Machine Tools World - October 2018 by Divya Media Publications Pvt. Ltd.

Volume 04 No. 05 | October 2018 | ` 150

Pages 104 | RNI No. MAHENG/2015/64267

The Revolutionary Smoothness of BALIQ – The Premiere in Colours With BALIQ® UNIQUE you can differentiate your tools at a glance – simply assign individual colours to your tool types or tool groups. Choose the colours that best match your application.

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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 SKILL DEVELOPMENT - The need for skilled labour Skills and knowledge are the driving forces of economic growth and social development for any country. Countries with higher and better levels of skills adjust more effectively to the challenges and opportunities of world of work. As India moves progressively towards becoming a ‘knowledge economy’ it becomes increasingly important that the country should focus on advancement of skills and these skills have to be relevant to the emerging economic environment. India is one of the few countries in the world where the working age population will be far in excess of those dependent on them and as per the World Bank, this will continue for at least three decades till 2040. This has increasingly been recognized as a potential source of significant strength for the national economy, provided we are able to equip and continuously upgrade the skills of the population in the working age group. If India wants to become a manufacturing-hub, given its requirement for employment generation to reap the demographic advantage; it must focus on skill development instead of present education system. Since, India’s education system has been skewed in favour of formal education focusing on academics; it has done well in services/ tertiary sector. As this sector is the most important recipient of formally educated work-force. Manufacturing processes, on the other hand, does not require academic skills to that extent, for majority of work-force. As a result, the people employed in this sector are either uneducated or unskilled as low-end firms can’t afford college graduates; or they are over-educated and yet unskilled at the task required, in case of firms that can pay. There is a need for concerted action in several key areas in order to ensure that skill formation takes place in a demand driven manner. Curriculum for skill development has to be reoriented on a continuing basis to meet the demands of the employers/industry and align it with the available self-employment opportunities. Accreditation and certification system has to be improved. There is a need to establish an institutional mechanism for providing access to information on skill inventory and skill maps on a real time basis.

CEO

MACHINE TOOLS WORLD OCTOBER 2018

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

Machining Center for Impeller and Small-size Complex Shape Processing

Specifications

A-Axis

X-A

xis

Z-A

B-Axis

Ram Type Moving (X/Z-Axis)

Ã&#x2DC;200

mm Table Size

kg Workpiece Weight

40,000 (HSK-E40)

r/min Spindle Speed

EA No. of Tools

300/300/200

mm (X/Y/Z-Axis) Travel

50/50/50

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

200/200

rpm (A/B-Axis) Rotary Table Speed

2G/2G/2G

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

SIEMENS 840D sl

CNC Controller

Rotary Tilting Table(A/B-Axis)

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

www.mtwmag.com

Publisher & Printer Shirish Dongre

CEO

Contents

Vol 4 Issue 05 | OCTOBER 2018

COVER STORY

Shekhar D.

Editor Shilpa Dongre

Assistant Editor Shweta Nanda

Marketing Team

Global leadership in machine tools & manufacturing systems

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

Digital Marketing Kailash P.

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

Online Division Ganesh Mahale

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

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

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

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

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

42 BUSINESS NEWS

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

MACHINE TOOLS WORLD OCTOBER 2018

IN FOCUS

ANCA launches a new machine with the CPX Linear Blank Preparation Grinder

ExxonMobil’s Breakthrough Mobil SHC™ Elite Technology

ELECOLORS meets the yellow of Top Automazioni

36 Head Office : Divya Media Publications Pvt. Ltd., 3rd Floor, Harmony Tower, N.S. Road, Thane-400 602. Maharashtra Tel: +91 22-25380574/75, Telefax: +91-22-25418254 E-mail: shekhar@divyamediaonline.com Website: www.mtwmag.com

Jochen Nahl, Member of the Board & CSO, GROB Group

India has a huge talent pool: Marc Jarrault, LAPP India

‘Hoffmann is in India for the long haul’: Pinaki Banerjee, APAC MD

COMPANY PROFILE

EuroBLECH 2018 promises enormous potential in digitalisation

The new STUDER favorit

Koike Aronson and NUM partner to produce precision 5-axis bevel head

Rajshakti : Cognitive heritage of technology excellence & precision

World Class Company, Specialised for ‘Specials’

Perfection Through Precision

The CNC E80 Series boasts drastic improvements in performance and a higher accuracy than ever before. The simple and easy-to-use E80 Series helps in achieving a greater cost performance, and fits best with simple machine configurations.

MITSUBISHI CNC E80 Series Fine segment processing capability

• Easier programming with interactive cycles • High accuracy control for lathe with milling functions • 3D solid program check function • Synchronous tapping with Analog I/F spindle

PLC process p capability

CNC-to-drive communication capability

E80

E70

2 times higher than E70

9 times higher than E70

3 times higher than E70

[kilo-blocks/min]

www.MitsubishiElectric.in

MITSUBISHI CNC THE CUTTING EDGE OF MACHINING CONTROL

Contents

Vol 4 Issue 05 | OCTOBER 2018

102

CASE STUDY Design outside the box: Modular O-Rail from Rollon enables infinite combinations

66 ATOM™ encoders allow rapid, high-accuracy FPD inspection & repair

PRODUCTS SHOWCASE

IFB Home Appliances Improve Lives Through Excellence In Functionality

KING CUT PRO – The Large Gantry Type CNC Cutting Machine

Ballscrews with Rotary Nut (Compact) - FSKT

The new Gast 86/87R Series of oil-less rocking piston compressors & vacuum pumps

100

Safety Pull Cord Switch

TECH TRENDS

Renishaw’s new multi-axis periscope enables unmatched flexibility

70 HEIDENHAIN Encoders for industrial robots

86 Measuring spindle growth in high speed milling machines

FastMig M – A new breed of industrial workhorse 12

MACHINE TOOLS WORLD OCTOBER 2018

Rolling power linked to the growth of the wind energy industry

Editorial Board

Editorial Index A

Ador Welding

76, 97

Kemppi India

ANCA B

20, 24

Kennametal

Bettinelli Automation D

Mr. Arun Mahajan General Manager

Mr. A.P. Jayanthram Consultant

AMT- The Association For Manufacturing Technology

Grob Machine Tools India Pvt. Ltd.

Mr. Arjun Prakash Managing Director Effica Automation Ltd.

Ms.Samina Khalid Marketing Manager Renishaw Metrology Systems Ltd.

Mr. GK Pillai Managing Director & CEO Walchandnagar Industries Ltd

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

L 60

LANXESS

LAPP India

DesignTech Systems 20, 64

Dormer Pramet E

Meech

Micro-Epsilon

Elesa+Ganter

ELGi

NUM

EOS

EuroBLECH 2018

Euromac

ExxonMobil F

Faccin SPA

FARO G

GROB Group H

HAIMER

STUDER

HEIDENHAIN

Superslides & Ballscrews 98

Hoffmann Group

Hoshi Tools

Unity Controls

P Precise Cutting Tools

R Rajshakti Machines Renishaw

56 66, 82

Rollon India

S Seco Tools

Shavo Technologies

Smart Sensors & Automations

99, 100

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

Mr. Dinesh Khambhayta President MTMA-RAJKOT

Manjit Singh Matharoo General Secretary Association of Ludhiana Machine Tool Industries

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

Mr. P.K. Balasubbramaniian President VBS Corporate Support

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

MACHINE TOOLS WORLD OCTOBER 2018

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

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

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

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

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

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

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

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

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

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BUSINESS NEWS

CONTOUR360 wins the ANCA Tool of the Year competition for profile accuracy CONTOUR360has been announced as the first ever ANCA Tool of the Year award winner at IMTS with their creative and eye-catching tool. Charles R. Day, Vice President & General Manager said: “It is with heartfelt pride that we accept ANCA’s prestigious Tool of The Year award. While indeed this recognition speaks to the craftsmanship of our toolmakers – it also makes a tremendous statement to the craftsmanship of the machine maker and the support provided!” “CONTOUR360 utilizes many different types of ANCA machines, including the recent addition of three new state-of-the-art FX7 Linear wheel exchangers, laser measurement and Fanuc RoboMate. But our business requires more than just state-of-the-art equipment! It

demands machines that are reliable day in and day out. It demands support, when needed, in the “lights out” environment in which we work today,” Charles concluded. To find the Tool of the Year ANCA held a competition for customers to submit their favourite tool with the winners judged and announced live at IMTS. Pat Boland, Joint Co-Founder at ANCA comments: “All the entrants were a very high standard and demonstrated a deep understanding

for tool geometry as well as taking full use of ANCA’s software. It was very close and difficult to decide, and I congratulate all the finalists including CONTOUR360, Daily Grind Industrial Tool, Acu Twist, Miltera, SAN Engineering and Kazimieruk.” “After measuring the surface finish and geometry on Alicona and Zoller machines respectively, the votes were tallied and CONTOUR360 won for their

complex tool that was brilliantly executed.Grinding a complex tool like that requires sharp wheels, accurate qualification of wheels and a perfect setup,” Pat concluded. Alicona President, Stefan Scherer said: “By including surface finish values as a criterion in their tool competition, ANCA shows that they meet the needs of their customers who in the end can produce stateof-start tools with outstanding lifetime and machining quality.”

DesignTech Systems signs MoU with IASC DesignTech Systems has signed an MoU with IASC (Instrumentation Automation Surveillance and Communication) Sector Skill Council – a not for Profit Organization under Ministry of Skill Development & Entrepreneurship, Government of India to provide advanced skills based training certifications to qualified trained personnel. The objective behind inking this MoU is to facilitate and encourage the aspiring and ambitious youngsters to acquire specialized technical skills based certifications and accreditations from an esteemed government institution, IASC, founded by the Ministry of Skill Development and Entrepreneurship under their premier Skill India Initiative. Industry recognized and respected Accreditation from IASC would certainly open up various quality employment opportunities for the certified job aspirants. As an assessment Partner and Associate for IASC, DesignTech, under the terms of MoU, will create awareness aboutand promote these Certification courses at the existing State Funded

MACHINE TOOLS WORLD OCTOBER 2018

Centres of Excellence managed and operated by DesignTech Systems. In accordance to the Agreements entered into with various State Governments such as Gujarat, Andhra Pradesh, Tamil Nadu, and Jharkhand, DesignTech Systems has established and is executing trainings on latest and most advanced technologies in electro-mechanical field at more than 25 Siemens Centres of Excellence across various cities in these states. With all the centres put together, cumulatively more than 1 lakh students have benefited from these trainings. Explaining more about this MoU, Vikas Khanvelkar, Chairman and Managing Director, DesignTech Systems Ltd., exclaimed, “Government of India with the Ministry of Skill Development and Entrepreneurship are

introducing new initiatives and promising programs to elevate and enhance the quality of education and skills based trainings in India. Lack of industry ready and employable manpower can regress Industry’s pace of growth, bear detrimental impact on the national GDP, while also increasing unemployment rate in the country. Applications based knowledge of contemporary technologies acquired through Centres of Excellence, and in addition, being certified by the industry recognized Government Body, IASC would certainly add value to students’ educational credentials that will earn them greater preference in securing a good job. DesignTech will help emphasize the importance of certification at all the Centres of Excellence managed and operated by us.”

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BUSINESS NEWS

ANCA launches a new machine with the CPX Linear Blank Preparation Grinder

Launched at IMTS 2018 the CPX Linear has a large working envelope and powerful grinding spindles to achieve the highest precision and

productivity for blank preparation in the market. Using the pinch peel method of grinding it offers the same strength, rigidity and thermal

stability expected from an ANCA tool grinder. Simon Richardson, Product Manager at ANCA said: “We have taken the best aspects of our technology to build a fantastic machine. For example, our specially designed polymer concrete base provides the upmost stability in our grinding process so we took that and used it in the CPX Linear model.” “We are known for our ongoing dedication to research and commitment to ensure our technology is surpassing our customers’ needs. This is another major milestone in that approach, providing a complementary machine for the full grinding process. What

can I say, our customers asked and we listened - designing our own blank preparation machine.” Specially designed for a lifetime of operation in harsh grinding environments, the LinX motors have a cylindrical magnetic field which means there is no additional down force on the rails or machine base. With no temperature variations (meaning no need for a separate chiller unit), and being sealed to IP67,there is minimal wear and tear so that the machine accuracy remains over the lifetime of the machine. The LinX linear motor has higher axis speed and acceleration, leading to reduced cycle times while maintaining a smoother axis motion.

EOS unveils EOS M 300 series for digital industrial AM production EOS, the world’s leading technology supplier in the field of industrial 3D printing of metals and polymers, will showcase its latest systems and solutions at the International Manufacturing Technology Show (IMTS) in Chicago, IL from September 10-15, 2018. At the show, EOS launches the new EOS M 300-4system which is part of the broader, modular metal 3D printing platform EOS M 300 for digital industrial additive manufacturing (AM) production. The EOS M 300-4 expands the portfolio of well-proven Direct Metal Laser Sintering (DMLS) systems, among them the highly popular EOS M 290 system. The EOS M 300seriesis an automationready, future-proof platform that is configurable, scalable, and secure. It comes with a build volume of 300 x

MACHINE TOOLS WORLD OCTOBER 2018

300 x 400mm and serves a variety of manufacturing fields, including aerospace, industry, medical, tooling and automotive. This new modular platform comes with aconfigurable and scalable equipment architecture, which enables full flexibility and customized system configurations. As such, it is the perfect choice for

organizations demanding reliable and robust industrial standard equipment for AM production. For better production flexibility and automation – and depending on system configuration– customers can choose between different solutions: one, two or four lasers, multi power laser configurations (400 or 1,000 Watt), fixed or variable

focus, different types of recoaters, new and expanded exposure strategies, part handling (manual or automated), monitoring options and three different clamping systems (3R, Delphin, Erowa). The system will be compatible with the EOS Shared Modules in which manual or automated peripheral modules and transport logistics supply several EOS metal AM systems. As a result, all set-up, unpacking, transportation and sieving actions will be carried out independent of, and parallel to, the AM build process. The EOS M 300-4 with four lasers will be able to offer variable laser power sources in the future – from 4x 400, to a mixed set-up of 2 x 400 and 2 x 1,000, up to 4 x 1,000 Watt laser power.

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BUSINESS NEWS

ExxonMobil’s FARO announces latest Breakthrough Mobil version of BuildIT SHC™ Elite Technology Construction 2018.5

ExxonMobil has launched Mobil SHC™ Elite, a breakthrough synthetic gear and bearing circulating oil that is specifically engineered to deliver long lasting protection for machines operating under extreme temperatures in industries such as general manufacturing, metals, energy, and pulp and paper. Extensive testing shows that Mobil SHC Elite can deliver 12 times the oil life of mineral oils and double the oil life of Mobil SHC 600 synthetic oils in continuous operating temperatures as high as 130°C (266°F), potentially replacing glycol-based lubricants in high temperature systems. This helps reduce the potential risk of mixing glycol-based products with incompatible mineral oils and most synthetic lubricants. The oil also protects equipment during intermittent temperature spikes of up to 150°C (302°F) and provides up to a 3.6% energy efficiency benefit versus mineral oils.* “Protecting advanced equipment from high in-service temperatures can be a major challenge for

MACHINE TOOLS WORLD OCTOBER 2018

industrial operators,especially if that equipment is difficult to access or take offline,” said Glen Sharkowicz, Director of Brand Strategy- Commercial Marketing, South Asia Pacific, ExxonMobil Asia Pacific Pte Ltd. “With Mobil SHC Elite, equipment owners now have an advanced lubricant that can deliver much better oil life and the assurance of extra protection during high temperature excursions during peak production rates.” Following field trials, Mobil SHC Elite has been approved by Siemens for its FLENDER gear units, which dependon robust lubrication protection in rigorous operating conditions. Mobil SHC Elite is the newest member of the Mobil SHC™ family of synthetic lubricants that provide performance advantages far exceeding the capabilities of conventional oils. These lubricants can help extend equipment longevity and generate potential energy savings, while their significantly longer life lowers maintenance costs and reduces worker exposure during oil changes.

FARO has announced the latest version of BuildIT Construction (2018.5). BuildIT Construction Software is a comprehensive verification software solution that accelerates projects and minimizes waste by now giving construction professionals the power of a single software ecosystem configured with automated workflows and powerful established platforms. Multiple import solutions are now available creating a more seamless experience in software integration. BuildIT 2018.5 now provides the ability to register Focus Laser Scanner data files directly during import. Removing the need of a registration software for various site workflows and enabling an on-site validation process within one software solution results in an efficient workflow. It is a key differentiator for BuildIT as it reduces the time from capturing reality to the validation report by half while also drastically reducing the steps. BuildIT Construction 2018.5 features the ability to AEC professionals are now able to import native Autodesk® Revit® files from version 2015 - 2018.5. This result in a faster process for model comparison due to native file import from one of

the major BIM design tools. Another benefit of this Revit™ File Import includes the avoidance of lost information due to data conversion limitations and improving traceability using the object’s project ID within various software platforms as well as in validation reports. In addition to the Revit File Importation feature, BuildIT 2018.5 also allows users to import IFC 2x3 and IFC 4.0 files. Since IFC files are a common standard in the construction industry, the practice of validation against design models is made more efficient and straightforward. BuildIT Construction new tank volume analysis command gives construction professionals the ability to analyze various tank forms. By understanding the volume of tanks, users will now document correct volume in a trusted and traceable way. Facility managers can calculate and create tank volume charts for calibration based on specified height intervals. Customers will also be able to perform important inspections accurately and quickly that range from inspection of floor flatness and levelness, topographic curves to measuring the deformation of constructed object.

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BUSINESS NEWS

ELECOLORS meets the yellow of Top Automazioni ELECOLORS is the affirmation of an insight that dates back to the beginning of the ’90s with the Ergostyle® line: design, ergonomics and colourful components in the mechanical industry world. The use of colour in industrial components offers a perfect aesthetic compatibility with the colours of the machines they are installed on. Elesa+Ganter today offers an extensive selection of standard components in the ELECOLORS chromatic range (RAL Colours): Pure orange, Light grey, Colza yellow, Pastel blue, Flame red, Jet black and Black grey. The success of the line and the growing market request has led to add a new colour: the May green, which completes the range. The opening of the industrial machines world to design and aesthetics has allowed this line to be very popular today even in sectors where, traditionally, a component had only to perform correctly and it was not required to be “beautiful”, as well.

Top Automazioni, a mechanical company based in Poggio Torriana (Rimini - Italy), is today the most innovative company in the production of bar feeders. The company was asking for a solution to better differentiate their products against competition helping visual identification, in a glimpse. Top Automazioni chose ELECOLORS components with yellow inserts – yellow is in fact its Corporate colour. In particular, they selected clamping elements, tubular handles and bridge

handles with Colza Yellow RAL 1021 colour inserts. “The huge advantage of ELECOLORS lies in the fact that they are standard products available in stock and in the colour you prefer, as our advertising campaign announces” says Stefano Barbati, Sales Manager in Italy “The possibility to easily integrate our loader with inserts in our corporate colour has led us to choose the ELECOLORS. A line, we were particularly impressed by. We like the elegance and the design in combination to colour which enhance the features of our loaders” - explains Nicola Bargellini, owner of Top Automazioni – “After all, even for a machinery, as for any other objects, aesthetics is the first aspect appealing a customer, grabbing its attention. Then, of course, it is up to the technical features and performances to determine the suitability for the user’s requests”.

Boeing Portland and HAIMER intensify collaborative membership The Oregon Manufacturing Innovation Center Research and Development (OMIC R&D) continues to grow a strong membership base with the addition this month of HAIMER, a world market leading German tooling company in the field of tool holding, shrinking, balancing and presetting. The partnership between The Boeing Company and HAIMER Group will be strategically expanded to a joint membership at the OMIC R&D institution. Through this partnership, Boeing -- with its center of excellence and main production plant for heavy metal machining in Portland, Oregon -- is intensifying its strategic partnership with HAIMER by sponsoring a joint membership at OMIC R&D. The partnership between Boeing and Haimer reaches back more than 10 years when HAIMER’s Safe-Lock™ pull out protection

MACHINE TOOLS WORLD OCTOBER 2018

system became a true game changer at Boeing. With one of the largest titanium machining shops in the world, Boeing Portland has set the standard for cutting tools and tool holder applications for difficult to machine materials. Due to its technology advantages, the Haimer Safe-Lock™ system has become the Boeing Portland standard for roughing in their milling operations. Haimer implemented an open

licensing policy where additional American and other cutting tool makers offer this technology as a standard solution which are widely used in the Boeing machining operations. In fact, the Boeing Company has also received an IP, patent and trade mark license from Haimer to be able to quickly respond to their machining needs for this innovative technology. Prior to implementing Safe-Lock™ in their production, Boeing was constantly facing the challenge of preventing the cutting tool from pull-out which potentially created very expensive scrap. Over the last 10 years, since implementing Safe-Lock™, they haven’t had a single tool pullout incident for their high value components – thus avoiding any sort of expensive scrap and machining failure which was a common problem before implementing Safe-Lock™.

ELC 160 LASER WELDING MACHINE FOR HIGH-YIELD PRODUCTION FAST

FLEXIBLE

MODULAR

PRECISE

HIGHLIGHTS + FLEXIBLE AND HIGHLY PRODUCTIVE: With its (patented) capability to automatically reset, the ELC 160 sets new standards in flexibility and output.

+ INTEGRATABLE: The ELC 160 is ideal for the integration into manufacturing lines to prepare individual parts for laser cleaning, ultrasonic testing or further processing of the welded components.

+ CUSTOMIZED: The ELC 160 can be equipped with CO2 or solid-state lasers (disc, fiber) from all leading manufacturers. The integration of diverse technological options, such as joining or induction hardening, provides customers with customized manufacturing solutions.

The ELC 160 is a modular laser welding machine that can be configured to perform a multitude of different tasks. The machine is equipped with a number of joining stations and welding attachments. The resetting process is NC controlled which allows for whole component families to be manufactured without the need for manual setting. Expansion options: joining of the components, induction pre- and post-heating, laser welding, laser marking, workpiece measuring – all on a single machine.

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

BUSINESS NEWS

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

MACHINE TOOLS WORLD OCTOBER 2018

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

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

Creating Tool Performance

A member of the UNITED GRINDING Group

HELICHECK PRECISION / ADVANCED Optical CNC measuring machines for non-contact tool measurement

Fully automated measuring machines HELICHECK PRECISION / ADVANCED for rotation-symmetrical tools. For tool diameters from 2 to 320 mm, tool lengths up to 420 mm. Tool weight up to 25 kg. www.walter-machines.com

United Grinding GmbH – India Branch Office & Technology Center No. 487, D1 & D2A, 4th Phase – KIADB Main Road, Peenya Industrial Area · 560 058 Bangalore · India Tel. +91 80 3025 7600 · sales.in@grinding.ch · www.grinding.ch

Creating Tool Performance

BUSINESS NEWS

EuroBLECH 2018 promises enormous potential in digitalisation This year’s 25th International Sheet Metal Working Technology Exhibition will take place from 23rd- 26th October 2018 in Hanover, Germany. A total of 1,500 exhibitors from 39 countries secured their stand at the world’s leading sheet metal working technology exhibition. This year, the show is mainly influenced by the topics Digitalisation and Industry 4.0.The Online Show Preview, which was recently published,provides an overview of new products and technological innovations which will be presented at the show in October. A total of 1,500 exhibitors from 39 countries have bookedtheir stands at the world’s leading exhibition for the sheet metal working industry.EuroBLECH 2018will feature more than 89,000 square metres net exhibition space, another growth of around 2%

compared to the previous event. The most important exhibitor countries are Germany, Italy, China, Turkey, the Netherlands, Spain, Switzerland, Denmark and the USA. For this year’s 25th edition of EuroBLECH, the main topics are Industry 4.0, big data and digitalisation. Especially for small and medium-sized companies these developments offer enormous

potential. These new business approaches offer advantages in terms of streamlined and less complex processes as well as improvement of productivity and efficiency. “While an app for maintenance control of machines or the interaction of machines and robots across the whole production process were still a vision of the future a couple of years ago, today

this is the reality in sheet metal working. Currently, not only large companies are gaining ground in this area, SMEs have also recognised their potential here. Their company size usually allows them to react flexibly and quickly to such transitions, therefore they are in a good position to use digitalisation to their advantage”, says Evelyn Warwick, Exhibition Director of EuroBLECH on behalf of the organisers Mack Brooks Exhibitions. “At EuroBLECH 2018 as the world’s largest sheet metal working exhibition, visitors can expect the most comprehensive technology range in terms of industrial digitalisation of sheet metal working. 1,500 companies will be exhibiting, ranging from large industrial corporations to small innovative start-ups”, continues Evelyn Warwick.

Euromac announces inauguration of new technology centre at Radcam Technologies Radcam Technologies MD Siddhu Jolad & Euromac Group President Mr Eugenio Lenzotti collaborated to cater to the Indian market. Euromac always has been a pioneer and commanding technology with patented features. The partnership would like to take this forward in a much bigger way, about 50 machines a year in India in the initial years. The partnership though wary of the China challenge, is confident of Euromac, which has got a technology edge and Radcam team which has team of hard working people, a client base who value quality over price

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The technology center will be a learning place and will be used for R&D, sales and support. The objective is to do academia interactions, where exchange of fresh ideas and showcase of latest technologies will be done. Information will flow from India to

Italy or from Italy to India; it will be that level of Technology center. The partnership is going to cover pan India exclusively and hence the proximity to the airport, there will be a lot of customer visits and apart from that the service Centre, whatever spares that one needs as

a customer that will be stored here and shipped immediately for quick support. All Euromac machines are built and tested in Italy and uses the most sorted parts from all over the world, that’s how we have good products with long life and less maintenance.

BUSINESS NEWS

The new STUDER favorit STUDER is expanding its product portfolio and bringing a new machine series to the market – the favorit. With centre distances of 400, 650, 1000 and 1600 mm, the favorit line is suitable for short to long workpieces and can be used universally. It comes in a completely new design and scores especially with its price-performance ratio. This CNC universal cylindrical grinding machine is designed for grinding in individual and batch production and can be automated. It can subsequently be easily adapted to other grind-ing tasks using various accessory kits such as in-process gauging, balancing system, contact detection and length positioning. The favorit is a very cost-effective machine. As with all STUDER cylindrical grinding ma-chines, the

proven solid Granitan® machine base ensures the highest precision, performance and reliability. The full enclosure ensures an optimal view of the grinding process. The wheelhead, which can be automatically positioned every 3°, can take one belt-driven external and internal grinding spindle respectively. Thanks to a 370 mm long X-axis the dressing spindle can be placed

behind the workhead or tailstock, without colliding with the grinding head. Geometrical clarifications are now a thing of the past. The dresser position can be manually adjusted in the T-slot. The STUDER favorit has an integrated coolant tray and a machine base with temperature control. Potential deformations of the slide on the Z-axis are eliminated. At the

same time the “active temperature control” option brings the machine to operating temperature faster. The practical STUDER grinding software with its proven StuderPictogramming means that even less experienced users can quickly and practically program grinding and dressing cy-cles. Also available is the optional StuderGRIND software, which enables efficient program-ming of special applications such as profiling grinding wheels for complex workpiece shapes. The modern and user-friendly design is complemented with a touch-screen panel, which al-lows the operator to easily and directly control the machine. Service doors at the rear and on the right of the machine ensure high ergonomic efficiency during machine operation.

Second Edition of Pune Machine Tool Expo concludes successfully The second edition of the Pune Machine Tool Expo 2018 – Western India’s most prominent B2B exhibition, was a phenomenal success as it concluded on 30 September 2018. With more than 85 exhibitors, the machine tool exhibition attracted over 9,500 visitors and more than 75 trade delegations from various industry sectors such as auto component, automobiles, capital goods, dies and tool, defence and aerospace. Along with host city Pune, the event attracted impressive number of delegates and visitors from the Tier II and Tier III cities such as Aurangabad, Nagpur, Kolhapur, Mumbai, Satara, Ahmednagar, Nasik besides the neighboring states of Gujarat and Madhya Pradesh. Visitors from Germany and Poland attended the event, while latest technologies from countries like Germany, US, UK, China, Switzerland, Spain, Japan, France and Italy were also on display. Organized by the Indian Machine Tools Manufacture’s Association (IMTMA), the exhibition was held for four days from 27th

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September– 30th September 2018 and served as a platform to demonstrate the latest manufacturing technologies. The expo covered both metal cutting and metal forming technologies including automation and robotics, tooling systems, CAD/CAM and other technologies, which are essential for today’s manufacturing. The Pune Machine Tool Expo, spread across three halls covering 4,500 sqmts, turned out to be fruitful both for the visitors as well as the exhibitors and most of the exhibitors were highly satisfied and impressed with the quality of the crowd and the business opportunities that the

exhibition provided them. “The exhibition is highly organized. The 4-axis, 5-axis machinery displayed is worth viewing. The overall experience has been quite good. I have earlier visited IMTEX and get the same feeling at hashtag PMTX 2018 too.” Ashish Bhosale, Owner -Ashish Industries. The success of Pune Machine Tool Expo has given further impetus to the IMTMA’s idea of Regional Machine Tool Expos – to address requirements of the Original Equipment Manufacturers (OEMs) of the various industry sectors in the Tier II and Tier III cities in the various regions of India.

BUSINESS NEWS

Koike Aronson and NUM partner to produce precision 5-axis bevel head CNC specialist NUM is helping one of the USA’s top fabrication equipment manufacturers to develop an ultra-precise 5-axis bevel head for its market leading waterjet cutting system. This innovative engineering project will enable customers to use extremely fast abrasive cutting speeds to further increase productivity of their precision metal parts fabrication processes. Koike Aronson, Inc. is a leading manufacturer of advanced cutting/welding machines and positioning equipment. Founded in 1918, the company is based in Arcade, NY, USA. Capable of operating three manufacturing shifts per day,

with up to 100 employees, Koike is renowned for its expertise in metal fabrication systems; its research and development resources include mechanical, electrical and software engineers with more than 250 combined years of design, process and technical experience. Koike’s latest generation waterjet cutting system, the K-Jet, is designed to cut various types of material – including steel, aluminium, plastic and glass – without creating any heat-affected zones. There is a choice of five machine configurations, offering standard cutting areas up to 72 x 144 inches (1,829 x 3,657 mm), and three KMT intensifier pumps with pressure ratings as high as 90,000 psi, making it the world’s fastest waterjet cutting system for straightline cutting. Each K-Jet machine features a robust, floormounted cutting table with a load capacity of 125 psf (610 kg/m2), which is equivalent to supporting 6 inch mild steel. The tables employ a heavy duty precision machined main beam and

saddles, fully enclosed air pressurised bellows, and hidden linear guide ways. There is a wide choice of optional Ebbco abrasive removal and closed loop filtration systems for efficient water management. As part of its ongoing commitment to helping customers improve the productivity of their parts fabrication processes, Koike, in collaboration with NUM, has now developed an innovative & highly versatile 5-axis CNC bevel head for its K-Jet waterjet cutting system. The cutting head is specifically designed to combine ultra-fast movement with precision positioning capabilities & is available with pumps up to 60,000 psi capacity.

LANXESS commissions new production line for additive specialties Specialty Chemicals Company LANXESS has commissioned a new production line at its Mannheim site for the synthesis of dimercaptothiadiazole (DMTD) derivatives. These chemicals are added to lubricants as multifunctional additives. The production line, which started in May 2018, doubles the annual production capacity of these specialty additives. The investment volume is in the single-digit-million-euro range. “With this investment, we have responded to the increased customer demand for these specialties. The new plant will enable us to meet their requirements for highquality lubricant additives, but also

MACHINE TOOLS WORLD OCTOBER 2018

helps us acquire new customers, and further develop our own package solutions for a rapidly growing market,” says Dr. Martin Säwe, Head of the Lubricant Additives business line in LANXESS’s Additives (ADD) business unit. DMTD derivatives are multifunctional additives, and are initially used as corrosion protection for lubricants in contact with steel alloys containing so-called nonferrous metals such as copper, nickel or cobalt. They prevent the leaching of nonferrous metal ions from the alloy, protect the metal surface from aggressive chemicals, and thus guarantee the integrity and longevity of steel alloys.

Thanks to their metal-surface bond, they also act as lubricants, even when under extreme conditions and high pressures metal surfaces start contacting each other. Therefore, and in addition to their function – that is, to provide protection against corrosion, they are also referred to as extreme pressure additives. Last but not least, these additives interact with and absorb aggressive chemical breakdown products in the lubricant, which could otherwise cause material damage in the long term. The main areas of application for these versatile products are industrial oils, greases, and metalworking fluids. Under the Additin brand name,

ADD supplies customers worldwide with DMTD derivatives, which are also used in additive packages at LANXESS. Due to a special manufacturing process used to reach the optimal composition, their performance is both excellent and consistent. Compared to competitor products, the additives stand out due to their stable quality and performance, a mild odor, and their bright, clear appearance. The products are manufactured exclusively at the site in Mannheim.

G-SERIES

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

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

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www.grobgroup.com

15.02.2018 10:20:47

COVER STORY

Global leadership in machine tools & manufacturing systems We will endeavour to strengthen our global leadership in customized manufacturing system solutions boosted with latest automation solutions, with both international auto makers and Indian auto companies.

Jochen Nahl, Member of the Board & CSO, GROB Group

MACHINE TOOLS WORLD OCTOBER 2018

COVER STORY www.mtwmag.com

The GROB Group headquartered in Mindelheim, Germany, is a formidable name in machine tools and manufacturing systems. The company, with a standing and reputation of nine decades in the engineering world, has a turnover of over 1.5 billion euros and a workforce of 6,600 employees worldwide. GROB’s present portfolio ranges from universal machining centers to highly complex manufacturing systems with own automation function through to manual assembly stations to fully automated assembly lines. It also sets up production plants for electric motors and assembly lines for battery and fuel cell technology. GROB is also taking a giant leap into the digital future, finds out P.K. Balasubbramaniian in an interview with Mr. Jochen Nahl, Member of the Board & CSO, GROB Group. Excerpts: Q. Grob is a global player in the machine tools field. Could you enlighten us on your checkered past? As a globally operating, family-owned company, we have been developing manufacturing systems and machine tools for more than 90 years. The success story of GROB-WERKE began way back in 1926 when the company was founded by Ernst Grob, who was producing folding boats, weaving machines and stationary combustion engines at that time. In 1952, Burkhart Grob, the son of the founder, assumed responsibility for the company almost completely destroyed during the war and was able to forge the link to the emerging automotive industry with high-quality and technologicallyconvincing production machines. In 1968, the Mindelheim plant was built and the company’s headquarters was relocated from Munich to Mindelheim due to expansion requirements and future growth vision. The Munich site was closed. Besides the parent plant in Mindelheim, the plants in Bluffton (USA), São Paulo (Brazil), Dalian (People’s Republic of China) and Turin (Italy) are part of the production network of GROB Group. This production network is expanded through twelve sales and service branches in South Korea, China, India, Russia, Great Britain, Hungary, Mexico, Poland, Switzerland, the Netherlands and the USA to guarantee the best service quality. Even after Dr. Burkhart Grob passed away in May 2016, the future of the family company has been strictly set out.

GROB Management Christian Grob takes the company into the third generation as the new Supervisory Board Chairman. Even at this early stage, the next generation is being prepared for future tasks. By purchasing DMG meccanica in January 2017, GROB has acquired a strong partner in the field of electromobility. GROB now also acts as a developer of system concepts for electromobility, which is a future-facing step for expanding the existing product range of highly-efficient manufacturing and assembly plants. In January 2018, DMG meccanica was renamed GROB Italy S.r.l.

Q. What’s the standing of the company today after nine decades of your journey? The GROB Group generates worldwide

revenue of over 1.5 billion euros with a workforce of about 6,600 employees. Our portfolio ranges from universal machining centers to highly-complex manufacturing systems with own automation function through to manual assembly stations and to fully-automated assembly lines. Furthermore, production plants for electric motors and assembly lines for battery and fuel cell technology are part of our product range. GROB engineers are delivering solutions for the technology involved in plasma coating of cylinder bores at engine components, in cutting high-strength turbine housings and machining structural and chassis components. By developing GROB-NET4Industry, our proprietary industrial software for the digitalization and networking of production systems, GROB is taking a giant leap into the

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COVER STORY digital future. Meanwhile GROB is in a transformation phase as a supplier in all aspects of mass production within electromobility.

Q. Which are your prominent product lines today? The product range of GROB-WERKE GmbH & Co. KG can be divided into the following areas: System solutions and special-purpose machines: Machining centers or flexible manufacturing systems are designed specifically for the customer’s part. Offering so-called turn-key solutions, GROB provides the required planning, engineering, manufacturing and commissioning on site at customers’ facilities – everything from a single source. In most cases, these systems consist of modular machining centers and special-purpose machines that are interlinked with the latest automation solutions. Typical parts are for example cylinder heads, crankcases, transmission case and housings for auxiliary units of the engine. Universal machining centers: The machining centers are mainly operated as stand-alone machines but are also available with automation solutions. They are typically used in the aerospace, automotive and medical industries, in tool and mold industries and in case of flexible contract manufacturers. Assembly technology: All assembly stations and assembly lines for the automotive industry are individually planned, designed and custom-built according to specific customer requirements. The systems are used for semi-automatic or fully automatic assembly of assemblies equipped with a variety of robot cells and measuring and test stations. They are typically used for example for the assembly of engines or manual transmissions for passenger cars and trucks. Assembly systems for electromobility: As a general contractor, GROB offers machines, automation systems and purchase components for electromobility

MACHINE TOOLS WORLD OCTOBER 2018

GROB’s futuristic products. The company’s system machines, universal machining centers & assembly lines are among the best in the world. as well as the required management expertise. From stator and rotor assembly through to final assembly, we deliver a modular and reliable plant concept for high-output electric motor manufacture but as well battery assembly systems for battery modules and packs. New technologies: At GROB, the development of new technologies has been a key element of the company’s success since the very beginning. New technologies that set benchmarks in the mechanical engineering sector are continuously emerging. The G550TS thermal spraying system developed by GROB thus expands the production chain for cylinder crankcases. GROB has also developed a motorized spindle with cross-feed – an outstanding concept for the complete machining of turbine housings on the machining center. We are taking a giant leap into the digital future with the proprietary software GROB-NET4Industry, developed for the digitalization and networking of production processes. Machining centers for frame structure and chassis parts: GROB presents its latest developments in the form of its G500F, G520F and G600F machines. These versions are designed specifically for single- or two-spindle machining of frame structure and chassis parts, as well as battery housings. The optimized chip transport facility and high machine dynamic make these space-saving machining centers the ideal solution for dry, MQL and wet machining of parts for the automotive industry. No matter whether stand-alone or linked to other machines, GROB machining centers

offer a convincing and perfect basis for the automated production of your frame structure and chassis parts.

Q. Could you throw some light on your engineering acumen and manufacturing excellence? GROB develops, manufactures and builds all machines and components in-house. It is an enormous advantage for GROB that all the links of the process chain are close together. Possibilities for improvements and optimization which arise during the whole process can be implemented immediately without wasting time. Any deficiencies are thus quickly eliminated and we receive products of highest quality. The core components are in the focus of the development process and stand for quality, performance and availability of the machines. For example, spindles from GROB are characterized by their stiffness and superior milling suitability. An optimally adjusted overall concept results from the combination of excellent stiffness and dynamic characteristics of the machines. In addition to mechanical engineering, GROB is also a pioneer in innovative technologies for large-scale productions. This strategy is an important part in all production plants of GROB and enables GROB to build machines with the same quality at all sites worldwide.

Q. What are your offerings for the automobile industry? Decades of experience combined with innovative technologies – highly flexible and efficient systems, universal machining centers and assembly lines make GROB the ideal partner for the automotive industry.

COVER STORY www.mtwmag.com

Profound know-how and use of the latest technologies make GROB a recognized expert in the system business. To precisely meet its customers’ requirements, GROB produces complete system solutions in the form of topquality customizable manufacturing lines. These lines consist primarily of modular machining centers and special-purpose machines that are interlinked with the latest automation solutions. From planning to engineering through to operationally ready delivery and commissioning, GROB offers all core competencies from a single source. This deep vertical integration allows dynamic and customer-specific adjustments to capacities and guarantees an outstanding degree of reliability. Looking to the future, GROB leads the way in the electromobility sector too: GROB develops new drive and system concepts to realize powerful solutions for the manufacture of electric motors and energy storage systems, responding to technological change with individually adapted processes. GROB has years of experience in the conceptual design of systems for the assembly technology sector. All of our assembly stations and lines are custombuilt according to customer-specific requirements.

Q. What are the cutting-edge technologies you have showcased for the aerospace industry? Reliable, efficient and incredibly precise – the innovative GROB 5-axis universal machining center cuts to perfection complex and extremely stable components for customers from the

aerospace industry. GROB universal machining centers are set apart by their compact design, high productivity and optimized accessibility. As milling or mill-turn machining centers, they are the preferred choice for aerospace companies that demand the best when it comes to the stability and machining volume of their parts. The universal machining centers are perfect for machining parts like turbine blades, structural components, titanium bearing blocks, aluminum parts, structural housings and frames.

Q. Could you give some idea of the value added services you offer for electric motor manufacture? GROB is one of the few mechanical engineering manufacturers in the world that is fully geared to the issue of ‘electromobility’, and it has once again demonstrated its value as a competent service provider and partner for the automotive industry. GROB Service portfolio for E-Mobility: • Support for the design of E-machines and electric motors • Concept planning, designing and commissioning the system technology • Feasibility studies and verification of the manufacturing processes • Test rigs • Broad range of winding technologies (wave winding, hairpin, needle winding, inserting technology, fan coil) • Tried and proven technologies for slot insulation • Know-how in forming and lacing/ knotting • Implementation of the slinky

technology • Prototype construction in small series production • Testing the power units • Quality assurance along the entire process chain • End-of-line test systems • Training programs

Q. What are the new technologies you have spearheaded recently? With machine variants G500F, G520F and G600F, the design engineers at GROB have developed a series with specific features such as large work areas and high dynamics. The name of this new development sets the tone. The “F” in the product designation stands for “frame”. Our G500F, G520F and G600F are designed specifically for machining lightweight components such as frame structure and chassis parts, and can produce battery trays as well. Positive features such as the axis arrangement combined with high machine dynamics and large work areas, made possible by the horizontal spindle position, speak for themselves. The enormous dynamic is down to the newly developed axis drives. In addition, the machines are designed for MQL, dry or wet machining and can be configured either as standalone solutions or linked to other machines as part of the automated line. The machining accuracy is optimally matched to the part requirements of the sector concerned. The customer can choose between two part loading methods: Either top loading via a GROB linear gantry or front loading by a GROB pallet changer, a part changer, a part pusher, a robot or manually by an operator.

GROB’s main plant and headquarters in Mindelheim

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MACHINE TOOLS WORLD

COVER STORY Q. Could you portray the shapes of things to come in digitalization akin to your line of business? Within GROB-NET4Industry, we have been developing applications and solutions for a networked production within the Grob Group for several years now – and we are also using the applications in our factory association to increase the efficiency. In addition, GROB gives substantial support to the initiative for standardized connectivity of the German Association of Machine Tool Factories (VDW). Industry 4.0 offers great opportunities for machine and plant engineering and thus creates the basis to run the machines and systems resourcefriendly, flexibly and productively. Using web technology, the GROBNET4Industry Manufacturing Execution System creates cross-plant transparency throughout the entire production process. GROB-NET4Industry features various modular components that can be combined in a highly customizable manner, ensuring the ideal solution for each specific application case. These applications form the basis for meeting the requirements of Industry 4.0 in a manner that is flexible, productive, and conserves resources. Modules within GROB-NET4Industry allow you to manage direct and indirect areas around the machining process – the aim being to achieve the most efficient utilization of your high-precision, premium-quality machines. From production planning, monitoring, and analysis to the visualization of workpiece machining processes, proactive servicing, and maintenance, all areas of production are integrated.

Q. What’s your contribution to machine tool and flexible automation? The GROB system machines, universal machining centers and assembly lines are among the best in the world – our matching automation solutions make them even more efficient. To maintain the highest quality standard, all components are produced in-house and are optimally

MACHINE TOOLS WORLD OCTOBER 2018

G550 with GROB4Pilot and Rotary Pallet Storage System matched to our customers’ specific requirements. No matter whether tried and proven loading systems and transport components or solutions developed in-house for our customers: GROB’s semi-automated to fully-automated technology guarantees optimized part handling and efficient production. This means no discussion about interfaces due to different suppliers for machines and automation. For example the extensive GROB universal machine portfolio has been expanded with the rotary pallet storage system for small and medium palletizations. This in-house development, with its compact construction, can be flexibly employed and is attractive due to its high practicality and functionality. Our customer’s progressively expanding product variations and the related challenges for machine manufacturers have continuously led to a more sophisticated design of automation applications with high-performance storage systems. True to its decades long systems-business philosophy to be more than just a vendor of machinery but to be a total system supplier, GROB has expanded its universal machine portfolio by yet another family member. Following the development of an extensive modular system in the area of tool management (additional tool magazine), GROB will present its automation solution for universal machines: The PSS-R rotary pallet storage system, currently available in three standard sizes for attaching to a G350 and G550 universal machine.

Q. What are your future thrusts and how would you make a difference to Indian industry? Indian Industry is in a matured

transition stage. When I go through the vision statements of some of the CEOs of successful Indian manufacturing enterprises, it gets very clear that many of them are convinced that there is a need to shift the perception from using low technology to ‘state-of-theart’. Customers all over the world are becoming very demanding in terms of reliability, productivity and precision apart from a sustainable competitive advantage and India is no exception. Our focus will remain on the proven 5-axes simultaneous technology with horizontal spindle machining in highly sophisticated industrial segments of Automotive, Aerospace, Die & mold, Medical and Precision Mechanical Engineering. We will endeavour to strengthen our global leadership in customized manufacturing system solutions boosted with latest automation solutions, with both international auto makers and Indian auto companies. As India is on the verge of embarking on an exciting journey towards electric cars, GROB will introduce electromobility expertise in building hybrid and electric drives. With an outstanding service team and our sales team being well experienced in supporting several large scale international manufacturers operating in India, we will try to create new standards of round-the-clock service competence. To augment our facilities and customer support for the future and to offer competitive turnkey solutions to customers in India and neighbouring countries, GROB has decided to enlarge their subsidiary for better localization in 25 acres of land near Bangalore in the state of Andhra Pradesh.

IN FOCUS

India has a huge talent pool: Marc Jarrault, LAPP India A leading supplier of cable and connection technology, LAPP India is focusing big on research and development activities. It is extremely bullish on Indian talent pool and believes that young minds will be at the centre in driving innovation in the Indian wire and cable market. LAPP India has collaborated with the major engineering institutes across India, as well as developed a full-fledged Innovation and Engineering Centre to design, develop, manufacture and test products made in India for India. In an interview with Shweta Nanda of Machine Tools World, Marc Jarrault, Managing Director, LAPP India talks about the importance of industry-academia collaboration and India’s changing innovation system. Excerpts

Marc Jarrault, Managing Director, LAPP India Q. In your view, how can collaboration between academia and industry foster innovation? Tell us about LAPP India’s initiatives in this direction. In the early days, industrial companies designed products and provided solutions to customers’ problems. But these days, customers look not only for solutions that address their issues but also for customization, efficiency, productivity and value for money. These kinds of customer demands can only be addressed with continual innovation. Formats such as design thinking competition and innovation competition, where one designs an innovative solution for the betterment

MACHINE TOOLS WORLD OCTOBER 2018

of the industry/ society, have worked successfully for many companies. LAPP, as a part of this initiative, conducts Innovation Awards, specially designed to motivate participants among its customers from various industry segments to display their innovation. The initiative is to recognize outstanding customers across industries, who use LAPP cables and associated products and solutions to develop innovative products. There is a strong impact on sales, productivity improvement, energy savings and sustainable development.

Q. How can partnerships between industry-academia contribute to the vision of making India the next manufacturing hub? Technology around us is changing at a rapid pace and so are our demands and needs. India has a huge talent pool, and LAPP believes that young minds are the future of India’s growth when it comes to R&D in the Indian wire and cable market. The collaboration between industry and academic institutions will encourage innovation, better learning systems and produce an employmentready workforce. Millennials, today,

look for these collaborations, which provide them with an opportunity to showcase their ideas and learn about trends, technologies, challenges and problem-solving. Indian corporates are slowly beginning to realize this and are engaging in more research-based work. Such initiatives will have an impact on India’s competitiveness in the global market to help India emerge as the next manufacturing hub.

Q. Tell us about your successful R&D initiatives internally and collaborations with the institutes and colleges in India. LAPP has been in India for over two decades now, and the company aims to drive and encourage innovation. As a part of our R&D initiatives, we have developed a full-fledged Innovation and Engineering Centre and a state-of-theart laboratory in India. At these centres, we design, develop, manufacture and test products made in India for India. We encourage our employees to look at generating more efficient and advanced ways of transmitting energy, power and data and innovating better. Moreover, a substantial amount of the company’s annual turnover is committed to LAPP’s

at: See us 2019 IMTEX 103 stand B all 3A,

Introducing the Equator™ 500 gauge – intelligent process control for larger parts The larger Equator 500 system now enables the gauging of larger parts, with a working volume of 500 mm diameter, up to 400 mm height and a payload capacity of 100 kg. • High speed gauging of size, position and geometry • Accuracy with rapid temperature changes, now over a 45°C range • Automatic update of tool offsets directly from Equator 500 • Available with new automatic part loading system

For more information visit www.renishaw.com/equator500

Renishaw India [Pune] S.No.283, Hissa No.3, Raisoni Industrial Estate, Village Mann, Tal:Mulshi, Pune 411057 T +91 20 6674 6400 F +91 20 6674 6211 E india@renishaw.com

www.renishaw.com

IN FOCUS engineering centres and laboratory to innovate and launch products to meet customers’ requirements. As a part of the industry-academia collaboration, we have established Centres of Excellence at reputed engineering institutions across India to foster and support knowledge creation, insights, implementation and imparting thought leadership. We, along with various institutions, also develop a curriculum for the students to have a greater understanding of cable and connection technology and impart application-based knowledge. This curriculum also provides students with hands-on practical experience of the industry. LAPP’s vision with these partnerships is to enable multi-disciplinary research centres addressing nationally and internationally challenging areas related to cables. Our first-ever collaboration was with PSG College of Technology, Coimbatore, in 2006. This tie-up involves PSG academics, LAPP experts and companies from other industries who focus on product innovation and research on new trends of cables. Through this initiative, LAPP also sponsors a few PSG students to travel and study in German institutes for a year to gain international market knowledge. The next tie-up is with RV College of Engineering, Bengaluru. This Centre of Excellence has been productive for both the institution and LAPP by providing product design and development about the latest trends and future prototypes. The centre consists of a laboratory facility with end-to-end cable research and testing equipment. It gives students an opportunity to develop sustainable and comprehensive cabling technology solutions. Apart from the involvement in the centre, LAPP also sponsored their hybrid car under the Ashwa Racing Foundation by providing them with cables for designing the car. This year, RV College won the second position at Formula Hybrid car race in the US. LAPP has also signed a MoU with

MACHINE TOOLS WORLD OCTOBER 2018

the Symbiosis University of Applied Sciences, Indore. We are in the process of collaborating with the institution to develop a curriculum for the students, aiding as knowledge partner, supporting joint research projects and providing internship/on-the-job training for greater understanding of the cable and connectivity solutions.

Q. Are there any R&D activities directed at the smart factories of the future? We are actively re-thinking and redefining the cable and connection technology to meet the challenges of the smart factory of the future. Our portfolio includes products and solutions that meet the global standards for the intelligent factory. As a step towards this initiative, we have developed the highly flexible ETHERLINE® FD Cat. 6A that can transmit high data rates with consistent reliability in drag chains that are under constant movement with a data rate of 10 Gbit/s. Another product for the new age factories is ETHERLINE® EC. These cables are 30% thinner than usual, yet robust solutions suitable for use at the sensor level, which allows the tightest bending radii. To further strengthen our offering for smart factories, we have launched ETHERLINE® ACCESS, the managed and unmanaged switches. The switches, along with data cables and connectors from Lapp’s range of products, offer industrial network solutions to ensure reliable connectivity.

Q. What kind of talent are you witnessing in Indian universities? The millennials in India are attracted to and engaged with more innovative methodologies of learning than under

normal lecture-based classroom environments. They demand a more hands-on or experiential form of a learning experience. Hence, the educational institutes are designing their courses to include more practical knowledge and move away from traditional theoretical lectures. The institutions are now collaborating with companies in the industry and organizing competitions to bring out their talent. Young minds, these days, have abundant talent in terms of creativity and innovation. The right guidance and knowledge on how to synthesise it into real-life applications would groom them. Companies, too, are looking for young talent with a fresh perspective to challenging situations that not only solves customers’ issues but also address areas like environment safety, better productivity, timeliness and value for money.

Q. Where does India stand regarding innovation vis-à-vis other countries? Compared to India’s counterparts in Western and Asian countries, India has now moved away from older economy models where innovation was seen as an individual force. It has now adopted innovation economics, where innovation is viewed central to the manufacturing unit of every sector. Now is a great time for India to prioritize manufacturing and invest in research and development, invent better products and services, and develop new ones. Companies should be supported by knowledge, technology and entrepreneurship to foster innovation. Prompting these factors should be the main goal of our economic policy, along with developing effective privatepublic partnerships that spark increased innovation and productivity. I think the Government’s Make-in-India initiative can make a mark if it also concentrates on fostering innovation along with encouraging companies to manufacture.

IN FOCUS

‘Hoffmann is in India for the long haul’: Pinaki Banerjee, APAC MD

Hoffmann Group, Europe’s leading system partner for quality tools, is eyeing huge opportunities in India market. The company asserts that India has all the three Ps: People, Passion and Profit, which are required in the tooling industry. In line with its extensive growth plans in India, Hoffmann recently participated in Pune Machine Tool Expo. On the sidelines of the expo, Shweta Nanda of Machine Tools World spoke with Pinaki Banerjee, MD, APAC, Hoffmann Group to know more about the company’s journey, the unique challenges and opportunities of Indian market and Hoffmann’s future roadmap. Excerpts: Q. Firstly, tell us about the response that you receiving at Pune Machine Tool Expo (PMTX)? PMTX was the first exhibition in our home ground, Pune and we have received a tremendous response. We witnessed an exciting mix of interest from machining tools to hand tools, measuring instruments to workstations and storage equipment. While the customers were enthralled on our ‘consultative approach’ we are excited

MACHINE TOOLS WORLD OCTOBER 2018

to bring our expertise in tools to the Indian market. We feel the market is growing and timing is just right as we move towards exhibiting at another tool exhibition IMTEX to showcase our winning combination of over 100 years.

Q. Tell us about your journey in India. How important is India market for Hoffmann? Hoffmann’s journey in India started last year when we officially registered our

company. We have received incredible response in the market and already have a large pool of customers across the major hotspots in the country. We are deeply committed towards India market and bringing quality products to the country. The fact that our team has expanded to 75 employees in the last 18 months clearly highlights our focus on the country. We are in India for the long haul and will continue to invest more and more into the market.

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Angle Encoders

Linear Encoders

Chennai 600031, India

Contouring Controls

phone +91 44 3023 4000

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Rotary Encoders

IN FOCUS Q. In your view, what are the major challenges and opportunities in India market? The challenge in India is two-fold: it is a price-sensitive market and quality expectations are extremely high. I always highlight the challenge in India by giving this example that customers expect the quality of Mercedes at the cost of an Ambassador. So, although companies want a product of top-notch quality, they are not willing to spend money for that quality. This is a difficult combination to meet. That said, India is also standing on the cusp of great opportunity given the governmentâ&#x20AC;&#x2122;s push on the manufacturing sector with Make in India initiative. With manufacturing getting a major boost, there are immense opportunities for machine tools players. Further, there is a lot of emphasis on productivity, quality and efficiency and this is where Hoffman is really sensing opportunity, being a premium tool supplier. India has all the ingredients, which makes it a great opportunity for the companies around

MACHINE TOOLS WORLD OCTOBER 2018

the world. It has all the three Ps: People, Passion and Profit that work in the tooling industry.

Q. What would you describe as your niche? How do you stand out from competition? At Hoffmann, we always focus on longterm relationship with the customers. In India, what is typically happening is transaction-based selling, whereas we focus on entrepreneurial-based, solutionbased selling. So essentially, we go and understand the needs of the customers and offer customized products. Also, with Hoffmann you get everything that you need for your factory in one single window. This is a great advantage in Indian market, which has numerous small suppliers. When we meet customers, most of them say they want to avoid the hassle of dealing with several small suppliers and are willing to pay more for a consolidated service. This is where Hoffmann fits the bill. We also have a team of technical

specialists who go to the customers and demonstrate and show our products to them in real-time. Apart from this, we are the first company in Indian market to introduce PPE (Personal Protective Equipment) Catalogue, which focuses on safety from head to toe. Health and Safety is of utmost importance to us and even companies in India are increasingly focusing on it. Further, we are the only company that is innovating over 10,000 products every year on a global basis. This definitely puts us ahead of the pack.

Q. What is your future vision and growth plan for the company in India? We have clearly defined objectives for Indian market and our team is working hard towards achieving them. Our first milestone In India would be to hit the 25 crore mark. Secondly, our goal is to be recognized as one of the top five suppliers within the country. We are aiming to achieve these two milestones between 3 to 5 yearsâ&#x20AC;&#x2122; time.

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COMPANY PROFILE

Rajshakti : Cognitive heritage of technology excellence & precision

ajshakti is Indiaâ&#x20AC;&#x2122;s premier company engaged in the manufacturer and export of premium quality Sheet Metal Machinaries. Since our inception in 1984, we have been catering to the needs of various industries with utmost precision. Our professional management, sound infrastructure and skilled workforce has enabled us to manufacture wide range of sheet metal machinery that functions with precision and still are low in costing. With over four decades of experience, we have not just gained the experience and expertise to fabricate a vast range of products but have also gradually come to be regarded as one of the pioneers in our field. At, Rajshakti we have a strong infrastructure setup. Our state of the art manufacturing unit well equipped with the latest machineries and managed by well qualified & experienced Engineers help us to design and manufacture superior quality products that confirms to international standards. Following stringent quality control procedures, we maintain a strict vigil on the entire manufacturing process and test all our products for any manufacturing flaws at our quality control department. The manufacturing facilities are

Mr. Pravinbhai Sidhdhapura, Director Rajshakti Machines (India) LLP

among the most sophisticated in India. The organization manufacturers most of the critical parts in-house to maintain the high international quality standards of its products. The organization has reached its leadership position through a continuous commitment to quality innovation and proven dedication to

meet the ever-changing needs of its customers in all kinds of industries. Keeping this in mind it has established an ultra modern, ISO 9001-2015 Certified manufacturing facility on par with international standards. We shall endeavour to establish a long and lasting business relationship with our customers by offering optimum quality products conforming to their specified requirements. To achieve this, we shall constantly interact with our customers, and upgrade our technology to meet their growing expectations. We improve the quality of our products through research & development and make continuous efforts with consolidated inputs, and team work by motivated and trained human resources. For more information, Website: www.rajshaktimachines.com

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COMPANY PROFILE

World Class Company, Specialised for ‘Specials’

recise Cutting Tools, an Indian manufacturing company, having a typical ‘MNC work culture, is located at Pune. The company was jointly set up in 2005, by two dynamic entrepreneurs, Mr. Lijo Cherian and Mr. Rajendra Chede. Precise Cutting Tools stands today as a leading organisation, in design, manufacture, & supply of standard, as well as, - Special Tools• Turning Tool Holders, • Boring Bars, • Cartridges, • Combination Boring Bars, • Micro Boring Tools, • ‘U’-Drills, • Grooving Tools, • Indexable Ball Endmills, • Face-Mill Cutters, • Side & Face Cutters, • Woodruff Cutters, etc. A wide range of Tool Holding Devices.

Precise Cutting Tools has its prominent presence in the industry sectors, like Automobile, Engineering, Machine Tools, Die & Mould, etc. Therefore, it can be said, that “Precise Cutting Tools is for those, wherever metal cutting is done!” With the strength of product quality and service reliability, the company has grown with 100+ employees, on a setup having 13,000 sq.ft. area. The manufacturing setup is fully equipped with state of the art of a large number of CNC and 5 Axis VMC machines, supported with a sophisticated Tool-Room.

In addition to the above, Harmle – C250 and Zoller–SMILE 400 for Inspection are the prime assets of the manufacturing facilities. The organisation is certified for ‘ISO: 9001- 2015, for Quality Management System.

PRECISE CUTTING TOOLS

Moreover, environmental care, industrial safety, health of employees and social responsibility hold as integral parts of the organisational business operations. Precise Cutting Tools has been approved by a number of MNCs for their audits of Safety, Environment and Supplier Code of Conduct aspects. Organisational Prime Business

• Reducing tooling cost at the customer’s end, • Delivery punctuality, and • Innovative solutions to tool up customer’s productivity. 30% annually increasing invoicing growth rate, supported by a large number of customers spread, all over the country, is an indicator of the business performance, and customer satisfaction level for Precise Cutting Tools.

Strengths are:

• Products to meet customer’s expectations, • Processes with modern equipment having high efficiency, and • People with professional competence and passion. Precise Cutting Tools strongly believes that customer is its first concern. And the customer focus is to ensure:

• Quality what customers expect, • Shortest possible lead time,

MACHINE TOOLS WORLD OCTOBER 2018

Mr. Arvind Khadke, Corporate Consultant

For more information, precise_cuttools@rediffmail.com sales@ precisecuttingtools.com www.precisecuttingtools.com

More Precision High precision sensor systems Inductive sensors (eddy current) for displacement, distance & position  Non-contact measurement of displacement, distance and position on electrically conductive materials  For demanding, industrial environments: dirt, pressure, temperature  High resolution and temperature stability  High bandwidth for fast measurements  Customer-specific sensors and controllers  Robust and industrial-grade sensor designs  Versatile application possibilities due to comprehensive product range

Spindle Growth System  Cost-effective design  Miniature sensor design  Miniature, compact controller  Sensor technology can be integrated completely into the sensor  Suitable for ferro- and nonferromagnetic materials  Temperature measurement integrated in the sensor

+91 20 2674 1009 | info@micro-epsilon.in | www.micro-epsilon.in

COMPANY PROFILE

We give strategic advantages to our customers from diverse industries

Rupesh Paparaju, Director, Bettinelli Automation Components, India

ettinelli S.p.A, established in 1953, specializes in the development and manufacturing of precision motion control components and systems. In 1996 a separate division named CDS Cam Driven Systems was created for engineering solutions in automation and motion technology. CDS produces the widest range of mechanical Cam Driven Units, commonly known as rotary / indexing tables for precision motion control applications, requiring rotary or linear transfer, positioning and handling. The products range includes, cam indexing and servodriven tables, ring positioning drives, intermittent and oscillating drives with parallel or right angle configuration, rotary & linear part handlers, precision link transfer systems, and epicycloidal servo reducers.

Wide ranging products

The broad product spectrum covers IP parallel shaft indexers, IT roller dial indexing tables, TR roller dial indexing tables, HP roller dial indexing tables, IG/ IGA roller gear indexer, TL precision link conveyors, MHP/LHP part handlers, FTHT open center ring tables and packages of rotary indexing tables. Bettinelli has a wide range of standard products. These are delivered in 3 weeks. When it comes to customized products, these are designed,

MACHINE TOOLS WORLD OCTOBER 2018

manufactured and shipped in 6-8 weeks. The manufacturing takes place centrally in Italy. The regimen starts with design & engineering, CNC induction hardening, CNC milling, grinding, quality check and then assembly, painting and shipment. In order to ensure quality, all components are machined internally, including the cam hardening by a proprietary CNC controlled induction hardening equipment. For better finish, the products are also subjected to chemical nickel plating, blasting and painting. The manufacturing process is constantly controlled to conform to international standards. The company’s quality systems are ISO-9001-2008 certified.

are used in pallet transfer tables, assembly machines, painting applications and test rigs, just to mention a few. In machining industry, they are used with advantage in deburring, lapping and pressing machines and in transfer lines. In SPM & robotics, they find applications in transfer lines, station loading, sequential operations and so on. Inwelding, these indexers are inevitable in positioners, synchronous welding, robotic welding and component transfer. Packaging too is a major application area. Cam systems are used in box filling machines, wrapping machines, cartoning and capping machines. Indexers are also used in casting, printing and cosmetics industries.

Strategic advantages

Over the years, Bettinelli Group and CDS Indexers have become synonymous with high quality automation products and technologies. “Our design and manufacturing systems have furnished competitive and strategic advantages to numerous industries in pharmaceutical, automobile, manufacturing, packaging and a plethora of other sectors. And for automation functions, our solutions are invariably preferred by companies,” says Rupesh Paparaju, Director, Bettinelli Automation Components, India. The Indian subsidiary, headquartered in Pune, serves its customers in India by providing installation, commissioning, and after-sales support. It also offers technical consultation. In the pharmaceutical industry cam driven systems are used in filling, blister pack, tablet making and packaging machines. In automobile industry, they

Parallel Shaft Indexer

Rotary Indexing Tables, TR Series Closer to the customer

The Indian arm of Bettinelli, based in Pune, Bettinelli Automation Components Pvt. Ltd., is highly customer-centric. “Our presence in India means quite something in fostering a symbiotic relationship with our customers. It helps us to match our world-class products with our eminent customer support,” underlines Paparaju, Director, who has built up a team to improve Bettinelli’s response time. “CDS are high-tech products which lend themselves to enhance the operational efficiency and productivity at the customer’s end. We stay close to the customer to understand his needs and offer customized solutions within the shortest possible time to ensure peak uptime of his equipment and operations”, he adds. - P.K. Balasubbramaniian

CASE STUDY

Design outside the box: Modular O-Rail from Rollon enables infinite combinations The Vimercate-based group enhances its range of solutions with modular self-aligning linear rails that allow operators to set up many types of design configurations, to respond to the most specific needs of individual applications.

ome follow the rules when it

such as high resistance to wear, silent

comes to design, but there is

operation, the ability to manage heavy

one company that tries to get off

loads and significant misalignment, and

the “tracks” of tradition to find more

a good level of resistance to corrosion.

innovative solutions. This is how Rollon

When combined with its extreme

has expanded its product range for linear

flexibility, these features make this

movement solutions. The new modular

solution suitable for several types of

rails are called O-Rail: a solution created

applications in different sectors.

to add flexibility, that can open the doors

that it has a good level of resistance to corrosion.

to a potentially unlimited number of

Some examples:

design combinations.

• Machine tools: O-Rail products make

Silent and reliable, the O-Rail linear rails reach a speed of 9 m/s and an

new design options available in the

acceleration of 20 m/s, while the double

A rail with a thousand tricks

machine tools sector. Large machine

ball bearings that slide along the rails

Integrated into the Rollon range after the

doors, which are normally supported

can handle a weight that can reach 4000

recent acquisition of the Italian company

by rails located in the parts underneath

Newtons each. Lastly, the self-alignment

T-Race, O-Rail is a truly unique linear

and above the door, can be supported

properties that allow them to compensate

rail with rollers: their modularity permits

and moved by two O-Rail products

for an axial variance of +/- 1 mm and

countless configurations depending on

positioned at the base at a distance

to correct possible parallelism errors up

the task required, the available space and

that produces an arm long enough to

to 5° are absolutely necessary to achieve

the load.

manage the movement.

extreme flexibility.

The particular form of this rail, the

• Museums: another example of a field

The O-Rail linear rails are the first of

O-Rail system has three raceways placed

where the O-Rail is useful: rails are

a series of products through which the

at 90° angles with respect to each other.

used to move cantilever extractions

Vimercate-based company is enhancing

Bearings can slide on each of these, which

of heavy drawers and shatterproof

its own range, adding value to the

makes the system adjustable in different

glass. It is possible to put two O-Rail

acquisitions that it has made in recent

directions. The system’s original structure

products together to form a telescopic

years and the constant work in research

allows the designer to combine it with

extraction assembly that can manage

and development. Other new products

another O-Rail (or a different product)

heavy loads and control moment,

will be presented in the next few months.

to create new design configurations

while guaranteeing silent sliding

and find the perfect one for the client’s

movement.

application: from a double rail to a portal a telescopic option. This is possible due to

Long life and misalignment management

For more information:

the technical features of O-Rail products,

If we look at the technical features in

ROLLON INDIA Pvt. Ltd.

system, and from a single-rail structure to

MACHINE TOOLS WORLD OCTOBER 2018

detail, O-Rail linear rails are

1st floor, Regus Gem Business Centre

structured in deep nitrided steel

26/1 Hosur road, Bommanahalli

profiles thermally oxidized with

Bangalore 560068, INDIA

an innovative process called

Tel: +91 80 67027066, Fax: +91 80 67027004

Rollon-Nox able to ensure that

Email: info@rollonindia.in,

the material is very hard and

Website: www.rollonindia.in

2018_10 ER_MTW.pdf 1 01/10/2018 15:20:20

Linear solutions global provider.

CMY

ROLLON India Pvt. Ltd. - INDIA 1st ďŹ&#x201A;oor Regus Gem Business Centre 26/1 Hosur road, Bommanahalli Bangalore 560068, INDIA www.rollonindia.in - info@rollonindia.in

Linear Line

Actuator Line

Telescopic Line

Actuator System Line

Rollon is a global provider of linear motion solutions for several industrial sectors, such as: industrial machines, railway, automation, packaging and logistics, aerospace.

CASE STUDY

IFB Home Appliances Improve Lives Through Excellence In Functionality The decision of IFB’s R& D team to go with DesignTech’s Fortus 900mc proved to be extremely fruitful. The engineers get more focused on functional prototype testing and reviews with iterations as it has reduced time pressures, corrected mistakes, revisions and reworks at the later stage of development

FB Industries Limited, originally

product designs withcomplex

known as IndianFine Blanks Limited,

geometry. In order to speed up their

started their operations in Indiain 1974

productdevelopment lead time, reduce

in collaboration with HienrichSchmid

cost and produceparts with complex

AG of Switzerland. IFB’s product range

geometries without worrying aboutthe

includes fine blanked components,

required number of variations and

tools and related machine tools like

iterations, theIFB R&D team decided to

straightness, decoilers, strip loaders and

invest in 3D printing. The team wanted 3D-printed parts

more. IFB has always represented the leading

to be tough anddisplay good finish,

edge of technology,which has manifested

and acquired the Fortus 9OO mc 3D

itself through their products and service solutions. IFB consistently and positively

printer for the high-quality materials and printing it offered. Also, the fact that the

touches people’s lives through their

efforts, includingproduct design,

Fortus 900mc was built specifically for

home appliances,automotive components

prototyping and testing boil down

manufacturing and heavy industriesand

and agro—based products.

tomeeting time-to-market deadlines. In

its build size, which is the largest in

this high- pressuresituation, there’s no

FDM, madeit easy for the team to adopt

margin for lapses in productdevelopment

the technology.

Tackling roadblocks on the journey to Product Excellence

schedules or quality benchmarks.

competitive homeappliances market,

conventional process of CNC machining

Adding Value to Peoples Lives, One Product at a Time

product design and functionalityis

was very time consuming and

From the time the R&D team started

crucial to success. All of their R&D

tedious,especially when producing

using the Fortus 900mc 3D printer, their

Since IFB operates in the highly

Knob assembly 3D printed in ABS Material

MACHINE TOOLS WORLD OCTOBER 2018

For the IFB R&D team, their

CASE STUDY www.mtwmag.com

for jigs and fixtures. This is because the

during the testing process. The printouts

Fortus 900mc is specifically suited for

are also expected to withstand a

direct digital manufacturing applications

temperature of 65 degrees Celsius during

to produce end-use parts such as jigs and

functional testing for critical components. The decision of R & D team to go with

fixtures. The printer’s build size allows

Door assembly 3D printed in ABS Material

the IFB team to seamlessly print parts of

the Fortus 900mc proved to be extremely

desired sizes without having to resize

fruitful. The engineers get more focused

them. The R&D team now routinely uses

on functional prototype testing and

the printouts to effectively communicate

reviews with iterations as it has reduced

with all team members of cross-

time pressures, corrected mistakes,

functional teams, and suppliers to ensure

revisions and reworks at the later stage

adherence to agreed benchmarks.

of development.

The team prints washing machine parts such as fascia, door assemblies and DD handles, and subjects all of them to stringent tests such as thermal, chemical, pressure, vibration and functional tests. All of these capabilities make the Fortus 900mc an ideal choice considering the parts endure high heat, caustic chemicals, and sterilization and highimpact applications. For the vibration test, the team fixes parts like the knob

Final Door Assembly

component; the PCB board and the DB handle to the prototype component, and then conducts the test for accurate results. After the tests, all printed parts undergo a preliminary environmental test, functional evaluation and limited validation. The team has stringent part checks, and all parts must fit seamlessly with each other and display firmness

“We are very happy with the way DesignTech supports us. They not only pay us scheduled visits formachine maintenance, but are also very prompt in providing technical assistance in case of breakdowns. Not only this, DesignTech also conducts useful trainings for our staff, which help us better utilize our 3D printers in newer applications.“ - Vithal Fadte, IFB 3D Printing Lab.

Checking Guage

METHOD

COST

TIME

use of the machine has only grown.

Past (CNC, without 3D printer)

INR 10,000/-

Four Days

Close to 80% of the machine’s usage is

Present (3D printer)

INR 4000/-

One Day

for prototyping, but the team also uses it

Savings

60%

70% (overall)

SNAP www.qviindia.com

Instantly measure small parts automatically with accuracy assured by traceable calibration.

OCTOBER 2018

MACHINE TOOLS WORLD

CASE STUDY

ATOM™ encoders allow rapid, highaccuracy FPD inspection & repair South Korean flat-panel display (FPD) process equipment manufacturers have held a marketleading position for some time and are the driving force behind many of the recent advances seen in the manufacture of organic light emitting diode (OLED) and active-matrix light emitting diode (AMOLED) displays

PC Motion (TPC), a well-

often used in the repair of a defect,

known Korean manufacturer of

before progression to the next stage in

motion-control components, has

the process.

developed a laser aperture stop (optical slit) assembly that employs Renishaw’s

Panel defect repair

miniature ATOM linear encoder system

As modern FPD manufacturing

on multiple X and Y axes. The aperture

techniques become more complex and

stop offers a compact and precise

difficult, panel defects are increasingly

aperture-control solution for the laser

likely. Robust inspection and repair

repair of FPD assemblies and metal

procedures have been developed to

leave a sub-pixel permanently on or

photomasks.

ensure that errors, where they do occur,

off, creating a tiny dark or bright spot

have minimal effect on display quality.

on the display. Broken or shorted TFT

involves a number of complex stages

Processes needing repair operations

data lines are often the cause of bright

that build one patterned layer at a

in liquid crystal display (LCD) manu-

/ black line defects. Repair structures

time. Each additional layer to the FPD

facturing, for instance, include those

integrated into the TFT layer allow

assembly must pass through inspection

involving thin film transistor (TFT) sub-

white pixel defects to be turned to

to identify any defects likely to impact

strates, colour filter (CF) substrates and

‘black’ or ‘dull’ by irradiation with a

display quality. Laser irradiation, by a

TFT / CF alignment (cell assembly).

laser. The laser is used in ablation /

The FPD manufacturing process

neodymium-doped yttrium aluminium garnet (Nd: YAG) laser or similar, is

MACHINE TOOLS WORLD OCTOBER 2018

Damage to any one of the millions of transistors within the LCD panel may

Linear motor assembly

welding and is focused on the defect to either vaporize it or to create new

CASE STUDY contacts in the case of TFT repair. The

provides improvements in aperture

spot-size (diameter) of the laser beam

control, whilst the low mass (<4 g) of

needs to be carefully controlled so as

the readhead ensures that overall design

to encompass the defect but leave the

weight remains uncompromised.” ATOM’s miniature readhead is only

normal substrate around it undamaged. Precise manipulation of the laser

7.3 mm x 20.5 mm x 12.7 mm (FPC cable

aperture, in the range of 5 – 50 microns

variant) and is ideal for applications

(µm) in diameter, is vital to ensure successful panel repair and improved process yield.

ATOM miniature encoder

with limited space.

For this application, we selected the ATOM encoder with 50 nm resolution

Laser beam shaping

and RTLF tape scale. The accuracy of

In the FPD repair process, the precise

ATOM allows us to precisely control

position of the laser beam on a panel

aperture sizes ranging from 5 x 5 µm to

substrate is controlled by a scanning

50 x 50 µm. Before attempting to repair

mirror, or similar, while the substrate

a defect, the aperture size is pre-set and

sits on an XY air-bearing stage. The ap-

then remains unchanged until the next

erture stop lies between the laser source

repair operation.”

and the intended target. Depending on

Linear motor bearing assembly

the application, changes may be made

Miniaturised design

High-repeatability and high-stability

to the laser beam shape, spread (diver-

TPC designed its aperture stop assembly

During defect repair with a laser, the

gence) or even intensity in order to meet

to be as compact as possible, in order

size of the laser aperture must be fixed

process requirements. TPC’s variable

to fit inside a small imposed footprint.

and stable between adjustments by the

aperture stop design is novel for FPD

Clearly, consideration of the physical

operator. This requires that the encoder

repair as objective-lens systems are typi-

size of the chosen encoder system was

outputs have minimal noise, such that

cal in this application. One advantage of

essential to meet this criterion.

each vane holds its position, without

a mechanically adjusted aperture is that

Mr Hwang continues: “The laser

wander, once in place.

laser spot sizes can be precisely con-

repair tool rapidly tracks back and

trolled to within 1 µm or less, the typical

forth across the panel to the location of

repeatability be maintained in the ±0.5

feature size of 10th generation devices,

every defect, which necessitates a light

µm range, in order to limit unintentional

which allows very accurate control of

weight design to maximise throughput.

damage to the surrounding substrate.

the beam spread.

The aperture assembly accommodates

Mr Hyun-Joo Hwang, director of TPC

TPC requires that aperture stop

Mr Hwang concludes: “The

four voice coil motors, each with an

ATOM series meets all of our main

Motion, explains: “The laser aperture

ATOM encoder, all enclosed within an

requirements for a high-performance,

stop consists of four moving vanes

area of approx. 100 mm square. ATOM’s

low-noise and light weight miniature

arranged in crossed pairs. Each vane is

best-in-class feedback performance

encoder system. Direct comparison with

driven by an individual voice coil motor

competing brands has demonstrated

with a maximum travel of only 2 mm.

beyond doubt that ATOM is indeed

All four voice coil motors are equipped with an ATOM encoder system for position feedback control.

best-in-class. Renishaw’s delivery leadATOM miniature encoder

times and after-sales support have also proven to be excellent.” TPC’s confidence is reflected by

TPC four voice coil motors equipped with an ATOM encoder system

its recent development of a precision miniature linear motion stage which also incorporates the ATOM encoder. Potential applications of this new stage will include: semiconductor, FPD and others characterised by flexible, highprecision and compact production equipment.

MACHINE TOOLS WORLD OCTOBER 2018

TECH TRENDS

HEIDENHAIN Encoders for industrial robots Significant accuracy improvement at the tool center point Speed, power and durability are key characteristics of industrial robots. These robots are typically used in applications such as welding or in lifting heavy components for vehicle assembly. Yet despite advanced calibration methods, the position accuracy of industrial robots has been inadequate for certain tasks. This is now changing thanks in part to highly accurate, output-side encoders from HEIDENHAIN and AMO.

he main driver behind this development has been the aerospace industry because it must perform highly accurate machining operations on very large components. Machine tools would achieve the required level of accuracy with ease but are either too inflexible or too expensive as special-purpose machines for the job sites and working spaces involved. A robot, however, can easily reach any position on a very large component, such as the fuselage of an aircraft, and can perform tasks on it such as drilling and milling.

• In order to achieve the desired level of maneuverability, robots with serial kinematics are required, such as articulated robots with six axes. • Each one of these axes is driven by a servo motor with a gear train. Zero position error, backlash, and joint elasticities are the main sources of inaccuracy. • Applied forces and dynamic effects during the machining process affect the rigidity of the robot’s mechanics and negatively influence the absolute position accuracy.

Accuracy is impaired by many factors For these kinds of applications, however, the tool center point (i.e., the tool at the end of the robot’s arm) must be positioned and guided with sufficient accuracy. This is where the classic industrial robot runs up against its limits. Deviations result from a variety of factors:

Thanks to advanced calibration methods, it is already possible to move a tool center point to a certain position repeatedly to within several hundredths of a millimeter. Depending on the manufacturer, the repeatability of articulated robots as per ISO 9283 is ±0.1 mm or better. However, when compared with

Figure 1: Classic HEIDENHAIN rotary encoder for motor feedback

MACHINE TOOLS WORLD OCTOBER 2018

repeatability, the absolute position accuracy that can be achieved within the robot’s coordinate system is worse by a factor of ten. Depending on their design, maximum range, and maximum load capacity, articulated robots currently achieve an absolute position accuracy of ±1 mm. This is insufficient for meeting the accuracy requirements of industries such as the aerospace sector. Yet robot manufacturers have been responding to this problem. Step 1: highly dynamic motor control Classic rotary encoders continue to provide the servo motor feedback at the robot’s axes. Because servo motors require high control dynamics, the robust inductive rotary encoders from HEIDENHAIN, such as those of the ECI 1100 and 1300 series, or multiturn models of the EQI 110 and 1300 series, are ideal for this type of application. These encoders deliver high control quality and system accuracy, and they are resistant to strong vibrations. Since these encoders feature a purely serial EnDat interface, even applications exposed to strong electromagnetic interference do not impair data transfer quality or safety. These inductive rotary encoders support safety integrity level SIL 2, category 3 PL d. They can even attain SIL 3, or category 4 PL e, if additional measures are taken on the control. These encoders also provided the added safety advantage of mechanical fault exclusion against the loosening of the shaft and stator connection. With this safety package, these inductive rotary encoders can also be used in systems designed for human-robot collaboration.

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

Figure 2: Improvement of the absolute position accuracy through the use of socalled secondary encoders on every axis

Figure 3: High-accuracy HEIDENHAIN and AMO encoders for absolute position measurement on robots

mounted after each gear train, capture the actual position of every robot joint. This allows the encoders to account for zero position error and backlash. The retroactive forces on each axis resulting from the machining task are measured as well. All of this results in a 70 to 80 percent improvement of the absolute position accuracy at the tool center point. Modular angle encoders, such as the HEIDENHAIN ECA 4000 with optical scanning, the HEIDENHAIN ECI 4000 rotary encoder with inductive scanning, and the AMO WMR angle encoder, are well-suited for these applications. Thanks to their modular design with a scale drum or scale tape and a separate scanning unit, these encoders are well suited for large hollow-shaft diameters and for the challenging installation requirements often encountered in robots due to space constraints. The signal quality of these secondary encoders is considerably better than that of the rotary encoders on the servo motor, meaning that the returned position values are significantly more accurate—even for highly dynamic movements. Step 3: accurate position measurement for movable robots In order to reach all of the machining positions on very large or long components, such as an aircraft fuselage or for manufacturing large composite fiber components, robots can be moved along the length of the component on linear axes. For the highly accurate

ECA 4000

ECI 4000

WMR

Scanning principle

Absolute, Optical

Absolute, Inductive

Incremental, inductive

Inside diameter

70 mm to 512 mm

90 mm / 180 mm 60 mm to 10 000 mm

Resolution

29 bits

20 bits

Depends on the subsequent electronics

System accuracy

±2“

±25“ / ±40“

±3“ per meter of arc length

Resistance to contamination

Mounting tolerances

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

MACHINE TOOLS WORLD OCTOBER 2018

positioning of robots with a linear drive, enclosed linear encoders from HEIDENHAIN are available in lengths of up to 30 m. Position measurement from a linear encoder compensates for thermal errors and other factors that influence the feed mechanisms. These factors cannot be captured by means of conventional position detection methods based on the pitch of the recirculating ball screw and the angular position of the rotary encoder on the motor.

Figure 4 : HEIDENHAIN linear encoders

Conclusion: highly-accurate position measurement improves accuracy at the tool center point The use of secondary encoders on all of a robot’s axes, as well as the use of linear encoders for positioning the robot relative to the workpiece, enables a level of accuracy at the tool center point that allows appropriately equipped industrial robots to perform positionally accurate machining and handling tasks on components. Angle and linear encoders from HEIDENHAIN and AMO offer not only the required system accuracy but also the necessary flexibility for installation in complex and compact robot mechanisms. The suitability of these encoders for safety-related applications also makes it possible to implement human-robot collaboration systems.

For more information Web: www.heidenhain.com

TECH TRENDS

Pulsed MIG/MAG welding and its advantages over conventional MIG/MAG processes

ulsed MIG/MAG welding is a variant of the conventional MIG/ MAG welding process in which the current is pulsed. Pulsing was introduced originally for control of metal transfer at low mean current levels by imposing short duration high current pulses. The cycle consists of applying the repeated pulse current over a constant background current: Modern welding sets permit the use of a wide range of pulse amplitudes, durations and waveforms at frequencies from a few Hertz to a few hundred Hertz. Pulse amplitude and duration are best combined to melt and detach a single droplet of the same/slightly smaller diameter as the electrode wire. Selection of pulse parameters for a given wire feed speed is a complex operation. Pulse height and duration are a function of wire composition, diameter and to a lesser extent, shielding gas composition. This has lead to the advent of Synergic welding sets. Synergic MIG/ MAG (GMAW) welding is a variant of pulsed MIG/MAG welding. A synergic welding set provides unit current pulses to detach identical molten droplets of predetermined volume from the electrode wire, combined with the other parametric

relationships necessary for stable wire burn off. Unit pulses are unique to a given material and wire diameter and their details are programmed into a synergic welding set. Modern sets contain a variety of consumable and wire diameter combinations, including programmes for flux and metal-cored consumables. The three essential characteristics of synergic operation are: a. Pulse parameters are selected automatically. b. Pulse frequency or duration is directly related to wire feed rate. c. Electronic control of parameters ensures uniform penetration and weld bead profile. In practical terms, this allows an operator to pre-select wire material and diameter once for any welding operation, then adjust the one control that governs wire feed rate. The ‘one knob’ operation synonymous with this type of power source is the principal advantage of such a system compared to conventional non-synergic sets, which require that the pulse parameters (pulse frequency, peak/background current etc.) be individually set for a given wire feed speed. Thus synergic welding sets offer the

advantages associated with pulsed MIG/ MAG welding, combined with a ‘welder friendly’ control system. Synergic control is also used in conventional MIG/MAG, in which the voltage is adjusted in relation to the wire feed. It is now possible to buy a ‘synergic wire feeder’ which performs this function in conjunction with a standard rectifier power source. Advantages provided by pulsing machines include: 1) Wire and gas savings: Pulsed MIG machines offer a wider operating range because they extend the low and high range of each wire diameter. For instance, before the operator would have to stock .035”, .045” and .052” wire diameters for varying applications, but with Pulsed MIG, .045” can be extended on the low end and top end range so that it can be used for a variety of applications. What this means is that rather than having two or three different sized wires, an operator would only require one. Having one wire type minimizes inventory costs and reduces changeover times. The same is true with shielding gas – one gas can reach both the low and high ranges of the application. In addition, the different types of spare parts (gun, gun tips, liners, etc.) are decreased for additional cost savings. 2) Spatter and fume reduction Compared to Conventional MIG, Pulsing offers reduced spatter and fume. Reduction in spatter translates into significant cost savings because more of the melted wire is applied to the weld joint, not as surface spatter on the product and surrounding fixtures. This also means less clean-up time. A reduction in the welding fumes creates a safer and healthier environment for the entire plant or shop.

MACHINE TOOLS WORLD OCTOBER 2018

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TECH TRENDS 3) Heat reduction Pulsing offers controlled heat input leading to less distortion and improved overall quality and appearance which means fewer production problems. This is especially important with stainless, nickel and other alloys that are sensitive to heat input. 4) Improved productivity Pulsed MIG offers high deposition rates. In addition, since the new machines are simpler and adaptive, it is easier to weld with pulsed MIG than other transfer methods, less time is spent training. 5) Better quality All these advantages of Pulsed MIG outlined above result in overall better quality of the finished and a more stable arc. In addition, operators are receiving a better quality working environment since they are not dealing with fume, spatter & extra clean-up or grinding time. One more benefit is that synergic power sources allow for these high quality welds to be achieved by those with relatively less training. Pulsed MIG Compared to Other Transfer Methods Short Circuit In short circuit, the wire touches the work piece and shorts to itself. This is the coldest form of welding that still offers good fusion. Short circuit allows operators to weld on both thick and thin material in all positions. It also has the benefit of a small, quickly solidifying puddle. Its disadvantages include limited wire feed speed, and deposition rates. There is also a danger of “cold lapping” on thicker metals. This is where there is not enough energy in the puddle to fuse properly. Short circuit also produces an increased amount of spatter over the other transfer methods. Globular The globular transfer mode is basically uncontrolled short circuit. It is characterized by a large volume of weld metal coming

MACHINE TOOLS WORLD OCTOBER 2018

off the electrode. These large droplets are pinched at the arc and drop into the puddle. This method of transfer produces a tremendous amount of spatter as well as high heat input. Also, globular is limited to flat and horizontal fillet welds. Less fusion is often common because the spatter disrupts the weld puddle. Also, because globular transfer uses more wire, it is generally considered less efficient. On the positive side, globular transfer runs at high wire feed speeds and amperages for good penetration on thick metals. Also, it can be used with inexpensive, CO2 shielding gas. It is used mainly when appearance is not an issue. Spray Arc Spray arc propels small molten droplet of the electrode to the work. It is a pure CV process that must produce enough current to send a constant stream of metal off the electrode. Its advantages include high deposition rates, good penetration, strong fusion, good weld appearance with little spatter. Its disadvantages include high heat input, a limited range of welding positions and proneness to burn-through on thin materials. Customization of the Waveform To take the pulsed MIG process a step further, complete customization of the welding waveform can be done through state-of-the-art Waveform Control Technology. This technology allows the power source to be finely tailored to the wire and process. The power source rapidly adjusts the pulse waveform for superior welding performance. It does this by providing a fast or slow front edge on the pulse to transfer the droplet at the proper rate, the back edge then falls at a controlled rate to add the heat needed to wet the droplet to the puddle. With Waveform Control Technology®, built-in templates are set up in the power source for standard usage on a variety of materials. Variables such as ramp rate, peak time, tail out, and step off, among others are controlled in a precise

manner so that when there is a change in the process set-up, there is a corresponding change in waveform configuration. Equipment Selection Pulsed MIG welding has evolved quite a bit since it was first introduced to the marketplace. In the 1980s, it was a highly complex process that could only be performed by the most skilled welders. That was because the operator would have to know exactly how to set the machine for the correct wire feed speed to perform this type of welding. Today, this is all done for him or her as part of the synergic control. When the operator adjusts wire feed speed, the synergic operation adjusts the wave-shape and frequency automatically. The synergic operation of the machine makes it easy to use, even for the beginning welder, with a single knob that controls all operations. In addition, its sophisticated internal electronics are even “adaptive” to adjust for variations in stickout, gap or the torch angle. Ador welding has introduced the latest generation pulsed mig equipment Salient features • Synergic function for automatic selection of welding parameters with respect to • Job thickness • Joint Geometry • Wire feeder with remote parameter setting facility • Pulse MIG Power Source • Water Cooled MIG Torch • Water Cooling Unit Conclusion : Cost savings, better quality, improved productivity and easier operation… all these factors make Pulsed MIG an option that should not be overlooked. Although the high price tag may scare you, carefully weigh the initial investment with the benefits that will be derived over the long term. Take advantage of the new technological advantages provided by Pulsed MIG – one machine to handle virtually any application, flawlessly. (Courtesy: Ador Welding Ltd.).

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TECH TRENDS

FastMig M – A new breed of industrial workhorse

The author, Ilhar Ul Hassan M S is a Solution Engineer at Kemppi India. He is an M.Tech in Welding Engineering from NIT, Trichy. Earlier he has done his B.Tech in Mechanical Engineering from GEC, Kozhikode.

astMig M is a multi-process welding solution from Kemppi delivering high performance in demanding industrial applications. FastMig M is a robust and heavy duty welding machine in modular design. Its compact and lean dimension and reduced weight increases its usability and mobility in worksites. The modular design in hardware and software enables the user to choose the preferred configuration suiting their requirements. FastMig M incorporates advanced control technology and strong duty cycle ensuring excellent arc characteristics, welding performance and increased productivity. 2-Product Package Offerings FastMig M enables the use of both GMAW and MMA welding. There are two product package offerings to choose from for the optimal welding applications - regular easiness and synergic diversity. The regular package is for basic use where the controls are done

MACHINE TOOLS WORLD OCTOBER 2018

by two knobs and the synergic package is for advanced demanding applications. The one-knob control of the synergic package facilitates easy parameter setting and saves time. After selecting wire material, its diameter and the gas combination, the required parameter can be controlled by the rotation of a single knob. 59 Welding programs come as standard in the package ranging from steel, stainless steel, aluminium and even brazing application. In steel it covers solid as well as flux-cored and metal cored applications. The synergic package also offers voltage fine tuning keeping the set wire feed speed or current constant. FastMig M comes with three power levels and three wire feeders supporting both regular and synergic package. The required configuration can be selected as per the user’s requirement increasing equipment efficiency and utilization. Whatever configuration you choose, it’s easy to upgrade later when the need arises. The available power sources are FastMig M 320A, 420A and 520A. When FastMig M 420A and 520A power sources deliver maximum current at 60% duty cycle, the FastMig M 320A power source delivers it at 100% duty cycle. And at 100% duty cycle FastMig M 420A and 520A machines deliver maximum current of 380A and 430A respectively which are figures that speak for themselves. Multi-voltage version of power source FastMig M 420A is also available.The three wire feeder combinations available are FastMig MXF 63, MXF 65 and MXF 67 where MXF 63 is supporting a 200mm

wire spool while MXF 65 and MXF 67 are supporting 300mm wire spool. FastMig MXF 67 has an extra strong dual-skin plastic casing for enhanced protection. Cooling unit can also be integrated as per the requirement. Features Galore Upto 5 programs along with other features can be saved in the memory channel and easily recalled in the synergic package providing even more easiness in parameter setting. Additional control features like Hot Start, Crater Fill, Creep Start, MiniLog and Panel

TECH TRENDS Lock also comes along with normal process settings. The normal process setting like Pre-gas and Post-gas will get automatically set in the synergic package according to the selected program which also can be changed as per requirement. FastMig M synergic version allows the usage of Kemppi’s Wise and Match software modules for welding optimization. Increased welding speed upto 30% higher, penetration, quality, and ease of use are achievable with WiseFusion. WiseFusion is a special process for synergic MIG/MAG and pulsed arc welding. It keeps the welding arc focused so that the arc density concentrates in a narrow area. Providing better penetration and faster travel speeds. In addition to that, lower deformations in the welded material means less straightening work, saving time and money. WisePenetration

application software delivers consistent power to the weld pool regardless of distance changes and deviations between the welding gun nozzle and work piece, reducing welding defects and parameter adjustments. WiseRoot and WiseThin give optimized root pass welding and thin sheet welding respectively. Employing WiseRoot increases the speed by three times when compared to TIG for root pass welding. WiseThin Provides 10-25% lower heat input than normal MIG/MAG welding, reducing post-weld material distortion. These Wise features will provide improved adaptability in demanding industrial applications. MatchLog enables quick change in welding parameters during welding

increasing productive time. SuperSnake extends the reach of standard Euro MIG welding guns, providing simple distance wire feeding for a variety of filler wires. The SuperSnake GT02S/GT02SW removes the need to carry wire feed units, reducing personnel fatigue, improving safety, and increasing productivity. SuperSnake extends your working range with FastMig M up to 30m. MagTrac from Kemppi integrated with FastMig M assures simple way to gain the benefits of mechanized welding, ensuring fast travel speeds and constantly high quality each time. FastMig M finds its applications in shipbuilding, pressure vessel and boiler manufacturing, railways, heavy machinery fabrication and many more. It is a reliable and robust work horse for the current industrial applications.

Renishaw’s new multi-axis periscope enables unmatched flexibility

enishaw’s new multi-axis periscope (RMAP) is designed to enable six degrees of freedom measurements in XY stage applications, utilising the performance from the RLD10-X3-DI interferometer head, to accurately measure pitch, yaw and roll. Measuring angular deviations within the stage motion enables correction of these errors, within the machine motion, to improve positioning accuracy. Whilst these measurements can be achieved using independent differential interferometer heads, the multi-axis periscope minimises the beam footprint to 18 mm by 35 mm, allowing for smaller stage mirrors and lowering machine costs. With an angular range of ±30 arc seconds, the multi-axis periscope is compatible with most high-performance stages, further optimising their performance. A single mounting face enables the multi-axis periscope to be

MACHINE TOOLS WORLD OCTOBER 2018

installed quickly and easily to the vacuum chamber or metrology frame. Using the RLD10-X3-DI head for angular measurements allows for errors generated from laser frequency variation

and environmental changes to be common between the two paths. This improves the accuracy and repeatability compared to angular deviations calculated from two independent beams.

TECH TRENDS

Rolling power linked to the growth of the wind energy industry

Plate bending roll for manufacturing wind towers

Mr. Giordano Toninelli â&#x20AC;&#x201C; Area Sales Manager â&#x20AC;&#x201C; Faccin SPA

n recent years, wind energy has become one of the most common renewable energy sources, leading the transition away from fossil fuels. The industry has been moving forward relentlessly throughout innovation and change, thus improving its competitive cost, and an assertive policy of developing renewable energies by governments. Wind turbine prices have fallen by almost a third since 2009 due to enhancements in turbine technology and onshore wind is now a competitive source of electricity compared to nuclear, coal or gas. Moreover, wind power costs are expected to decline even further, averaging 26% to 35% by 2025. Environmental benefits are also associated to this trend. Water is an essential ingredient for energy production processes and wind power requires none. Additionally, doubling the share of renewables would also decrease harmful emissions from pollutants. Furthermore, green energy

MACHINE TOOLS WORLD OCTOBER 2018

would eventually contribute to mitigate climate change, a worldwide problem that needs to be addressed, and will have a positive impact in the labor market by reducing the level of unemployment since renewable energy requires more people per unit of electricity than oil or gas. Wind power demand is rapidly rising in practically every corner of the world, pushing the wind towers to evolve in size & type, from onshore to offshore towers, increasing the electrical capability from 4 MW up to 8 MW. Consequently, a big share of the electricity will most likely be produced by facilities located offshore, where winds are stronger and more reliable. One of the main differences between onshore and offshore towers, besides the diameters and thicknesses of the sections, is the need to connect the offshore tower to the seabed using a dedicated foundation system, a basement made of different designs, which anchor the tower to the seabed.

As a result, bigger and safer structures must be built, turning the foundations fabrication into one of the key production processes related to the wind tower market. Wind Tower Foundations: plate rolling Business Connected to the Wind Power Industry The most common foundation types currently used in the wind tower business (Wind Europe 2017) are monopiles, which represent approx. 81.7% of all installed substructures in Europe, Jackets, close to the 6.9% and Gravity base foundations with almost 6%. The rolling capacity demanded for tower production, for instance, is different compared to foundations production; additionally, different foundation types also have different requirements. Which Plate Bending System? Bending hundreds of cans per month

TECH TRENDS www.mtwmag.com

Advantage Package that consists in +50% movements speed, simultaneity of the movements and micro-positioning in order to reach the floor-to-floor production time of 20min per rolled tube with the best accuracy. The rolling machinesâ&#x20AC;&#x2122; geometry and controls must be planned to reach the tightest tolerances and to minimize the re-rolling percentage of the cones that is a common problem on the lower quality plate rolls. Thanks to its long experience, FACCIN SPA provides a dedicated customized package for every requirement related to the rolling of cans for towers and foundations: its WIND TOWER AUTOMATION SYSTEM, a purposedesigned package available for the most exigent producers looking for reliability, speed, accuracy and costs reduction.

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MACHINE TOOLS WORLD

TECH TRENDS

Measuring spindle growth in high speed milling machines

n order to minimise positioning errors in machine tools, the eddy current sensor SGS 4701 measures the thermal extension of high-frequency spindles. The spindle is at the heart of a machine tool and so plays a decisive role in the dimensional accuracy and surface quality of the respective workpiece. High speeds and the heat generated result in the axial extension of the workpiece spindle and to the resultant positioning error during finishing of the workpiece. The new eddyNCDT SGS 4701 miniature eddy current sensor measures the thermal and centrifugal force extension of highfrequency spindles by measuring on the labyrinth-ring. The measured values are fed into the CNC machine tool as correction values and compensate for any positioning errors. The miniature sensor models have dimensions of 4.5 x 10 x 12 mmÂł or 4 x 4 x 10 mmÂł and can be integrated with the controller

MACHINE TOOLS WORLD OCTOBER 2018

into the machine tool spindle. For ease of handling and in order to achieve maximum accuracy, the eddyNCDT SGS 4701 is factory calibrated for ferromagnetic or non-ferromagnetic materials used by the customer. For temperature compensation of the eddyNCDT SGS 4701, the temperature of the sensor is measured via the resistance of the eddy current coil. This signal is also available to the customer, which can eliminate the need for any additional temperature sensing technology. Due to its interchangeability with the previous model, the new mini-sensor technology can be easily upgraded at any time. This sensor is now available as a standard catalogue product and suited for OEM modifications as well.

For more information, Website: www.micro-epsilon.com

TECH TRENDS

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

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

MACHINE TOOLS WORLD OCTOBER 2018

blowing valve. And since the air gets throttled in the process, its temperature drops substantially. If there is moisture in the air, there are chances of that moisture freezing in air passages or in the blowing valve itself. Hence in the humid marine environment, maintaining air quality is crucial not just for diving and rising but also for engine controls, weaponry and various other control systems. Compressed air is therefore maintained at a minimum of -20o C at atmospheric dew point. Failure to do this resulted in the sinking of the USS Thresher, a US navy nuclear submarine in 1963. The vessel sank as the presence of moisture in the compressed air led to icing in the blowing valve. Following this disaster, the usage of air dryers on all submarines has been made mandatory the world over. However, the traditional absorption technology that is widely used in air dryers has its disadvantages. The desiccant granules in dryers turn into clay or become powdery over time that need to be replaced periodically.

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

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TECH TRENDS

Difficult milling made easier Dormer Pramet’s family of solid carbide milling cutters for difficult to machine materials offers a variety of options from roughing through to finishing

he S2 assortment includes a range of neck options for deep milling and multi-flute designs to support numerous applications in tough steels, titanium and nickel. Its differential pitch cutters (S260, S262, S264), for example, reduce chatter and offer fewer tool offset adjustments, providing effective chip removal at high feed rates. The trio of cutters - available in diameters from 3mm-20mm - feature an optimized cutting-edge to reduce chipping and prolong tool life. All have an AlCrN coating for improved wear and oxidation resistance. In addition, the S264 milling cutter has a robust corner chamfer on the end teeth to further reduce chipping and a roughing profile for greater removal rates. Also, the S262’s corner radius provides a more precise finish and optimizes performance, especially in ramping operations. Meanwhile, Dormer Pramet’s six to eight-

MACHINE TOOLS WORLD OCTOBER 2018

flute cutters (S225, S226, S227) feature a high helix angle to keep the cutting edges constantly engaged with the work-piece. This results in clean, efficient machining and a high-quality surface finish. Several neck options are available to support pocket milling, up to 8.8xD, by preventing contact between the shank and work-piece, eliminating the risk of vibration and scouring. To support general milling applications, the company’s range of fourflute cutters (S216, S217, S218, S219) offer a reach up to 9xD. This range also features

an optimized cutting-edge design and an AlTiN coating for high hot hardness and oxidation resistance. A special edge treatmentprovides a smooth and quiet machining process, further prolonging tool life. Finally, an assortment of ball nose cutters (S229, S231, S233) are available in 1.5mm-16mm diameters, offering up to 8.3xD. As well as a special edge treatment to support smooth machining, its TiSiN coating provides improved wear and oxidation resistance in extreme cutting conditions.

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TECH TRENDS

Double Quattromill® 22 of Seco Boosts Heavy-Duty Face Milling Operations The new cutter, for both roughing and semi finishing, features eight inserts with multiple cutting edges that cost-effectively increase depths-of-cut for high output

eco’s latest breakthrough in face milling cutters, the Double Quattromill® 22, significantly boosts metal removal rates and allows shops to push machine tools to their full milling potentials. The new cutter, for both roughing and semi finishing, features eight inserts with multiple cutting edges that cost-effectively increase depths-of-cut for high output.

The Double Quattromill® 22 comes in 45° and 68° lead angle versions for depths-of-cut up to 9mm (0.350”) and 11mm (0.430”), respectively. Unlike those on standard tangential-type face mills, the Double Quattromill® 22’s doublesided inserts are extremely free cutting for lower cutting forces/machine power consumption and longer tool life. Because of its two lead angle options,

Double Quattromill® 22 fits into the transitional area between easy and economical cutting. Choose cutter bodies in fixed-pocket and cassette styles, standard or close pitch and metric or inch versions. Seco also applied its new surface texture technology to the Double Quattromill® 22’s cutter body flute surfaces for enhanced chip control and evacuation as well as durability.

The Double Quattromill® 22 offers three insert ranges with various edges and grade options. The ME12 geometry works with superalloys and stainless steels. The M12 geometry comes in many grades for compatibility with most workpiece materials. The M18 covers steels and cast irons, which require heavier edge protection.

MACHINE TOOLS WORLD OCTOBER 2018

TECH TRENDS

Kennametal’s newest helical milling cutter takes first place Maximum metal removal rates, and maximum flexibility characterizes the new HARVI Ultra 8X

magine burying a roughing tool in a block of Ti-6Al-4V titanium and ripping away more than 1000 cm3 (61 cubic inches) of material in just one minute. If you’d been at a recent test of Kennametal’s new HARVITM Ultra 8X helical milling cutter, you’d have seen exactly that. Using a 95 mm (3.74 in.) axial depth of cut, 20 mm (0.78 in.) radially, and a feedrate of 423 mm/min (16.65 ipm), the 80 mm (3.15 in.) diameter HARVI Ultra 8X plowed through this difficult aerospace superalloy for nearly three minutes straight without flinching. Maximum Excitement Tim Marshall, senior global product manager for indexable milling, has tested the HARVI Ultra 8X with a variety of customers, pushing the limits of the new cutter on everything from 15-5 PH to cast iron to Aermet 100 (high strength steel) and seeing outstanding results with each. “Kennametal developed the HARVI Ultra 8X to meet two distinct needs,” Marshall says. “The first came from the aerospace industry, which thanks to the large numbers of aircraft being built today requires the highest metal removal rates possible but still achieving excellent tool life. At the same time, machine tool builders and users alike are asking for tools able to withstand higher cutting speeds but generate lower machining forces, so as to reduce wear and tear on machine components during extreme cutting conditions. The new HARVI Ultra 8X does all that, and a lot more besides.” Massive piles of chips notwithstanding, your shop almost certainly wants its tools to stay in the cut far longer than three minutes. Marshall agrees, saying the HARVI Ultra 8X was designed to predictably remove 20 cubic inches (328 cm3) of Ti-6Al-4V each minute while attaining 60

MACHINE TOOLS WORLD OCTOBER 2018

minutes of tool life per cutting edge. What’s in a Name? This last point is particularly important. A variable helix geometry greatly reduces carbide-killing vibration. Using 12 mm and 10 mm inserts also helps, as their smaller size means more inserts in the cutter body, more inserts engaged in the workpiece, and more inserts to absorb the pounding of a heavy machining operation. Yet the HARVI Ultra 8X has even more tricks up its sleeve. Precision through-thetool coolant nozzles direct cutting fluid where it’s needed most. An enhanced flute design assures maximum chip evacuation. Oversize M4 Torx Plus screws for greater insert stability. The option with a KM4X adaptor brings greater toolholding stability. Specially-prepared insert edges optimized for the KCSM40 grade greatly extend tool life. Corner radii from 0.8mm to 6.4mm, in both inch and metric, means there’s little you can’t machine. Beyond Ti-6Al-4V “We’ve optimized everything about the HARVI Ultra 8X,” says Marshall. “The flutes and the coolant nozzles assure maximum chip flow, something that’s very important when you’re removing this much material—without it, the chips get jammed up and you’re facing catastrophic failure. Our KCSM40 grade has proven to be a top performer in high-temp

Inserts with 8 cutting edges in a helical milling cutter. No one else has that. Insert sizes with IC10 and IC12 mm, 8 different corner radii available.

Stiff, stiffer, HARVI Ultra 8X. The bolt taper flange cutter with a KM4X adaptor provides unmatched stability.

Whether pocketing or profiling, the HARVI Ultra 8X consistently removes up to 20 cubic inches of titanium per minute, with tool life of one hour or more

alloys, but we also offer several equally excellent grades for other work piece materials. And eight cutting edges per insert? Nobody else has that in a helical cutter.” Double sided inserts not only means lower cost per edge but the ability to increase speeds and feeds beyond what was previously possible, Marshall notes. And because the HARVI Ultra 8X is available with an integral shank or the “crazy strong” BTF46 mount, users can adapt the cutter to virtually any machine tool spindle with no loss of rigidity. “We go up against our competitors’ and sometimes even our own helical cutters and are blown away by the performance improvement,” he says. “For anyone who’s looking for the highest productivity at the lowest possible cost per edge, this is the cutter for them.”

TECH TRENDS

Custom Designed Toolings: Are They Justified?

Mr. Riyazuddin Pasha M. Head - Developments, Hoshi Tools (P) Ltd

onger waiting period, too complicated and expensive are some of the first impressions of engineers at production shops about the Special Tooling. Is it really, true? Letâ&#x20AC;&#x2122;s analyse. Custom Designed Cutting Tools, also called as Special Cutting Tools, are considered, only in specific cases. Initially, they may feel to be expensive, but when analysed thoroughly they prove to be profitable. There are two kinds of Cutting Tools: Standard tools, which are applicable for general manufacturing conditions and Custom designed cutting tools, which are best suited for specific machining requirements. Let us consider a simple example of specific need of a component, with multiple cascaded bores with chamfering & facing at each bore, to be machined; in a conventional way, by using a suitable boring tool, programmed to trace the entire contour on a CNC machine could be the solution. Here the boring tool is a single point tool, we have to program for multiple passes & tool retracts, thus taking longer time for machining, also there is certain amount of tool deflection of the tool, being loaded at single point, which is to be compensated while machining. The programmer also needs fair amount of experience of CNC Programming. Consider the same situation, with a Custom designed cutting tool, 2, 3 or more

MACHINE TOOLS WORLD OCTOBER 2018

cascaded bores can be accommodated in a single tool, positioning the inserts in such a way to generate each diameter, distances between bores, chamfers, facing etc, predefined at tool design stage. Most commonly, each diameter is generated by 2 or more inserts, thus resulting in machining time reduction. The tool is also well balanced, because it moves with single axis & the cutting edges are well positioned. The programming is, as simple as Z-Axis movement, Start & End-points with Single pass of the tool, for entire machining. Due to complexity of custom designed tools, it takes time initially, but once established, the ordering process remains as good as Standard Tools. There could be multiple solutions for the same special requirement, but considering the material to be cut, quantity & quality of the product to be produced, machine capacities for optimal usage, it is essential to look for an appropriate design of the

tool. The customer who are considering special tooling, shall plan ahead of scheduled production, because it takes some time for trials and fine tuning of tool for optimal results with variable parameters of machining for establishing the tool for production-ready. Hoshi Tools, at Bangalore is one among the very few established Custom Cutting Tool Manufacturers, since the year 2002. Its proven track record shows that it is a trusted partner by various industries as well as Standard tool manufacturing MNCs, for their special requirements. Through advanced CAD / CAM applications, the designs can be simulated to avoid possible errors, after manufacturing. Our engineers stand-by & assist the customerâ&#x20AC;&#x2122;s production team while the machining is being established. For higher Productivity & Profitability, Custom Designed Cutting Tools, are justified.

PRODUCTS SHOWCASE www.mtwmag.com

PRODUCT SHOWCASE KING CUT PRO – The Large Gantry Type CNC Cutting Machine Ador’s KING CUT PRO is a CNC portal cutting machine which is very precise and reliable. The machine has one head for plasma sheet metal cutting and one head for flame cutting of sheet metal with a dual side longitudinal drive with AC motors. The standard equipment comes with a basic machine package with CNC controller, one torch, central gas diffusion with manometers and a remote flame ignition.

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

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

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

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

OCTOBER 2018

MACHINE TOOLS WORLD

PRODUCTS SHOWCASE

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

Following are some of its unique features:

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

• • • • • • •

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

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

Ballscrews with Rotary Nut (Compact) - FSKT The ball spline has load groove of three row on the outside diameter of shaft. Due to the Gothic arch groove design, it could be make sure three grooves withstand clockwise or Counterclockwise of torque, and then increase the service life and rigidity. The Spline nut has a special designed support bearing directly set up on the outer ring of tThe 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

For Product Enquiry Contact Superslides & Ballscrews Co. India Pvt Ltd SUPERSLIDES HOUSE, A-774 T.T.C Industrial Estate, MIDC, Firebrigade Road, Off Thane- Belapur Road, Koparkhairne, Navimumbai-400 701 (INDIA) Tel.: 022-4935 5555 (40 Lines), Fax: 022-4935 5556 E-mail: sales@superslides.in / info@superslides.in Website: www.superslides.in

MACHINE TOOLS WORLD OCTOBER 2018

• 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 sti ness 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 Con¬figuration: 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.

PRODUCTS SHOWCASE www.mtwmag.com

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

Designed to performs

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

“When we set out to re-engineer our rocking piston compressor, we aimed to do more than just increase pressure. We set out to dramatically reduce sound, enhance flow, create a standard footprint for easy retrofit anywhere in the world and improve the compressor’s aesthetics,” says Gast. The inherent design of rocking piston technology makes it the optimal choice for applications requiring high pressure or vacuum and air flow in a small package. The flexible cup is made with superior materials and mounted on top of the connecting rod, creating vacuum or pressure while maintaining a tight seal against the cylinder walls in a rocking motion. The forgiving design has fewer components, causes less friction and has a low exhaust temperature, for greater reliability and durability for the life of the product. Despite it’s small size, the versatility of 86/87R means this is the right product to deliver quality air solutions.

Accessories for Safety Pull Cord Switch SMARTsaa, an associate company of Protocontrol Instruments I Pvt. Ltd. Pune offers variety of accessories for Safety Pull Cord Switches for use on machines like cutting machines, printing machines and wood working machines for emergency stoppage.

Accessories:

For Product Enquiry Contact Smart Sensors and Automations E-12, Mangalmurti Industrial Estate, T-80, MIDC, Bhosari, Pune: 411026 India Mobile : 7028376392 E mail: sales@smartsaa.com, smartsaasales@gmail.com

• Wire Rope Holder : CPA-01 : For easy removal of rope while maintenance work • Wire Rope thimble: CPA-02. Protects rope against breakage due to small loop • Cable rope clamp : CPA -03 , for holding the rope tightly • Pulley : CPA-04 to be used when rope is turned around the corners • Stay Bolt : CPA-05 for holding the rope • Turnbuckle for adjusting the cable tension: CPA-06 • Spring for rope tension : CPA-07 • Steel rope , PVC coated, 5 mm diameter : CPA-08 • LED Lamp for indication of operated switch • Additional Junction Box for termination of wires : JB SPC • Cable glands : M 20 , ½ inch NPT , ¾ inch BSC The rope is to be hooked around the work area and at convenient height such that the operator will find is convenient to pull when in an emergency by using turn buckle, spring and thimbles.

OCTOBER 2018

MACHINE TOOLS WORLD

PRODUCTS SHOWCASE

Safety Pull Cord Switch SMARTsaa. An associate company of Protocontrol Instruments I Pvt. Ltd. Pune offers new and advanced range of Safety Pull Cord Switches for use on machines like cutting machines, printing machines and wood working machines for emergency stoppage. To be used with steel wire. The contacts of these switches are to be interlocked such that when switch is operated the machine should stop, protecting human, machines and other vital and machine elements.

Salient Features: • • • • • • • • •

The switch works actuates contact when rope is pulled The switch also actuates when rope is broken, slack The switch provided with reset button for local reset Single switch for long conveyors up to 160 Mtrs against multiple number of conventional switches Robust design, Enclosure , totally sealed IP 67 Optional LED indicator Compatible to EN418 norms Confirms to EN60947-5-5 , IEC60947-5-1 Available in Single side operation or both side operations

The rope is to be hooked around the work area and at convenient height such that the operator will find is convenient to pull when in an emergency by using turn buckle, spring and thimbles. The switch resets when rest push button on switch is pressed. The switch designed for different rope length up to 120 meters is available. Single side operation (left or right side) as well as both side operation options are available. Special switches with rope break indication contact are also available. LED indication lamp can be provided for remote indication

SPCIFICATIONS:

• • • • • • •

Safety Pull Cord Switch Operation: Left, Right, both way operations Rope length: Both side operated switch: Up to 80 Meters each side Contact arrangement: 1 NO + 1 NC, 4 NC / 2 NO, 2 NC / 1 NO, Contact Rating: 10 Amp resistive at 230 V AC Enclosure: Field mounting IP 65 / IP 67, Plastic, Metal Cable Entry: ½ inch NPT

Accessories: Pull Cord Cable, Turn Buckle, Wire Rope Thimble (Rope Eye), Pulley, Stay Bolt, spring.

Looking for industrial Products for your plant/workshop ??? Connect to right manufacturers & suppliers http://www.mtwmag.com/category/products/ 100

MACHINE TOOLS WORLD OCTOBER 2018

PRODUCT INDEX A

Energy Absorption & Vibration Isolation

AC / DC Geared Motor

AC Linear Servo Motor

Actuator

Flex Clamps

Actuator Line

Flexible Couplings

Air Compressors

Alloy Wheel Machining Solutions

Aluminium Profiles

Gas Flow Products

Angle Encoders

Gas Management

Automation Products

Gauge

Gear Boxes Gears, Racks & Pinions

Planetary Gear Boxes F

G 71

H 79

High Pressure Filtration

Horizontal Machining Center Hydraulic Press

Cam Driven Systems

Hypid Gear Boxes

Casting

Circuit Identifiers

Clamp Meters

22, 23 87 74, 75

I Inserts

FRONT GATEFOLD

Instrumentation Fittings & Valves

Clamps for Linear Guides

CNC Grinding Machines

CNC Horizontal Boring Machine

CNC Lathe

Lathe Machines

L Length Gauges

CNC Smart Mills

Light Energy Management Systems

CNC Solutions

Linear Actuators

CNC Turning Center

Linear Encoders

CNC Vertical Machining Center

Linear Guideway

Linear Line

Linear Motion Guides

Continuity Testers

Lubricants

Contouring Controls

Current Testers

Curvic Coupling Cutting Tools Cycloidal Gear Boxes

S Screwiacks

Sensor Systems

Slewing Ring

Stabilizers

Static Elimination Solutions

Stepper & BLDC Motor

Surface Cleaning

T Taps

FRONT GATEFOLD

Telescopic Line

Test & Measurement Tools

Thermal Imaging Cameras

Threading & Grooving Solutions Tool Holders

IFC

FRONT GATEFOLD

Turning Centers

BACK PAGE IFC

Twist Drills

Mass Flow Controllers

Megohmmeters

Metal Forming Machines

Ultra Isolation Transformers

Metal Working Fluids

Universal Machining Centers

74, 75

9, 33

Milling Solutions

Dimensional Measurement Systems

Moisture Meters

Double Column Machining Centers

Motion Toolpaths

Drill Tap Center

Motor Rotation Testers

Multimeters

Multi-Spindle Machining Centers

IFC

FRONT GATEFOLD, FALSE COVER

IFC 57 IBC

E Endmills

Machining Centers

Digital Inverter technology

Drills

FALSE COVER

Rotary Encoders

Turning Solutions

Drilling Solutions

R Reamers

Harmonic Filters

Consumables

Real Time Power Factor System

Cables

INNER IFC

Precision Ball Screws

74, 75

Coatings

Precision Air Moving Products

Pump Solutions

CNC Machines

Power Conditioners

Ground Resistance Testers

Grinding Machines

Power Analyzers

Brake Motors

Position Displays

73 37

Project Engineering Solutions

Ballscrews Boring Sytems

74, 75

Plasma CNC Cutting Machines

Pressure Control Solutions

Ball Transfer Units Bevel Gear Boxes

FRONT GATEFOLD, FALSE COVER, 19

Oil/ Coolant Mist Cleaner

Oxy-Fuel CNC Cutting Machines

V Vertical Machining Centers

Voltage Detector

W Welding Equipments

3-Phase Testers

OCTOBER 2018

MACHINE TOOLS WORLD

101

ADVERTISERS INDEX COMPANY NAME

PG. NO.

A ACE DESIGNERS LTD. ADOR WELDING LIMITED ANCA MACHINE TOOLS PRIVATE LTD APEX PRECISION MECHATRONIX PVT. LTD.

COMPANY NAME

PG. NO.

GLOBE-TECH ENGINEERING EXPO - 2018

GP PETROLEUMS LTD.

PARAGON MACHINERY CO. LTD.

GROB MACHINE TOOLS INDIA PVT. LTD.

PRECISION MOTION INDUSTRIES, INC. ( PMI )

GRUNDFOS PUMPS INDIA PRIVATE LTD.

BACK PAGE

COMPANY NAME

PG. NO.

69 7

QVI INDIA PVT. LTD.

B BETTINELLI AUTOMATION COMPONENTS PVT. LTD. BIRLA PRECISION TECHNOLOGIES LIMITED

C CNC SOFTWARE, INC.

INSIDE BACK COVER

D DOWEL ENGINEERING WORKS

DUTCH TECH TOOLS PVT. LTD

R 53

HOSHI TOOLS (P) LTD

HYUNDAI WIA INDIA PVT. LTD.

I IMTOS - 2019

INTEC - 2019

JYOTI CNC AUTOMATION LTD.

ELECTROTHERM (INDIA) LTD.

ELGI EQUIPMENTS LTD.

EMAG INDIA PVT. LTD.

33 74 - 75

F FACCIN S. P. A.

FATTY TUNA INDIA PVT. LTD.

FLIR SYSTEMS INDIA PVT. LTD.

GEDEE WEILER PRIVATE LIMITED

MARPOSS INDIA PVT. LTD.

MEERA CASTING

MGM-VARVEL POWER TRANSMISSION PVT LTD

MICRO-EPSILON INDIA PRIVATE LIMITED

MITSUBISHI ELECTRIC INDIA PVT. LTD.

MMC HARDMETAL INDIA PVT. LTD.

INSIDE FRONT COVER

MACHINE TOOLS WORLD OCTOBER 2018

OERLIKON BALZERS COATING INDIA PVT. LTD.

RENISHAW INDIA (PUNE)

ROLLON INDIA PVT. LTD. - INDIA

RR KABEL LIMITED

SHAVO TECHNOLOGIES PVT. LTD.

T TRUCUT PRECISION TOOLS PVT. LTD.

FALSE COVER

TUMAKURU MACHINE TOOL PARK (TMTP)

RAJKOT MACHINE TOOLS SHOW - 2018

EPPINGER TOOLING ASIA PVT. LTD.

102

HEIDENHAIN OPTICS & ELECTRONICS INDIA PRAIVATE LIMITED

INNER INSIDE FRONT COVER

UNITED GRINDING GMBH

UNITY CONTROLS PVT. LTD.

Y YAMAZAKI MAZAK INDIA

22 - 23

YG-1 INDUSTRIES INDIA PVT. LTD.

FRONT GATEFOLD

THE FUTURE STARTS HERE

To see how Mastercam 2019 helps streamline your entire process, from job setup to job completion, visit Mastercam.com/2019.

Preparation/ Setup

Tool Support

CNC Programming

Validation

Job Management & Documentation

RNI No. MAHENG/2015/64267 Postal Reg. No. THC/173/2018-2020. Posted at Mumbai Patrika Channel Sorting Office G.P.O. Mumbai 400 001 on 15th of every month and Published on 10th of every month

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