal Working Fluids, Spindle Oils, Hydraulic Oils, Gear Oils, et al. ExxonMobil has established itself as one of the leading companies to provide lubrication for heavy machinery and services to increase the life time of a machine shop. In addition to the high performance lubricants and fluids, Mobil also provides a range of technical services to help keep the machine shop running at peak efficiency - also
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Problems like unplanned shutdown, overheating of electrical appliances and connections, insulation problems and harmful gas leakages can lead to a major issues and bring an entire production to a standstill. To tackle these problems and to resolve them on time, FLIR brings a wide range of preventive maintenance solutions which help you identify problems before they arise or start to worsen. Include FLIR's state-of-the-art gadgets in your regular preventive maintenance check-up and make your business operations hassle-free.
INDUSTRIAL APPLICATIONS: Electrical & Mechanical | Building Diagnostic | Automation | R&D | Gas Detection | Firefighting | Test & Measurement For more information, please call us at +91-11-4560 3555 or write to us at flirindia@flir.com.hk FLIR Systems India Pvt. Ltd. 1111, D Mall, Netaji Subhash Place, Pitampura, New Delhi â&#x20AC;&#x201C; 110034 | Fax: +91-11-4721 2006 | www.flir.in /FLIR | /FLIR | /FLIR
Images for illustrative purposes only.
PROBLEMS ARE ALWAYS HIDDEN, AND WE HELP YOU FIND THEM
TECH TRENDS extending the life of the machine, reducing downtime and lowering operating costs. With commitment to the core business ethos of Advancing Productivity, Safety and Environmental care, Mobil has a portfolio of lubrication solutions and technical services that are tailor made for the Machine Shop segment. A few of Mobil’s key offerings are: Slideway Oils Poorly formulated slideway oils may not separate readily from aqueous coolants. This results in the formation of ‘tramp oil’ which compromises the effectiveness of the coolant by shortening its effective life and adversely altering cutting performance. Tramp oil can also lead to bacterial growth resulting in foul odour, short service life and potential health as well as safety concerns. To identify high performance slideway oils, maintenance professionals should seek out products such as Mobil Vactra™ Oil Numbered Series of slideway oils with the following performance characteristics: Exceptional coolant separability which enhances the performance and life of water based metal working fluids, outstanding frictional properties which enable increased machine accuracy and reduced chatter, and stick-slip. Mobil Vactra Oil Numbered Series are premium-quality slideway lubricants specifically designed to meet the requirements for accuracy, aqueous coolant separability, and equipment protection of precision machine tools. Water Soluble Cutting Fluids To optimise productivity it is very important to choose technologyleading aqueous coolants. The
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highest performing coolants can reduce maintenance requirements by resisting biological attack thereby extend batch life. Ease of maintenance needs to be balanced with performance as well as protecting the Machine Tools components from corrosion and sticky deposits. In addition, the fluids should meet the latest Health and Safety regulations, be easy to monitor and maintain in service. Collectively, these properties will help deliver long service life, excellent cutting performance and reduced maintenance downtime. The new Mobilcut™ series from ExxonMobil, comprises of milky emulsions, high performance microemulsions and a fully synthetic grinding fluid. The high performance, long life semi-synthetic cutting fluids in particular have been designed to meet the wide variety of applications and operations found in medium to small sized Machine Tools. Mobilcut 250 is a high performance semi-synthetic fluid formulated to enhance performance when machining aluminum and aluminum alloys and where low staining potential is important on sensitive components. Containing high levels of lubricity agents, it provides high machining performance of carbon and alloy steels and yellow metals. Neat Cutting Oils Neat or straight cutting oils are used in applications which are beyond the typical performance profile of aqueous coolants, such as tapping and threading of high alloy steels. They improve machining in high speed automated machining centres through outstanding cutting performance, reduced tool wear and enhanced surface finish. Ideally they should be light coloured to allow clear visibility of the workpiece; have low misting characteristics to
help workplace safety and product usage; and are chlorine free to support environmental concerns, while balancing with a high degree of lubricity and machining performance. Specially designed to meet the increasing demands of today’s sophisticated machining centres, tooling trends and health and safety regulations, Mobilmet™ series of cutting oils and the new series of Mobilgrind grinding oils from ExxonMobil have been developed for applications where excellent surface finish, high precision machining and improved productivity are the primary objectives. Spindle oils Spindle oils are used for high speed spindle bearings and equipment where high speeds and fine clearances are involved. It provides exceptional lubrication of close-tolerance bearings which helps keep the bearings running cool and helps maintain the precision required by many of today’s critical machine equipments. These are designed for spindle bearings, they exhibit the required properties to function as low pressure hydraulic and circulating oils as long as the proper viscosity is selected. This feature helps minimise inventory costs and reduce the potential for product misapplication. The Mobil Velocite™ oils are premium performance products primarily designed for the lubrication of high-speed spindles in machine tools. They are also used in some critical hydraulic, circulation systems and air line oilers where the appropriate viscosity grade is selected.
For more information on Mobil Industrial range of lubricants and services, visit mobil.com/industrial
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TECH TRENDS
Drake MH Model Thread Grinders
T
here is no need to compromise quality, reliability or accuracy based on your budget. Drake MH model thread grinders are the economical choice in precision grinding. Available for external and internal grinding, these manual helix machines are made to last. Built on a compact cast polymer base for vibration damping and thermal stability, MH grinders are easily integrated into your production facility. The use of linear motors with high-resolution scales on positioning axes fully eliminates ball screw wear, allowing for multi-directional stiffness and low maintenance. This ensures repeatable precision when grinding parts, maintaining Drake’s high standard of accuracy. The MH models are equipped with Drake PartSmart™ software that is easy to use and increases production efficiency. Utilizing menu-driven screens, this software offers versatile grinding and form style options to meet your requirements. Grinding Style Options include: • Straight Grind • Multiple Taper Grind • Dual Lead • and more
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Form Style Options include: • ACME • 60° V • Gothic • Various Worm Profiles • API Buttress • and more Optional upgrades including the Drake SmartForm™ software package are available. In addition to the MH model grinders, Drake’s line of precision machines includes: • External Thread Grinders: grind external threads up to 4m • Internal Thread Grinders: grind internal threads up to 220mm • Dual Spindle Grinders: grind multiple operations in one fixture setup • Crown Grinders: grind drums for tapered roller bearings • Vertical Thread Mills: rough mill parts for finish grinding • Rack Mills: high speed rack milling
full service, turnkey manufacturer of precision CNC machines and provider of engineered solutions. Founded in 1972, Drake is headquartered in Warren, Ohio. The premium Drake brand is known around the world for innovation and process expertise throughout the thread grinding industry. For more information, WWW.DRAKEMFG.COM For additional information, contact our local representative. EMPIRE MACHINE TOOLS Mr. Alok Naik, alok@empiremt.com 2493 7340 / 2494 7066 / 2497 3184 sales@empiremt.com
DISCOVER DRAKE We are Drake Manufacturing. We are a
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TECH TRENDS
New concepts in graphite milling: SEAGULL® tools have impressively high life cycles
Wet or dry? This is no longer the question! Electrode milling in conjunction with cooling lubricant offers a good alternative to dry working. An extensive comparative test of Zecha’s SEAGULL® tools demonstrates the numerous advantages of wet milling: cleaner working, more flexible machine utilisation, improved dimensioning and lower tool wear
SEAGULL® mill cutters are eminently suitable for the wet processing of graphite.
T
he many advantages that graphite electrodes offer have made them the mainstay of spark erosion - no manual reworking, no deburring, hardly any burn-off, even intricate geometries are possible and the electrode comes out of the milling machine ready for eroding. Nevertheless, its manufacture frequently continues to be plagued by graphite dust. Electrode milling in conjunction with cooling lubricant offers a good alternative to dry working. An extensive comparative test of Zecha’s SEAGULL® tools demonstrates the numerous advantages of wet milling: cleaner working, more flexible machine utilisation, improved dimensioning
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and lower tool wear. Can graphite, copper and hard machining take place on one milling machine? So far, this has hardly been worthy of consideration due to the stubbornness of graphite dust. Dry working even creates additional financial hurdles, especially for small and medium-sized companies, as an additional milling machine had to be purchased besides the eroding machine. Wet processing of graphite might be the solution in so far as cooling lubricant permits a flexible utilisation of the milling machine: The graphite dust, generated during the milling process, is
flushed with the cooling emulsion and in following filtered out of the emulsion by means of a special system. Pipes and machines remain clean and free of graphite deposits. What are the effects on the tools, the electrodes and, last but not least, the end component? A comparative test of SEAGULL® mill cutters produced amazing results. Wet or dry– SEAGULL® flying high SEAGULL® mill cutters produce superbly fine ribs and the most intricate of electrode geometries: Patented short flutes - just 0.6 mm at a diameter of 2 mm - as well as a tailored combination of high quality hard metal, diamond coating and special geometry with the tightest
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More Precision Sensors for displacement, distance & position Draw-wire displacement sensors Easy, precise and accurate Different models with measuring ranges from 50mm to 50m Customer-specific OEM series For harsh, industrial environments Different outputs: encoder, potentiometer, current, voltage
Magneto-inductive displacement sensors Ideal alternative to inductive sensors and proximity sensors Linear output signal, high basic sensitivity and temperature stability Selectable measuring ranges up to 55mm with different magnets Long-life sensor due to non-contact measurement
Inductive sensors (LVDT) and gages More than 250 different models with measuring ranges from 1 to 630mm High accuracy Integrated or separate controller Standardized and customer-specific sensor designs also for integration into hydraulic cylinders
+91 20 2674 1009 | info@micro-epsilon.in | www.micro-epsilon.in
TECH TRENDS
of tolerances of just 5 µm ensure minimum flute pressure and cutting forces. This enables excellent surface qualities and maximum life cycles. Zecha offers the SEAGULL® mill cutters in two quality categories: The quality line - subdivided into Series 568 (ball nose end mill) and Series 578 (end mill with corner radius) - offers optimum value for money for standard applications and is pitched at the price-conscious user, who still requires high quality machining results - even during wet milling. These tools come with the tried-and-tested diamond coating, with a concentricity of 0.005 mm and diameter tolerances of 0/-0.015 mm. The right choice for superb surface qualities and tightest tolerances (diameter of 0/-0.010 mm and concentricity of 0.003 mm) is the high-end line with ball nose end mills (series 567) and end mills with corner radius (series 577). Thanks to a 10 µm thick high-performance diamond coating, these tools also boast a long service life. Whether high-end or quality line, every single tool is measured separately and has its actual dimensions documented on the packaging. This consistently narrow tolerances and highest process capability are guaranteed when intricate graphite electrodes are manufactured. All SEAGULL® mill cutters are available in diameters from 0.3 mm up to 12 mm.
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“The SEAGULL® tools have had a fundamental influence on further improving dry graphite processing. We now wanted to move forward and experience what could be achieved by wet processing,” says Mangesh Awate, Manager Sales at Zecha Precision Tools Limited. Longer life cycles and greater dimensional accuracy. Wet processing ensured longer life cycles for the tools and thereby increased significantly the dimensional accuracy of the electrodes. After 490 minutes the dimensional accuracy of the wet process electrodes was still in the 0.005 mm tolerance range. Large dimensional deviations had been observed for dry processing. Good eroding results “The excellent life cycle results during milling and high dimensional accuracy of the electrodes should also match to eroding” says Arndt Fielen, Sales Director at Zecha Hartmetall-Werkzeugfabrikation GmbH.” A series of tests compared the eroding time, surface roughness of the end components as well as the electrodes’ burn-off. One roughing and one finishing electrode were used in the test set-up. Arndt Fielen explains: “Although we were unable to record significant improvements in this case, the results were
definitely comparable - whether using the dry or the wet milled electrodes.” The burn-off ranged between 3 and 6 µm and the surface roughness of the component between Ra 0.82 and 0.87. All the electrodes were in use for approximately 40 min. In addition, wet processing keeps the electrodes washed and clean and benefits quality measurements as well as eroding in highest accuracy. Conclusion Manufacturing graphite electrodes with cooling lubricant offers an alternative to dry milling that is well worth considering. It enables tool and mould makers to machine copper, graphite and steel on one and the same machine with utmost cleanliness. It is precisely the short flute of the SEAGULL® tools that is, both, suitable for producing astonishing dry working results, and ideal for wet processing of graphite. Life cycles are prolonged, tool costs reduced and dimensional accuracy increased.
For more details please contact ZECHA Precision Tools Limited Mr. Mangesh Awate DGM- Business Development Email: mangesh.awate@zecha.in WEB: www.zecha.in
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Innovative Solutions in
Steel to Steel Connections
for On-Site Structural Installations to save On-Site Welding & Drilling
a Cost eďŹ&#x20AC;ective a Easy to install a High Strength a Adjustable
TECH TRENDS
Integrated drive technology reduces machine footprint and control cabinet space requirements By integrating a servo drive directly into a servomotor in an ultra-compact design, AMP8000 Distributed Servo Drive system from Beckhoff offers cost and space savings
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he new AMP8000 distributed Servo Drive system from Beckhoff breaks new ground for modular machine concepts. The space-saving AMP8000 integrates a servo drive directly into a servomotor in an ultra-compact design. By relocating the power electronics directly into the machine, the control cabinet only needs to house a single coupling module to supply power to multiple servo drives with a single cable via a distribution module. The result: significant savings in terms of cost, space, materials and installation effort. With the AMP8000, space requirements for drive technology inside of control cabinets can be reduced to a single coupling module. Via EtherCAT P, providing EtherCAT signals and power with one cable, such a coupling module can control up to five distributed AMP8000 Servo Drives via an IP67-protected AMP8805 distribution module. Since the entire AMP8000 system is cascadable, even complex motion systems can be implemented with a remarkably simple topology. In addition, Beckhoff offers preassembled cables that simplify logistics considerably and minimise wiring errors. With fewer and smaller cable routes to the motors, installation efforts are significantly reduced. Optimized design for efficient drive integration The drive integration concept of the
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Distributed Servo Drive system with the one cable solution EtherCAT P. The new AMP8000 provides the ideal basis for compact & fully modular machine designs. AMP8000 features an exceptionally compact design. Since the power module is conveniently located at the back end of the motor shaft, the attachment dimensions of the new distributed servo drives are identical to those of the proven standard AM8000 series servomotors. The only dimensional change is to the overall servomotor length, which is extended by approximately 7 cm. For the machine builder, this means that only a little additional space is needed at the motor end, and adjusting the overall motion control concept is easy without having to otherwise alter existing machine designs. The AMP8000 distributed Servo Drive system is available in flange
sizes F4 and F5. Various models are available with power ratings from 0.61 to 1.23 kW and standstill torque ratings from 2.00 to 4.8 Nm (F4) or power ratings from 1.02 to 1.78 kW and standstill torque ratings from 4.10 to 9.7 Nm (F5). STO and SS1 safety functions are integrated into the AMP8000 series by default, and a range of additional safe motion functions are in preparation.
For more information, Website: www.beckhoff.com
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An ISO 9001:2015
An ISO 9001:2015
TECH TRENDS
FIBRO Mould Line Gas Springs: Keep your mould running well
I
f additional movements are needed in a mould, designers often rely on cam pins, compression springs or latch locks. Now there is an alternative from FIBRO: Mould Line, the gas spring for mould making. Gas springs are always the right choice whenever, for instance, another intermediate plate or a slide unit is to be moved parallel to the mould opening at the parting line. Benefits include, above all, pressure monitoring and simple force control. An additional aspect is the overload protection. Should a component, which is to be moved, be jammed – for example, a stripper or an intermediate plate in a 3-plate tool – latch locks can often pull until a component breaks. Not so with the FML Mould Line gas springs from the standard parts manufacturer FIBRO GmbH, Hassmersheim: Once it reaches the set force, it remains in position. Better yet: it can be used to diagnose a pending failure and replacement can be planned without having to interrupt production. A replacement can be installed whenever a break in production occurs. Used in conjunction with standardised elements for mould making, gas springs provide basically the same functions as a latch lock. They are placed, for example, behind the intermediate plate to be moved so that this plate is shifted by a certain distance during opening. Mould Line gas springs are characterised by their high force, their small size, a long service life of at least 1,000,000 strokes and a continuous op-
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erating temperature of 120°C. They are approved as per the European Pressure Equipment Directive 97/23/EG (14th GSGV ordinance on pressure vessels). In addition to technical advantages, there are also practical cost benefits: Various mounting possibilities ensure simple installation and the elimination of the lateral machining for the fastening of latch locks on the mould. This saves about two-thirds of the costs, according to the manufacturer. Advantages of Mould Line gas springs. • Minimal adjustment required • No lubrication required • No maintenance required for up to 500,000 strokes • Variably adjustable forces • Mould temperatures up to 120° C • Approved as per the European Pressure Equipment Directive 97/23/EG • A pressure monitoring system makes it possible to recognise an
impending failure at an early point (prevention) • No tool breakage, should the 2nd parting line lock (the plate comes to a standstill; after the removal of the jam, production can be resumed) • In all Cost savings of 60 -70 % versus a latch lock Additional information on Mould Line gas springs as well as technical data and mounting examples can be found in the new FIBRO Standard Parts catalogue for mould making.
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DER ANTRIEB Reliable. Versatile. Global.
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nord.com
TECH TRENDS
Sensorless standstill monitoring DOLD has released sensorless standstill monitor UG 6946 of the SAFEMASTER S series, with a width of only 22.5 mm, for detecting and signalling the standstill of machines
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uring maintenance and service work or the elimination of faults on machines and plants, intervention during the production process is often necessary. In many applications the access areas are protected by safety doors. The safety door must not be unlocked until moving parts of the system come to a standstill. Here the sensorless standstill monitor UG 6946 of the SAFEMASTER S series
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from DOLD, with its small width of only 22.5 mm, is the right choice. If there is no dangerous movement from the machine any more, the safety door can be released directly and within the shortest time when a standstill is detected. The sensorless standstill monitor UG 6946 can be easily retrofitted and is therefore also suitable for retrofitting. There is no need of additional sensors or encoders
so the installation is simple and cost-saving. The standstill monitor complies with SIL 3 or PL e/Kat. 4 and is used to enable a solenoid guard lock or activate a holding brake, e.g. for saws in woodworking, machine tools or conveyor technology.
For more information, Website: www.dold.com
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Tough by design – the safety solution that goes the distance.
Shocks, vibrations and collisions can’t always be avoided, even in a state-of-the-art production facility. Temperature fluctuations and dust are also just some of the typical challenges. So it’s a good thing that Pilz light curtains can take some punishment. Because the new PSENopt II range has been developed to guarantee machine availability even under demanding conditions. Having started with finger and hand protection, the robust system is no less convincing when it comes to body protection – as the world’s first Type 3 light curtain for use up to the highest category (PL e). In conjunction with the Pilz configurable, safe small controllers PNOZmulti 2 you can be sure you have a safety solution that goes the distance.
Pilz India Pvt&Ltd Pune,73760 India Ostfi Tel: +91 + 91 20 49221103 info@pilz.in GmbH Co. KG ldern20 4922 07111100 3409-0Fax:info@pilz.com www.pilz.com
TECH TRENDS
Ballscrews with Rotary Nut 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¬fied because it does not need support bearings. • Structure • 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/
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Bridge Type Machining Center/ Double Column Surface Grinder Ballscrews with Rotary Nut(Compact) – FSKT The Rotary Ball Screw is a rotary-nut ball screw unit in which a ballscrew nut is integrated with a support bearing. The support bearing is an angular bearing that has a contact angle of 60°.It is best suited for an application that requires rotation of the ball nut while the screw shaft is ¬fixed. Features • Compact and High Positioning It is a compact design using nut and
support bearing as an integral unit. Angular contact ball bearing makes a better axial load. Zero backlash and higher stiffness construction give a high positioning. • Simple Installation By simply mounting this model to the housing with bolts, a ball nut rotation mechanism is gained. And the timing pulley (prepared by the user) is directly secured to the end face of nut. • Simple Shaft End Configuration Shaft end con¬figuration is simple because this unit does not need support bearings. • Rapid Feed No inertial effect produced by the integral unit rotating and the shaft fixed. Thus in high slenderness ratio also rapid feed requirement and select smaller motor to drive. Application Semi-Conductor Industries/Robots/ Wood Machines/Laser Cutting Machines/Transporting Equipment… etc.
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Safe, sensorless speed monitoring Increase the productivity of your machines and the safety of your operators
SAFEMASTER STS Guard Lock
SAFEMASTER S For safety applications up to Kat. 4 / PL e, SIL 3 Sensorless and easy for retrofitting Fast response time For frequency controlled drives For encoders and initiators Over-, underspeed or window monitoring
Sensorless Standstill Monitor LH 5946
Sensorless Speed- and Frequency Monitor UH 6937
Speed monitoring is important for machine safety. Speed monitors from DOLD are used for over-, underspeed monitoring, they also allow for Safe Speed Range (SSR), Safely Limited Speed (SLS), Safe Torque Off (STO) and Safe Operating Stop (SOS). Usually speed and standstill monitors are combined with guard locks from SAFEMASTER STS. In machine applications the access areas are usually protected by safety doors. Unlocking a safety door shall only be possible, when moving machine parts are in a safe mode, allowing for maintenance and teach mode.
SIL 3 PL e
TECH TRENDS
Edge Finishing, Surface Polishing Machine and Process P30-1
P
30-1 Edge finishing machine is applied for tool edge finishing, surface polishing and aftercoating process. Edge Finishing (Rounding): Tool edge Finishing keeps highly consistent. According to roundness requirement, the Finishing process can generally be controlled in 1~20 minutes under the levelμ, highly maintaining Finishing consistency. Polishing: Tool surface polishing largely prolong tool life. 5-30 minutes’ tool surface polishing before tool coating can significantly reduce roughness of cutting groove and tool surface, thus to effectively improve the adhesion of tool edge coating, reducing the breaking probability and prolonging tool life. After-coating process: Clear particles to improve cutting efficiency. Micro-particles generate in the process of physical coating. After about 3-5 minutes polishing treatment, these particles can be completely removed (no impact on the coating result), reducing cutting resistance and improving cutting efficiency. It has Uniquely Designed Sandcontainer. Sand-container up-down
Easy changing chucks travel path can be automatically defined according to the tool length and passivation depth. It has Easy-changing of Sandcontainer. Sand-changing can be easily done by only one person. It has Program Modularization Design. One-time programming, recycle operating can be automatically invoked. Program integrated with sand type, passivation & polishing process It has Unique Integrated Driving Head. Different from separate structure, which shakes easily, the integrated driving head enables a more stable tool rotation and a better polishing integrity.
before
after
It has Fast-changing Connector for Automatic Chuck-locking, making it easy to change chucks. Suzhou Haller is a company specialized in the production and development of 5-axis CNC grinding machines. We have been dedicated to providing complete solutions of tool grinding since company established in 2014. We have German technology combined with over ten years’ tool machining experience in China, strong application ability and professional application training, excellent after-sales service to realize customers’ requests fully satisfied by grinding machine with German Design, European Quality and Built in China. For more information, Web: www.hawema-haller.com
Easy changing sandbox
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30pcs batch production
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TECH TRENDS
Simple support structure improves the efficiency of a warehouse packaging module
Though limited by challenging design constraints, N-III created a supporting structure that mounts underneath a distribution center packaging module, integrating an arrangement of plywood, aluminum extrusions and Rollon linear bearings.
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utomation is changing how traditional distribution centers operate as companies search for new ways to maximize their efficiency, increase order accuracy and fulfill customer demand. When it comes to automated technology, most people tend to think about robots, automated guide vehicles and pick-and-place systems. But just as important are the smaller, simpler structures that must be engineered to interface with the high-tech systems, and their designs present their own set of challenges. Rollon, a multinational company specialized in the production of linear, telescopic, actuators and automation systems, is well aware of this and developed specific experience in this field, operating internationally through a series of local branches, including the Bangalore office in India. Rollonâ&#x20AC;&#x2122;s experience has been useful to the American systems integrator N-III Inc. that recently devised a simple, yet large-scale solution to improve the efficiency of an existing warehouse packaging staging module. Though limited by challenging design
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constraints, the company created a supporting structure that mounts underneath the existing module and integrates an arrangement of plywood, aluminum extrusions and Rollon linear bearings, an achievement that required attention to ergonomics, ease of assembly and cost efficiency. Engineering Challenges In this recent application, an automated package distribution center was looking to improve its packaging modules. Each module is made up of four chutes that feed packages from the top of the system down to the station
The linear bearings used in the packaging module had to handle very high loads. A 150-pound package placed at the end of a table, for example, would create a 600-pound moment load on the supporting structure.
operator. The operator is notified of an order and, from there, can pull it out, package it and place it onto a conveyor belt beneath the chutes. The customer wanted to incorporate support platforms onto the design of this existing structure, which the operators could utilize to box the finished orders. A few solutions were initially proposed, including a scissor lift, drop shelf and a motorized, wheeled cart. However, all of these systems would operate apart from the existing module without having to mechanically interface with it. These ideas were ultimately scrapped because they were too costly or had ergonomic problems associated with them, requiring workers, for example, to twist, running the risk of injury. N-III ended up solving these issues with a simple design that connects to the module and even uses its existing bolt holes. For a work surface, the engineers created tables made of strong ply, which they capped with an ABS plastic. These ABS â&#x20AC;&#x153;topsâ&#x20AC;? were water jet cut and served as the template to rout the tables from the ply. The
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Linear solutions global provider.
Linear Line
Actuator Line
Telescopic Line
Actuator System Line
ROLLON India Pvt. Ltd. - INDIA 1st ďŹ&#x201A;oor Regus Gem Business Centre 26/1 Hosur road, Bommanahalli Bangalore 560068, INDIA www.rollonindia.in - info@rollonindia.in
Rollon is a global provider of linear motion solutions for several industrial sectors, such as: industrial machines, railway, automation, packaging and logistics, aerospace.
TECH TRENDS tables were then mounted onto a Rollon linear slider, which was mounted simply into a standard aluminum extrusion. From there, workers can slide a table along the length of the chutes to where it is needed—a taping station, for example. While there is one table per four modules, tables can travel freely across up to 12 modules, maximizing design flexibility and minimizing the number of tables that need to be installed. Structural Engineering Required The success of N-III’s solution is owed, in part, to engineers’ flexibility over the course of the design process. For example, it became apparent that the use of a 1 x 1-inch lateral bar would not be able to accommodate the moment loads created by the weight of the packages on the table-tops. A 100-pound package placed at the end of a table would create a 600-pound load on the supporting structure, pulling the bearing out of the rear track. To ensure that the system could hold up to these loads, engineers first ran a finite element analysis (FEA) test to analyze and compare system stress under loads using a 1 x 1 and 1 x 2 lateral bar. Whereas the 1 x 1 bar deflected, engineers discovered that the 1 x 2 bar could handle the high loads of the heavy packages. They therefore integrated this new component into their design.
N-III’s solution added only four inches to the vertical space between the module and the conveyor underneath.
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maintain a certain height so as not to impede the conveyor belt beneath the staging module once it was attached. N-III’s solution added only four inches to the vertical space between the module and the conveyor underneath.
The packaging module includes tables, which are made of strong ply and are capped with an ABS plastic. The tables were mounted onto a Rollon linear guide, which was inserted into a standard aluminum extrusion. Designed For Assembly N-III’s solution overcame several design constraints, all of which were dictated by the existing packaging structure. For one, engineers had to figure out a way to attach the tables to the structure without any additional drilling or the use of T-nuts. Besides being more expensive than the aluminum sliders themselves, logistically, incorporating T-nuts would have been a design nightmare. Instead, the engineers designed predrilled and tapped bars that, once inserted into the extrusions, readily aligned with the track’s 4,000 existing bolt holes. It was also important that the design
Cost savings Additionally, unlike the motorized, wheeled cart originally proposed, N-III’s final design included no complex moving parts. It integrated a simple, space- efficient structure that could be attached to the existing staging module, using the structural members, bolt holes and brackets from the existing the structure for seamless integration—reducing overall implementation costs by 40 percent.
For more information: Rollon India Pvt. Ltd. 1st floor, Regus Gem Business Centre 26/1 Hosur road, Bommanahalli Bangalore 560068, INDIA Tel: +91 80 67027066 Fax: +91 80 67027004 Email: info@rollonindia.in Website: www.rollonindia.in
ROLLON COMPACT RAIL COMBATS MISALIGNMENT Bearings that aren’t aligned properly during installation can cause problems on any precision machine, resulting in wear or even reduced bearing life. The Rollon Compact Rail system is inherently tolerant of misalignment, thanks to a rail geometry that can absorb alignment errors in one or two axes. Whereas ultra-high precision guides measure acceptable misalignment in arc minutes and microns, the Compact Rail measures it in degrees and millimeters. For example, Compact Rail rollers can rotate up to 2 degrees relative to the rail without affecting functionality or increasing wear. For machine builders, having a self-aligning system results in greater design freedom and cost reduction. Simple spacing tools make installing to the proper tolerance easy.
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TECH TRENDS
High IQ tools optimize metalworking in a digital world
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he digitization of manufacturing â&#x20AC;&#x201C; a key element of Industry 4.0 - is redefining production methods and the metalworking industry is taking note, despite its characteristic traditionalism. Metalworkers have started to adapt to this new environment by building or overhauling systems to facilitate more efficient processes. New demands have affected and influenced almost every element of a technology process: from planning and communication (networks) to machinery and even cutting tools, which are arguably the most conservative element in a manufacturing system. Cutting tool producers need to react appropriately and provide products according to these new requirements. Digitization in the cutting tool field has two emerging trends. The first trend is to enable the cutting tool to communicate with advanced machinery and cyber physical production systems in order to advise about tool wear, predictable tool life, total time of the tool involved in cutting etc. The second trend relates to information about the tool that should be provided by a cutting tool manufacturer. Manufacturers are expected to supply data about their products, and catalogs and guides have long been an integral part of the product itself. The challenge now is to include digital information as a necessary essential element of a cutting tool, which ensures applying tools in various steps of a production
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process, starting with virtual manufacturing. A good illustration is the ISO 13399 standard, which specifies computer representation and data exchange for information about the cutting tools and their holders - a first step for making the tool digital data platform-independent. Only tools digitally specified in accordance to this standard will be utilized by smart factories, making comprehensive digitized data sources an important direction for cutting tool manufacturers; this integration of data will form an inseparable part of a cutting tool. Cutting tool manufacturers will not
only improve their own production by implementing advanced technologies but will represent an essential link in a industrial information chain providing data for smart factories and engineering companies. ISCAR recognizes the central importance of developing and adopting digitized solutions for metalworking operations. MATRIX, an automated tool dispenser that is an integral shop-floor-level element of a smart factory, tool assembly options in 3D and 2D formats in E-CAT, ISCARâ&#x20AC;&#x2122;s electronic catalog â&#x20AC;&#x201C; these are a few examples of products intended to unify the
Fig 1 Tool assembly in ECAT
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TECH TRENDS material and virtual worlds of smart manufacturing. Virtual assembly In addition to the existing milling tool assembly option, E-CAT has enriched its instruments for virtual manufacturing by introducing a new assembly option that relates to drills and taps. This new function allows creating the twin representation of a drilling or tapping tool assembly based on the ISO 13399 standard (Fig. 1). The assemblies are accessible in both 3D and 2D files, which can be downloaded from E-CAT on the ISCAR website and incorporated directly to a user’s CAM system. As a result, various simulations of cutting operations, collision checking, finding an optimal tool configuration etc. can be performed. The simulations prevent or significantly diminish possible errors on the shop floor and help to save time and cut costs in process planning. Smart scan Data on ISCAR’s tool dimensions, inserts, appropriate tool holders and recommended cutting data is accessible via the ISCAR 4.0Pro mobile application, developed for maximizing tooling utilization.
ISCAR 4.0Pro is a smart 2D Matrix barcode scanner (Fig. 2) that acts as a digital gateway to advanced tooling resources of the company, so that customers can make better decisions regarding tool selection and their realization on the shop floor. The application provides quick access to technical data for each ISCAR product. The information corresponds to the ISO 13399 standard and to the tool assembly, cutting conditions, tool material grades, weight, user manuals, and other items. The data is accessible by scanning the 2D Data Matrix barcode, which appears on ISCAR tools and product packages. A world of information ISCAR recently launched ISCAR WORLD, an expanded application that embraces all ISCAR’s online apps, interfaces, and product catalogs in a single space (Fig. 3). The app gives instant access to E-CAT, ISCAR 4.0Pro, E-Commerce (an online tool ordering system), a media channel, ISCAR Tool Advisor – an expert system for tool selecting, technical data, machining calculations, frequently asked questions and more, enabling users to review, compare, check, and select the tooling solutions that are right for their
Fig 3 ISCAR WORLD app needs. The application constantly updates and expands its store of knowledge by collecting new data, opening a virtual doorway to a whole world of updated information. Smart manufacturing in the Industry 4.0 era features a combination of real and virtual worlds, based on network technologies, for every link of the manufacturing chain including cutting tools. Advanced manufacturing systems require cutting tools to “possess” a rich world of relevant data – a high IQ - as a necessary condition for incorporating the tool into their intelligent machining processes.
For more information,
Fig 2 ISCAR 4PRO
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Website: www.iscar.com
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TECH TRENDS
Precision displacement measurement using draw-wire sensors Micro-Epsilon offers draw-wire sensors in many different variants, sizes and forms that are ideal for integration and subsequent assembly in high volume OEM applications
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isplacement measurement using draw-wire sensors can be compared to taking measurements with a tape measure. For more than 60 years, wire has been used to measure position and distances between 50mm and 50,000mm. Draw-wire sensors from Micro-Epsilon are ideal for integration and subsequent assembly in high volume OEM applications. These sensors are available in many different variants, sizes and forms. Their extremely small sensor size is a unique characteristic. The most compact model, for example, is just 30mm in size with a measuring range of 750mm. Many different analogue and digital outputs are available, as well as housings made from plastic or aluminium. As only high precision components are used in its design, the sensors benefit from a longer than average service life. Wherever distances and tilt angles need to be measured by contact, draw-wire sensors are ideal. wireSENSOR measuring principle Draw-wire measurement is a contact measuring technique. A draw-wire sensor fundamentally consists of wire, a drum and a spring-driven motor (referred to as mechanics) and a potentiometer or encoder for the generation of measurement signals. Draw-wire sensors are used when large measuring ranges are required using a low cost compact sensor. Typically, the wire is made from extremely thin steel, which is, depending on the respective version,
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Displacement measurement using a draw-wire sensor is comparable with tape measurement. polyamide-coated. On average, the wire is approximately 0.8mm thick, depending on the load. From movement to an electrical signal Using a draw-wire sensor, a linear movement is transformed into a rotary movement. The free end of the wire is fixed to the moving object. At the open end of the wire is an eye that can be fixed or hung from the measurement object. An encoder subsequently translates the rotary movement created by the extension
of the wire into an electronic signal. A spring-driven motor provides sufficient wire pre-tension. This is a coiled spring with torque load similar to clockwork mechanics. The more the wire is pulled out, the higher the tension force of the spring. This has the advantage of reducing wire sag in horizontal set ups. A typical example of retrofitting is the mounting of the sensor on the supports of elevating work platforms or truck-mounted cranes. Cranes often have to move heavy loads in their working range, which can be
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TECH TRENDS up to 100 metres. Due to this wide lift distance, fixed limits are specified for the permitted load torque, which is defined by the load capacity and the length of the boom. These limits must be complied with in order to guarantee the safety of the crane. For this reason, truck-mounted cranes have lateral supports, which extend the footprint of the crane. If possible, these supports are fully extended in order to use the maximum footprint. However, in some situations, for space reasons it is not possible to fully extend the supports, whereby the permitted load capacity of the telescopic boom is unexpectedly reduced. In such situations, up to now it has not been possible for a crane operator to operate the crane, as this only functioned with fully extended supports for safety reasons. It is a legal requirement that operation of the crane with load torque limitation. A well-known German manufacturer of truck-mounted cranes installs
Draw-wire sensors are used in forklift truck in order the measure the optimal lift height determining the ideal travelling speed.
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draw-wire sensors from MicroEpsilon as standard for its working platforms, in order to make working possible in confined spaces. There are two sensors on each support. The sensors notify the crane controller how far the support has been extended. The maximum permitted load torque is determined using other measured values, such as the hoist capacity and the length of the boom. The crane only lifts the load if the permitted limit values are complied with. This rules out that the crane will tip over due to overloading of the boom when the supports are not fully extended. Lift-height measurement in forklift trucks Logistics is critical today and will be even more important in the future. Increasing supply chains of goods must be shipped and transferred in ever-shorter time periods. As a result, logistics service providers are attempting to shorten the transfer times in the warehouse and to optimise warehouse movements. Here, a high level of potential optimisation can be exploited by applying displacement sensors in forklift trucks. Typically when raising and lowering the load, large safety margins must be observed, so that when rounding a corner, or braking and accelerating suddenly, the truck is not placed in a dangerous tilted position. If the lift height of the load can be measured, the optimum driving speed can be determined from this. In addition, the system is protected against erroneous operation, i.e. the operator cannot knowingly or unintentionally cause critical driving conditions. This then optimises the speed but also improves the safety of the operator. Furthermore, the sensor can also be used to automatically bring the load
In truck-mounted cranes, drawwire sensors determine how far the supports have to be extended in order to guarantee safe crane positioning. to the correct lift height in order to speed up the movement to the correct shelf height. The manufacturer of this innovative forklift truck relies on draw-wire displacement sensors from Micro-Epsilon. They are specially adapted to the requirements on the forklift truck. An especially flat design has been chosen which enables the sensor to be used in restricted installation spaces. For safety reasons, the sensor is designed redundantly. Two electrically independent signals ensure that a high level of safety is achieved.
Author: Dipl.-Ing. Thomas Birchinger Thomas.birchinger@micro-epsilon.de Website: www.micro-epsilon.com
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TECH TRENDS
Access permission plus operation mode selection now modular - fusion of safety and security
The modular operating mode selection and access permission system PITmode combines safety and security in one system.
With PITmode fusion, Pilz now offers a modular operating mode selection and access permission system. The modular system is characterised by more flexibility for functionally safe operating mode selection and for the control of access permissions to plant and machinery. This way, PITmode fusion enables efficient operation mode selection and access permission management that covers both safety and security specifications.
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he new PITmode fusion from Pilz consists of the reader unit PITreader with RFID technology and integrated web server and a Safe Evaluation Unit (SEU). Its modular design allows PITmode fusion to be integrated individually into the design of existing control consoles. Existing pushbuttons can be used, enabling better operation for the user. PITmode devices are used on plant
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and machinery in which you switch between a range of control sequences and operating modes. Access only with permission! Authorised users receive the machine enable suited to their individual task on a coded RFID transponder key. You can define up to five safe operating modes, such as automatic mode, manual intervention under restricted conditions or service
mode. The key is inserted into the control console, the SEU detects the specified operating mode and PITreader ensures functionally safe switching. So accidents, misuse and manipulation are prevented. Users benefit from higher availability of their machines. â&#x20AC;&#x153;Security plusâ&#x20AC;? The RFID keys are read and taught
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TECH TRENDS in the PITreader. To increase protection against manipulation, they can be coded with companyspecific programmed PITreaders, that is, the keys include a passwordprotected signature. Any keys that do not have company-specific coding will be denied access. In addition, RFID keys and PITreader can be used to implement a groupbased permission management. In this case the various enables are transferred to whole groups with the same access permissions instead of individual persons. This simplifies the assignment and administration of access permissions, particularly with companies in several locations, including internationally. The administrative effort is reduced and time will be saved. Open for further tasks You can use PITmode fusion to
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implement a wide range of functions beyond access permission and operation mode selection. It may be a simple enable that replaces a key switch at the control console, or access permission for machine subfunctions. On top of that, a complex hierarchical permission matrix with various groups and permissions can be created in the free user area. These functions are bundled on the RFID key, replacing additional mechanical keys or access cards. This will make handling easier for the user. Flexible to use versions Two other versions of the PITmode are available in addition to the modular version. PITmode is a compact all-in-one device that includes the pushbuttons for operating mode selection and the SEU, which enables a space-saving
installation. The reader unit PITreader can be used to control access permissions, and is particularly flexible as a standalone device or in conjunction with a Pilz controller such as the configurable small controller PNOZmulti or the automation system PSS 4000. PITmode and PITmode fusion offer functionally safe operating mode selection and access permission up to PL d.
For more information, Website: www.pilz.com
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TECH TRENDS
Schmersal produces AZM300 with innovative Plasma-SealTight速 technology for the first time New manufacturing process for plastic-metal bonds is being tested in first industrial application
Schmersal produces the AZM300 solenoid lock using innovative Plasma-SealTight速 technology for the first time.
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new, innovative process to manufacture plastic-metal bonds is currently being tested in an industrial application. Plasmatreat GmbH has developed a process for hybrid injection-moulded parts in cooperation with the plastic compound manufacturer AKROPLASTIC GmbH. This new process provides a significant improvement to bonding in hybrid plastic-metal components and can be integrated into series production lines. The Schmersal Group is now using this innovative Plasma-SealTight速
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technology process for the first time in a pilot project to produce its AZM300 solenoid lock. Used on safety doors, this interlock features a metal bracket integrated into a plastic actuator. The bracket engages with an interlock cross-head to ensure that safety doors are securely closed. A reliable, firm bond is crucial during the joining process to produce a high-quality, resistant joint between the dissimilar materials plastic and metal. In a plastic-metal bond, interfaces without a special seal represent a constant contact surface
where water, air or other media ingress. The Plasma-SealTight速 plasma seal process developed by Plasmatreat and AKRO-PLASTIC offers a completely new approach to providing a highly bonding, media-resistant hybrid joint. In this new industrial solution, the plastic compound formula, the process parameters, and the composition of a plasma-polymer seal layer created under atmospheric pressure were matched to one another in such a way that they would create a durable, media-tight bond in the component.
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TECH TRENDS them even more efficiently.
A firm bond is crucial to ensure quality in plastic-metal hybrid components. The advantage of the new process is that it not only achieves better product quality, but also a reliable, reproducible, cost-efficient production process with the added bonus of respecting the environment. Thanks to the Plasma-SealTight® technology, there is no need to apply cost-intensive, environmentally harmful chemicals to metal surfaces. Such chemicals are often used to create a firm bond with the help of solvent-based adhesion promoters. The AZM 300 is an innovative safety interlock which is now used in many sectors of industry. AZM 300’s outstanding features include a new patented operating principle with a hub and cross-head. It brings the advantage that the safety door is pulled into its end position when closed and is securely locked free of almost any clearance. The solenoid interlock operates as an integrated guard catch, hence removing the need to fit a separate catch. An RFID sensor is used to identify the actuator reliably, thus providing three different code levels and, consequently, protection against manipulation. After the new process has proven its worth in the pilot project, Schmersal intends to use it in both new and existing products, thus producing
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About the Schmersal Group The Schmersal Group is an international market and expertise leader in the challenging field of machine safety. With the world’s most comprehensive range of safety switchgear products, the Schmersal Group develops safety systems and safety solutions for special requirements in a variety of user industries. Schmersal’s tec. nicum Business Division offers a comprehensive service portfolio to complement the range of solutions offered by Schmersal. Founded in 1945, the company is represented by seven manufacturing sites on three continents with its own companies and sales partners in more than 60 countries. The Schmersal Group employs some 1,850 people worldwide and generated a group turnover of around €240 million in 2018.
For more information www.schmersal.com www.tecnicum.com
About AKRO-PLASTIC GmbH Originally founded 30 years ago, AKRO-PLASTIC has formed part of the Feddersen Group since 2004. AKRO-PLASTIC has grown steadily ever since and today produces more than 100,000 tons of plastic compounds at its production facilities in Germany, China and Brazil. The company operates in an international network, which is able to provide services ranging from development through to logistics. AKRO-PLASTIC uses the globally standardised compounding and extrusion technology ICX®, which
it developed in cooperation with its sister company FEDDEM. AKROPLASTIC GmbH and its subsidiary AF-COLOR develop and produce engineering thermoplastics and master batches in Niederzissen, Germany. In 2014, the portfolio was expanded to include bio-plastics and the BIO-FED subsidiary was founded at the Cologne location. AKRO-PLASTIC GmbH operates other production sites worldwide – in Suzhou, China, for the Asian market, and in São Paulo State, Brazil, in South America. For more information www.akro-plastic.com
About Plasmatreat GmbH Plasmatreat was founded in Steinhagen, near Bielefeld, Germany, in 1995. On developing its Openair® Plasma technology, Plasmatreat established itself as a leading manufacturer and supplier of plasma systems and a globally active provider of surface technology services. After acquiring Plasma Technology Systems LLC in the US, the company widened its expertise to include Aurora lowpressure plasma technology. Plasmatreat applications are mainly used in industrial microfine cleaning, surface activation and plasma coating on surfaces made of materials such as plastics, metals, glass, cardboard, textiles and composites. With more than 225 employees at 34 locations, the Plasmatreat Group has a presence worldwide and provides guidance and support to customers in almost all manufacturing industries – automotive engineering, transportation, electronics, packaging technology, consumer goods, life sciences, textiles and new energies. For more information www.plasmatreat.co.uk/
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AEROSPACE INDUSTRY Despite various turbulence aviation still expected to outgrow slowdown A global economic slowdown is affecting almost all the sectors including the aviation industry. However, the saving grace is tourism which is still growing albeit slowly and is expected to drive growth in aerospace industry. Article by Arijit Nag
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ince 2018 the aviation or aerospace industry has taken a turn for the worse. The first jolt to the industry came on October 29, 2018 when a Boeing 737 Max 8 belonging to Indonesian domestic airlines Lion Air crashed. A second 737 Max 8 of the Ethiopian Airlines crashed within five months on March 11, 2019 leading to a huge crisis in the aviation industry. The planes were grounded a few days later following the Ethiopian crash and till date have not been allowed to fly again. So far there have
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been multiple delays in putting the planes in the air. This has resulted in hundreds of flights being cancelled across the world. The problems have been compounded as uncertainty regarding the Max 8’s return to air continues. However, a tentative time frame is being touted by Boeing that the Max 8’s are going to be pressed into service from March next year but how far that will come true can only be known in January 2020. Starting from Norwegian Airlines to Ryanair, every airline company had to juggle with their figures. While
Norwegian Airlines has said that its operating expenses have been severely impacted by the grounding of the Max 8 fleet, Ryanair has cut down its growth figures from seven per cent to three per cent. Meanwhile, in the USA, Southwest Airlines reported that delays in the return of the Max 8’s to flying have cost the company $435 million. Something similar happened in India when arguably the most professionally operated airline company in India, Jet Airways, filed for bankruptcy earlier this year. The
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TECH TRENDS entire schedule of flights went for a toss, flight routes went haywire and flight tickets shot through the roof. Jet Airways’ slots, which are integral to operating an airline, were allocated to SpiceJet quite promptly. The revival efforts and procedures of Jet Airways were clearly sabotaged by the government itself. Although other Indian airline companies came forward to fill up the gap left behind by Jet Airways things continued to remain topsy-turvy. Routes got truncated, schedules were re-arranged and ticket prices shot through the roof as number of seats shrank. Meanwhile, as the global aviation scenario continues to go through turmoil, International Airlines Group, the owner of British Airways, have decided to buy Spain’s Air Europa for $1.2 billion. This development comes at a time when the aviation industry worldwide is facing high-profile failures, fierce competition, economic woes and high fuel prices. Through this acquisition, IAG will be adding another cost-effective airline to its bouquet of aviation companies. This will also help IAG to better cover the Latin American and the Caribbean sectors. Just a few days ago the air transport associations and the hotel associations of the sector had converged in Rio De Janeiro to deliberate upon ways to augment connectivity. Meanwhile, at the recently held Amadeus Airport IT conference experts and stakeholders deliberated upon technological trends that will dominate in the near future in the aviation space. Speaking at the conference, Frost & Sullivan’s aerospace director Diogenis Papiomytis stressed that automation, machine learning and artificial intelligence will become the key drivers for airports in the future.
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Data is the new oil! Underscoring some of the megatrends that have already been implemented in various airports across the world, Papiomytis said 5G has changed the way data is communicated. “Better connectivity is not only improving productivity but it is upgrading operations in more ways than we can imagine,” he added. Over the past couple of years, as the speed of data communication has escalated, he said big data and prediction analysis will be integral to making airport operations smoother. The amount of data being created by passengers and airport companies today is growing at a “terrifying” rate, according to Papiomytis. “Data will transform our lives in ways that we cannot even imagine because [data generation] has grown from one gigabyte to one terabyte per second,” he added. Papiomytis further stated that more than two-and-a-half million terabytes of data are being produced every day, and that data is “being communicated real-time from human-human, humanmachine and machine-machine”. And processing this humongous amount of data will be the driving force of the aviation industry. It may sound clichéd but the fact remains that the aviation sector will be facing enormous challenges in the days to come. The number of air travellers all over the world is growing exponentially. It is expected that air traffic will double by the next 50 years. Contrary to common perception millennials are largely a digitally native demographic and expect much more when travelling. In order to meet these demands, the aviation industry must alter their business models through the integration of services by collaborating with other companies in different industries. In another development, in a bid to improve the travel experience of
passengers, airlines and airports spent a record $50 billion in 2018 on IT. As a result, passengers are beginning to enjoy the benefit of that investment. Data published by SITA show that this investment has resulted in a significant improvement in both the satisfaction levels for passengers and average processing time. The SITA 2019 Air Transport IT Insights published recently, show that 60 per cent of airline CIOs recorded up to a 20 per cent yearon-year improvement in passenger satisfaction. During the same period, 45 per cent of them recorded up to 20 per cent improvement in the number of passengers processed. These strong returns on investment in technology were also seen at airports where 63 per cents of CIOs reported a year-on-year improvement of up to 20 per cent in passenger satisfaction levels while 44 per cent recorded quicker passenger processing times. The current SITA report shows that the aviation industry has continued to increase its IT spend, reaching $50bn in 2018. This was driven in part by a sharp increase in airline IT spend after several years of almost flat growth. Total IT spend for airlines as a percentage of revenue rose to 4.84 per cent while airport IT spend grew to 6.06 per cent of revenue in 2018. Projections for 2019 show investments will continue to grow. The global economic slowdown may affect the aviation industry but it may not be for a very long period as so far the tourism industry has continued to grow. This growth of the tourism sector is expected to neutralise a majority of the negative impact on the aerospace industry. Article by… Arijit Nag is a freelance journalist who writes on various aspects of the economy and current affairs.
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TECH TRENDS
Auto sector plunge continues as demand remains slack, govt policies misfire As the country goes through an economic slowdown the auto sector seems to be witnessing one of its worst phases. Compounding the demand shrinkage are the misguided government policies portraying a bleak scenario for the days to come. Article by Arijit Nag
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ver the last year or so the automobile sector has been going through an extremely rough phase. If one goes by the numbers emanating from the industry, it’ll seem as if things have turned really grim. The slowdown has hit the sector so hard that even the arrival of the festive season has failed to revive it even partially. Almost all the major carmakers have cut down on production. Even heavy vehicles and two-wheelers have witnessed a major slowdown in sales. Auto companies like Ford Corp., Hyundai Motors, Tata Motors, Maruti Suzuki, etc. shut down production in
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more plants than was expected. An unheard of concept – nonworking days – was introduced to the Indian auto sector. This affected the contractual workers the most as the term meant the plant will remain open but there won’t be any work done. The September results continued to look dismal. Tata Motors registered a drop of 48.02 per cent in sales, according to a report in The Hindu. On a year-on-year (YoY) basis, -Maruti Suzuki India – the passenger car market leader, reported a 24.4 per cent decline in its total vehicle sales, including exports.
A total of 122,640 units of Maruti, including exports, were sold in September, compared to 162,290 vehicles sold in September 2018. Out of the total sales, domestic sales fell 24.8 per cent to 115,452 vehicles. The auto major’s exports in the same month were recorded at 7,188 units, 17.8 per cent lower than 8,740 units exported in September 2018. Another auto major, Hyundai Motor India (HMIL), also reported a fall of 8.1 per cent in its overall sales from 62,757 units in September 2018 to 57,705 units in the same period this year. Interestingly, the company’s exports registered a growth of 13.5 per
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TECH TRENDS cent but it didn’t reflect in the overall results as its domestic sales plunged by 14.8 per cent. The situation of the commercial vehicle sector is even worse where sales dipped more than 62 per cent last month. Tata Motors sold only 8,097 passenger cars in September, which is a decline of 56 per cent compared to the same period last year when the company had sold 18,429 units. Furthermore, Mahindra & Mahindra’s automotive sales went down overall by 21 per cent in September 2019 to 43,343 units compared to 55,022 vehicles in the same period last year. Having said all that there was some positive impact of the recent policy changes made by the government. Sales momentum during August 2019 did move up marginally, however, most market observers opined that more time was required for the recent policy measures to take effect and extra incentives need to be given to customers for the growth trend to reemerge. In an apparent effort to boost consumption and increase investments by private companies, the government reduced corporate tax rate from 30 per cent to 22 per cent. The effective tax to be paid by the companies will be 25.17 per cent. However, in my opinion the government measures are slightly misdirected. Instead of equipping the consumer with the necessary buying power, the measures focus on the supply side. The problem is – if the consumer does not have the resources how will he buy anything? No matter what we proclaim about our consumption pattern, buying a car in India is still a status symbol. Hence, the priority of owning an automobile in an Indian’s life is still way below many other things.
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However, sales plunged once again in September as passenger car off-take went down by 23.69 per cent and that of commercial vehicles by 62.11 per cent. This proves that government measures have not really helped the ailing sector. Maruti-Suzuki, the country’s largest automaker has cut down production for the eighth time in as many months. Seemingly, the government is missing the woods for the trees. This is evident from the statements emanating from the Union finance ministry. The Union finance minister blaming the millennials for the downturn does not only show a lack of understanding but also a blatant trivialising of the problem. According to most economic experts, things won’t change in the near future and definitely not in October. Unless the demand side is reinvigorated chances are bleak that things will look up for the automobile sector. Another point to be noted is that while we are focused on the production of automobiles we seem to have become distracted from the auto ancillary industry. This segment witnessed an overall decline of around 10 per cent and job cuts of approximately eight to 10 lakhs. The captains of the ancillary industry don’t expect any relief in the immediate future. However, there is a streak of good news amidst all this gloom. According to data from TAM, there has been some growth in auto advertisements in the southern parts of the country. In the four major southern states of Andhra Pradesh, Tamil Nadu, Kerala and Karnataka, automobile ad volumes have shown a hefty hike in print media. Festive ad volumes from automobiles in print media showed a 3.3 times growth this year as compared to Onam 2018.
The rise in ad volume is led by tyres that have shown 8.7 times increase in print compared to Onam in 2018. In TV, tyres saw 7.9 times growth against the same period last year, and for radio it was 11.1 times growth. Meanwhile, all three financial institutions namely, Reserve Bank of India, World Bank and International Monetary Fund, have cut down on India’s growth figures drastically. While RBI has projected the GDP growth to be 6.1 per cent down from 6.9 per cent which the apex bank had predicted in April this year, the World Bank has projected six per cent, down from 7.5 per cent. The IMF forecast is a little better at seven per cent which is still considerably lower than its earlier figures. People seem to be getting euphoric over the surge in the stock markets after the government slashed corporate taxes. What nobody seems to realise is that buying or selling shares do not boost industrial activities or produce physical assets or generate employment. A share market boom can happen even when foreign institutional investors pour in money into the exchange. Stock markets are not really a very good indicator of an economy. It is unlikely that the economy will turn around any time soon in the face of global slowdown and misdirected policies. To revive the auto sector mere tax cuts won’t suffice, the demand has to be rekindled to offload inventories. We can only hope the government will do something to revive the demand side of the economy in the next few months.
Article by… Arijit Nag is a freelance journalist who writes on various aspects of the economy and current affairs.
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TECH TRENDS
Automation in sheet metal cutting and welding The paper examines welding and cutting process trends in the sheet metal and plates used in various industries like automobiles, infrastructure, ship building, aerospace industries, wind tower manufacturing etc. Productivity gains in arc welding are reviewed, and the increasing use of laser cutting and welding, as well as laser-arc hybrid welding, particularly in Europe, is discussed and explained. Some friction technologies are already widely adopted, but they could make more impact with further development. Electron beam welding could also be used with economic benefit in some situations, but as with all non-arc processes, it will only be adopted if significant gains in productivity and cost reduction can be created to justify the more specialist welding equipment required. Many productivity improvements can come from non-welding activities in the fabrication process. 1. INTRODUCTION Leadership in manufacturing (welding and Cutting) can come from addressing the factors of QUALITY, COST, PRODUCTIVITY, SAFETY and CONTINUAL UPGRADATION OF TECHNOLOGY. Inflection in Metal Fabrication Technology has taken place in the Manual / SemiAutomatic Welding Power Sources - (Digital control inverters), Welding Automation - (Developments in HNG SAW, HNG MIG, Tandem MIG / SAW, Friction Stir, Electron Beam, Saddle Welding Automation, Robotics, Laser spot welding, Hot wire TIG, Orbital systems, automation with hybrid welding systems like Plasma â&#x20AC;&#x201C; MIG, Laser - MIG) and major advances in the cutting processes (Precision Plasma, Laser Cutting, Water-jet cutting etc.). This paper reviews current trends in arc welding and cutting processes used for Sheet metal processing and will discuss some of the newer processes which are beginning to replace arc welding for such steels, or have potential to do so in the next 10 years. 2. ADVANTAGES OF AUTOMATION a. Consistency in weld result - Error Proofing: A welding supervisor can limit the amount of changes an operator can make during a program,
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b.
c.
d.
e.
preventing him from accessing the override screen through the use of a key switch or password. Multiple parameters for multiple weld-run: In addition to the ability to adjust parameters between weld passes, operators of microprocessorbased welding machines can also program changes to weld parameters during each pass, which offers distinct advantages for certain applications. Store parameter for sharing on other machines with same applications: A microprocessor-based power source can store programmed welding procedures on data cards. This allows the operator to easily transfer programs developed on one machine to other machines being used either in the same facility doing the same type of work. Quality control: Microprocessorbased machines can immediately alert the operator if weld parameters fall outside pre-selected limits. Parameters can be directly to a quality-control computer program for storage or statistical analysis. This eliminates time-consuming radiography in many applications. Date storage and records: It is now very easy to display a set of welding parameters and operator or supervi-
sor can observe the welding procedure. Moreover, the data can be printed in the form of reports, which can be presented to the customer as quality assurance procedure. f. Quicker Weld-Fault diagnostics lower repair time: The system can be stopped if the measured values cross a certain preset variation limit. It is possible to stop the machine in out-of-tolerance conditions. This enables the operator to perform timely functions and take necessary steps to prevent the deposit of faulty welds. 3. TANDEM MIG AND ROBOTIC WELDING Significant improvements in productivity are nowadays hard to gain in this mature process. In gas-shielded MIG/MAG processes, the growth of tubular wire over solid wire is still slow despite the deposition and bead shape benefits of the former although tubular wire usage is higher in the USA and Japan compared to other parts of the world. The lower price of solid filler wire, particularly in Europe, is still a dominant factor that continues to favour their use. Self-shielded cored wires are still widely used in the USA but less so in Europe because of the fall-off in fabrication of large offshore
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TECH TRENDS installations. Care is always needed in selecting self-shielded wires if weld metal toughness is a critical design factor. Schematic of Equipment for TANDEM MIG
new robot installations per annum, but generally robot take-up for welding is still majorly for the automobile sectors. Robots are being employed in situations where product repetition and/or tonnage throughput are high, combined with relatively standardised designs. Robot profile cutting is increasing in usage and in Japan, some building frames are now being welded on robot lines and agile robots are also used for site welding building column joints at height. The applications most suited to robot use involve butt and fillet welds in the fabrication of beams, welding of stiffeners to beams, welding of end plates and the assembly of panels or decking. A likely trend is to ‘take robots to the work’ and use them for large part and sub-assembly manufacture in cells which house autonomous vehicular robots. These robots, mounted on moving platforms are manoeuvred around the parts to be welded and are capable of all-positional welding using the MAG process with tubular wires, (Fig.2).
Fig. 1: TANDEM MIG
Advantages of TANDEM MIG: • Exceptional welding speeds • High weld metal deposition rate • Superior weld quality: » Reduced heat input » Resists burn-through on thin materials » Maintains low spatter levels » Produces good penetration on thick materials » Improves bead wetting at weld toes » Resists undercut • Bead profile control • Lowers production costs • Increases productivity The greatest potential for productivity improvements comes from using robots. Japan still leads the work in
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Fig.2. Schematic diagram showing autonomous robot vehicle navigated by vision system, being used for all positional MIG / MAG welding
4.NARROW GAP SAW In submerged arc welding, multi-wire, iron powder additions and narrow gaps are common ways to increase productivity. However, the use of tubular wires is increasing in popularity and can offer better weld quality compared to solid wires in some situations, e.g. when submerged arc welding of primed plate. In building and bridge construction MIG/MAG welding is
more suited to automation and is now beginning to replace submerged arc welding, reducing costs and distortion significantly. 5 . LASER – IN CUTTING AND WELDING Low power CO 2 lasers were originally developed in the late 60s for cutting and welding operations, while Nd: YAG lasers entered the market only in the early 1980s. In the shipbuilding and off-road vehicle sectors, higher power lasers (3-10kW CO 2 and 2-4kW Nd:YAG) have become popular in the last decade because their use brings more precision in dimensional control, and greater accuracy in assembly, as well as the additional advantages of high cutting and welding speeds, and cleaner working. Laser cutting is now an essential route to accurate assembly in steel fabrication. Parts can be cut to a precision of ±0.3mm in 10 metres compared to ±1-2mm for conventional plasma cutting. Sub assemblies can then be arc welded to tolerances of a few millimetres in 15 metres, with the same lasers being used for marking and hole drilling on the cutting table. Even though arc welding is still regularly used for assembly of laser cut parts, cost reductions can be dramatic because of the improved accuracy of assembly and the potential for eliminating distortion correction and other processing operations downstream from welding. Direct costs have been cut by up to 50% using lasers for cutting in many shipyards, and this shows the extent of benefit which could follow from more widespread use of laser cutting in building, bridge and public infrastructure construction.
Fig.3. A typical laser welded sandwich panel and advantages over conventionally stiffened panels
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Fig. 5.Schematic diagram of the FSW process: (A) Two discrete metal work-pieces butted together, along with the tool (with a probe). (B) The progress of the tool through the joint, also showing the weld zone and the region affected by the tool shoulder.
Fig.4a. Nd:YAG laser - MAG hybrid process being developed for land pipeline girth welding. Picture of the welding head
Fig.4b. macro section showing MAG root and cap beads & central hybrid weld bead
6. LASER-ARC HYBRID WELDING There is tremendous interest in the use of CO 2 laser-arc or Nd: YAG laser-arc for steel construction at the present time. The concept has been around since 1978 and was actively developed in Aachen in the late 90s using high power CO 2 lasers in combination with one or two MAG torches directed into the same weld pool in series with the laser. Already one shipyard in Germany has such a system in production on a panel line, the process replacing submerged arc welding. The advantages of moving from simple arc processes to a hybrid laser-arc system include higher joint completion rates and associated control of distortion. As noted above, laser systems alone are usually not suf-
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ficient to cope with variations in joint gap in large structures. However, where plates are thin, it is possible to produce stiffened panels successfully by laser welding. 7. FRICTION TECHNOLOGIES There have been many exciting developments in friction welding and probably more process innovation in the last decade than in the previous 40 years when friction welding first came on the scene. In the context of metal joining and construction, friction stud, radial friction and friction stir welding are good examples of more recent approaches, with friction stud already being used in the production of sandwich structures comprising steel skins and a concrete core and for welding attachments in high volume such as shear connectors and reinforcing bars to end plates. Attachment of anodes under water to offshore installations using steel studs and electrical connections to railway lines are other applications of friction stud welding.
Automotive, Railway Rolling Stock, Fabrication 8. ELECTRON BEAM TECHNOLOGY There have been several key improvements in this process in the last decade which have made EB welding increasingly attractive for large-scale fabrication of steel structures such as buildings and bridges. The two main areas of improvement are in gun development and reduced pressure technology.
Reduced pressure electron beam welding system Reduced pressure EB welding using
APPLICATIONS Shipbuilding and Offshore, Aerospace,
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• RS-RT mmNm. centres. • RD worm helicalgearboxes: gearboxes:2850toto150 2300 Two and three stages. One stage worm, and double • RN parallel shafthelical/worm gearboxes: 180 to 3300 Nm.worm. Two and three stages. • RD helical gearboxes: to 2300 Nm. andNm. three stages. • RO-RV bevel/helical50 gearboxes: 180 Two to 3300 Three stages. • RN shaft gearboxes: to 3300 Nm. and three • parallel RG precision planetary180 gearboxes: 10Two to 230 Nm. stages. • RO-RV gearboxes: 180 to 3300 Nm. Three stages. Onebevel/helical and two stages. • RG precision planetary 10 to 230 Nm. • VR dry friction speedgearboxes: variators: IEC63 to IEC90 One1and stages. to 5two stepless speed range, 300 to 1500 rpm. • VR• dry friction speed variators: IEC63 to to IEC90 VS planetary speed variators: IEC71 IEC112 1 to15tostepless speed range, 300200 to 1500 rpm.rpm. 5 stepless speed range, to 1000 • VS planetary speed variators: IEC71 to IEC112 1 to 5 stepless speed range, 200 to 1000 rpm.
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TECH TRENDS
chamber pressures of around 1mbar has been another major step forward in simplifying EB welding operations. The beam shape and beam penetration at, say 5mbar, is identical to that at the more conventional pressure for EB welding of 5 x 10 -3 mbar. This reduced pressure option does away with the need for large vacuum chambers and worries about leaks and seals. Simple mechanical pumps and local seals are sufficient to achieve ~1 mbar. These systems are also more tolerant to fluctuations in working vacuum pressure, gun to work distance and work-piece cleanliness. 9. WIND TOWER MANUFACTURING – SPECIALIZED CUTTING AND WELDING PROCESS APPLICATIONS Wind Tower fabrication employs extremely precision applications of metal cutting and welding processes like gas cutting triple torch, with Single pass three torch cutting Automatic setup which provides High accuracy, Capacitive height adjustment, Infinite rotation of cutting head, Automatic angle adjustment 20 - 50° (Option for 30 - 60°). In addition, plasma cutting system is used with Automatic Setup, Highest Accuracy, and Bevel angle adjustment: +/- 52°, Initial height setting with tactile sensor, Cutting height adjustment via automatic arc voltage sensing process.
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Precision High end CNC Plasma cutting process is utilized with high degree of automation needed to guarantee consistent quality. Programming software, Numerical control and Automatic rotating bevel tools are used to dispense with manual tasks. Automated SAW systems with Twin Wire, Tandem, Tandem – Twin and Multi – wire systems are used along with customized welding heads, wire feed systems, joint tracking systems, Column and Booms, TELBO systems, Rotators and Positioners. In addition, Tractors and Fit – up units are all used for this application and also for many other welding applications. 10. CONCLUDING REMARKS Where will engineering construction be in five years time? Productivity improvements can come from many different areas in the total fabrication process, e.g. general design, detailed
design, contract drawings, CNC instructions, cutting and profiling, welding, inspection, finishing etc. It needs to be realised that optimising the welding process and procedure in isolation may have only a small effect on overall productivity. As an example, fabricators in the bridge and building sector continue to make big improvements in reducing the cost per tonne of steel fabricated by focussing on efficiency improvements in non-welding operations. These non-welding areas will continue to receive much attention in the next few years. For example, 3D solid modelling is expected to be at the heart of the improvement process enabling virtual assembly, direct instruction of cutting and welding machines, computer modelling of metal processing and welding operations and optimising of welding sequences. In addition automated inspection and data gathering will increase in usage to give more comprehensive Quality Assurance. Productivity improvements could also come from greater standardisation in steel specifications and in joint details and from modularisation of large structures to reduce the time spent on site fabrication and erection. Use of new welding processes and an increased use of automation and robots will take place slowly and gradually, only being justified where the introduction creates significant gains in productivity or cost reduction. As such, these changes can be expected particularly in situations where skilled labour is short, where welding cells can be kept fully occupied or where customised, made to order components are needed. (Contributed by Ador Welding Ltd.)
For more information Web: www.adorwelding.com
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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
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SOFT 60Rb (Bronze) to HARD 70 Rc (ungsten carbide) Benefits of Plasma Sprayed Ceramic over Hard Chrome Environmental: Less hazardous as there 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.
â&#x20AC;&#x201C; P.K. Balasubbramaniian
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PRODUCTS SHOWCASE
PRODUCT SHOWCASE Electronic position indicators: new wireless system
DD52R-E-RF Electronic position indicators, data transmission by radio frequency
UC-RF Control unit for DD52R-E-RF PLC connection 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 Email: info@elesaganter-india.com Web: www.elesa-ganter.in
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The new wireless spindle positioning system, designed for an efficient manual spindle positioning, consists of UC-RF control unit and, up to 36 electronic position indicators DD52R-E-RF (Elesa Patent). Most often, machine setup is performed manually by means of traditional mechanical indicators coupled with handwheels or crank handles, following a specific list of set-up parameters. The new electronic position indicators DD52R-E-RF are networked to UC-RF control unit via radio frequency (RF). The PLC, connected to the UC-RF control unit, allows the remote monitoring of the indicators. This system is particularly suitable for applications that require frequent format changes, facilitating the correct adjustment of the target/current position of the machine parts, also representing a safety system. PLC can be programmed in order not to allow the machine to start the production cycle, thus avoiding production issues. The installation of the system is quick and easy as it does not require any cable connections between the indicators and the control unit or the PLC. Thanks to the available functions and to the programmable parameters, one item only can be used for many applications including all shaft pitch variations, direction of rotation and unit of measure. • 6-digit display ensures excellent readability even from a distance and from different viewing angles. • High protection degree IP65 or IP67 for applications that require frequent washing, even with intense water jets. • Corrosion resistance: AISI 304 stainless steel boss with Ø 20 mm. • Long battery life: over 3 years. Product technical data sheets, along with drawings and tables with codes and dimensions are available on our website.
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PRODUCTS SHOWCASE
Criss Cross Gloves Features & Benefits These gloves are made from Poly/Acrylic or Poly/Cotton in 7 Gauge Knitting. The Criss Cross pattern PVC Coating on both sides allows excellent grip & good mechanical protection to the wearer & the gloves are reversible. The main users for these gloves are Construction, Fishing, General Handling, Gardening purpose, Shipping & Receiving, Bottling Industries .
For Product Enquiry Contact Marvel Gloves Industries Manufacturers, Exporters & Importers of Gloves & PPEs 187/188, 2nd Floor, Ashoka Shopping Centre, G.T. Hospital Complex, L. T. Marg, Mumbai 400 001 Phone : +91 22 2262 6546 / 2262 6876 Email : marvelgloves@gmail.com www.marvelgloves.com
Application • General maintenance • Shipping & receiving • Food processing • Light fabrication • Shipping & Port Handling • Drilling Rigs & Offshore companies • Packaging • Automotive Industries • Material Handling
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
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The Nexgen Refrigerated Air Dryers from Gem Equipment are known for engineering excellence, innovation and reliability.The heat exchangers are designed to provide worry-free, highly efficient heat transfer whether you are processing simple fluids, viscous solu8tions, or particulates. They feature honey comb construction of aluminium fins, true cross-flow for greater effective temperature differences, non-clogging larger cross-sectional area for air flow, integral air-air and air-refrigerant exchanges, with stainless steel demister moisture separator, robust non-corrosive grade aluminium, and larger heat transfer area for higher efficiency. The rugged electronic panels display both inlet and dew point temperatures. They incorporate a Tripper module with alarm for compressed high discharge pressure, compressed low suction pressure, expansion valve malfunction, auto drain valve function and fan motor cycling. Introduction of speed control is one of the major developments towards the optimization of refrigeration systems based on average load. For periods of high cooling demand, the compressor speed can be increased which results in a higher refrigerant flow and thus higher cooling capacity and vice versa during periods of low cooling demand. Compressed air purification equipment must deliver uncompromising performance and reliability while providing the right balance of air quality with the lowest cost of operation. As a quality-centric group, Gem ensures that its dryers are test at each stage of assembly as per ISO 7183 or relevant standards. It maintains stringent engineering practices throughout the production process to achieve higher reliability. Gem’s state-of-the-art ISO 9001-23008 certified facility is equipped with dedicated men and machines to chisel out products of impeccable quality and reliability.
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PRODUCTS SHOWCASE
Effortless cleaning of oily machinery, factory floors and plastic bins by the use of O-CLEAN3
For Product Enquiry Contact STEEL PLANT SPECIALITIES LLP 211, Raikar Chambers, Govandi East, Mumbai - 400 088, India Tel.: 022-67978060 / 022-25552459 Cell: +91-9820493373 Email: info@steelplantspecialities.com www.steelplantspecialities.com
Cleaning of factories is carried out meticulously during the festival season of Dussera and Diwali in India. Oil and dirt accumulated on machinery and factory floors since many months is very difficult to clean. To reduce cleaning efforts, hazardous chemicals, acids, kerosene, thinner, sawdust and such items are used. Besides being harmful or flammable, these products often damage or stain machinery and remove the lustre of paint finish. O-CLEAN3 is an eco-friendly, economical water-based alternative to harmful acids, kerosene or sawdust. It works by breaking the bonds of hydrogen and carbon molecules that form hydrocarbons or oils. As a result, oils and dirt that have accumulated since many months can be cleaned effortlessly and in less time. Using O-CLEAN3 is easy: it must be applied on the oily machinery, allowed to react for approximately 30 minutes, and then washed off with water or with wet cloth to achieve oil-free, clean surface. The residue, that is water and small portion of carbon, can be easily separated and disposed off,as required. If disposed off in effluent treatment plant, the treatment time will be substantially reduced as compared with effluents of harmful chemicals. O-CLEAN3 is a safe, multipurpose cleaning liquid that can be used for effectively cleaning oily machinery, CNC/VMC, chequered plates, plastic bins, epoxy floors and concrete floors. It is also used for degreasing machine parts and as a handwash for cleaning workmens’ oily hands.
Welding Fume Extractor, King Extractor-II-MU 3 Welding Fume Extractor, King Extractor-II-MU 3 is a mobile mechanical high efficiency self-cleaning filter designed for workplaces. The filter cleans air from different kinds of dry dust, welding aerosols and other dry contaminants from most industrial processes. The filter cartridge is cleaned automatically without interrupting the filtration process. The cleaning extends the cartridge service periods and minimizes maintenance.
For Product Enquiry Contact Ador Welding Limited Akurdi Chowk, Chinchwad, Pune 411 019 Tel.: 020- 4070 6000 Email: cmo@adorians.com Web: www.adorwelding.com
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The Filter is designed for continuous indoor operation under the following climatic conditions: • Air temperature from +10 deg. C to +45 deg. C. • Relative humidity : 80% at 25 deg. C • The compact construction integrates the filter, extraction arm and fan • The filter can be used at workplaces unreachable to other ventilating equipment, and • The filter requires connection to a general compressed air supply. The standard delivery set includes Built-in fan, Control console, Filtering cartridge of respective type, Spark arrester, Oil separator with reduction box for compressed air system, & Electrical grounded cable L= 5 m with plug.
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FLIR TG297 INDUSTRIAL HIGH TEMP THERMAL CAMERA – DESIGNED FOR AFFORDABLE INDUSTRIAL HIGH-TEMP IMAGING The FLIR TG297 is a one-of-a-kind industrial diagnostic tool that combines accurate temperature measurement with the ability to image up to 1030°C. Patented FLIR MSX® (Multi-Spectral Dynamic Imaging) enhancement improves image clarity by embossing visual scene details on full thermal images. The TG297 is ideal for high-temperature industrial uses such as measuring the heat of glass furnaces, kilns, and forges as well as manufacturing applications, allowing you to accurately target potential faults, troubleshoot repairs, and monitor processes. Record images to assure your team that machinery and systems are functioning safely and at peak efficiency.
For Product Enquiry Contact FLIR Systems India Pvt. Ltd. Tel: +91-11-45603555. E-mail: flirindia@flir.com.hk Website: www.flir.in
Features: • 160 × 120 IR pixel imager • Thermal Sensitivity <70 mk • IP54 • Can withstand 2-meter drop test • FLIR 2-10 warranty • Peer into the darkness and hard-to-reach areas with the bright LED flashlight • Display and capture thermal or visual images with temperature readings.
GARANT PPC : Shorter process times and excellent surface quality The PPC milling process, also known as Barrel milling, is a Further development of the full radius milling. (PPC stands for Parabolic Performance Cutting) The main areas of application are Luminous Operations of complex free-form surfaces and complicated workpiece geometries in general machine, tool and mould making. PPC tools are also used when the highest surface comitations are required, E.g. for Pressing Tools, to minimize subsequent polishing work. Advantages of the PPC process: 1. Shorter processing time due to large line jump 2. Lower set-up costs 3. Minimizing the inventory by universally applicable cutter 4. Higher surface quality with lower maturities 5. Outstanding process reliability 6. Extreme wear resistance 7. Increased productivity For Product Enquiry Contact Hoffmann Group Web: www.hoffmann-group.com
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The Barrel Cutter in Action Benefits such as a better surface quality and a larger line jump can also be demonstrated mathematically.
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ADVERTISERS INDEX COMPANY NAME
PG. NO.
A
COMPANY NAME
PG. NO.
COMPANY NAME
DVS TECHNOLOGY GROUP
20 - 21
H
ACCUSHARP CUTTING TOOLS PVT. LTD.
87
E
ACE DESIGNERS LTD.
BACK PAGE
ELECTROTHERM (INDIA) LTD.
13
ADOR WELDING LIMITED
105
ELGI EQUIPMENTS LTD.
25
EMAG INDIA PVT. LTD.
51
ENGIMACH - 2019
27
EPPINGER TOOLING ASIA PVT. LTD.
94 - 95
EXXONMOBIL LUBRICANTS PRIVATE LIMITED
17
ANCA MACHINE TOOLS PRIVATE LTD
5
APEX PRECISION MECHATRONIX PVT. LTD.
117
B BECKHOFF AUTOMATION PVT. LTD. BETTINELLI AUTOMATION COMPONENTS PVT. LTD. BIRLA PRECISION TECHNOLOGIES LIMITED
9
101
73
64
HOSABETTU HEAVY MACHINERY LLP
41
HURCO INDIA PVT. LTD.
65
I INNER INSIDE FRONT COVER
J JERGENS INDIA PVT. LTD.
66
JYOTI CNC AUTOMATION LTD.
43
31
L FIBRO INDIA PRECISION PRODUCTS PVT. LTD.
C CLEANOIL
HANGSTERFER'S
ISCAR INDIA LIMITED
F FACCIN S. P. A.
PG. NO.
42
FLIR SYSTEMS INDIA PVT. LTD.
81
77
D
LAKSHMI ELECTRO CONTROLS & AUTOMATION
54 - 55
M G
DELTA ELECTRONICS INDIA PVT. LTD.
7
DMG MORI INDIA
35
DOLD ELECTRIC INDIA PVT LTD
93
GEDEE WEILER PRIVATE LIMITED
19
MACHINE TOOLS, MANUFACTURING & TECHNOLOGY EXPO
GLEASON WORKS (INDIA) PRIVATE LIMITED
57
MARVEL GLOVES INDUSTRIES
118 - 119
MASTERCAM INDIA
INSIDE BACK COVER
MEHTA CAD CAM SYSTEMS PVT. LTD.
75
DOWEL ENGINEERING WORKS
103
GLOBE-TECH ENGINEERING EXPO - 2020
DRAKE
29
GP PETROLEUMS LTD.
www.mtwmag.com
129
69
NOVEMBER 2019
15
MACHINE TOOLS WORLD
135
ADVERTISERS INDEX COMPANY NAME
PG. NO.
COMPANY NAME
PG. NO.
COMPANY NAME
PG. NO.
METAL + WORKING EXPO 2020
97
PILZ INDIA PVT. LTD.
91
STEEL PLANT SPECIALITIES LLP
107
MGM-VARVEL POWER TRANSMISSION PVT LTD
127
PRECISION MOTION INDUSTRIES, INC. ( PMI )
111
SURYA MANUFACTURING COMPANY
79
MICRO-EPSILON INDIA PRIVATE LIMITED
83
Q
MILLENIA TECHNOLOGIES (I) LLP
52 - 53
MMC HARDMETAL INDIA PVT. LTD.
INSIDE FRONT COVER
N N. GANDHI & CO.
115
NICOLAS CORREA, S. A.
47
NORD DRIVESYSTEMS PVT. LTD.
89
49
R
RENISHAW PLC
71
RENMAKCH INDIA PVT. LTD.
85
ROLLON INDIA PVT. LTD. - INDIA
99
MACHINE TOOLS WORLD
TRUCUT PRECISION TOOLS PVT. LTD.
FALSE COVER
V
V M TRADERS
113
WOHLHAUPTER / ALLIED MACHINE & ENGINEERING COMPANY
60
23
P PARAGON MACHINERY CO. LTD.
59
39
S
OKUMA INDIA PVT LTD
THE ASSOCIATION FOR MANUFACTURING TECHNOLOGY
W RR KABEL LIMITED
O
136
QUAKER HOUGHTON
T
33
NOVEMBER 2019
SECO TOOLS INDIA (P) LTD.
37
SPRAYMET SURFACE TECHNOLOGIES PVT. LTD.
109
Z
ZECHA PRECISION TOOLS LIMITED
11
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