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

Email: info-in@schmersal.com | Phone: 02138 614 743

Turning workplaces into safer places

www.schmersal.in

The comprehensive range of more than 25,000 products for various industries includes: ■ safety switches ■ solenoid interlocks ■ emergency stop – switches ■ security sensors ■ safety mats with safety function ■ Photoelectric light barriers and end switches, which include limit switches, position switches and micro switches.

Pages 114 | RNI No. MAHENG/2015/64267

Volume 04 No. 04 | September 2018 | ` 150

QUALITY CUTTING TOOLS

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

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

anca.com

linkedin.com/company/anca

CEO CORNER MANITAINANCE & MACHINE UPTIME For business continuity Maintenance is a risk management practice used to maximise production and minimise loss and waste. Selecting a successful maintenance strategy requires a good knowledge of equipment failure behavior and maintenance management practices. Once you appreciate why equipment fails, how equipment fails and when equipment fails you can select the right mix of maintenance strategies to extend and maximise its service and performance. Strategic maintenance decision making involves selecting the right care and repair methodologies that maximise equipment life and performance for the least cost to the user. But to be able to make successful maintenance management strategy choices you must understand how equipment fails. When you know the equipment’s weaknesses and strengths you can care for it properly and get maximum service from it at least cost. Strategic maintenance planning should start on the drawing board. Once an item of plant is built you are stuck with it! A piece of equipment requires what maintenance it needs to maintain its performance. There is no escaping the fact that the design specifies the maintenance requirements. Unless the necessary maintenance is done it will fail! If you want less maintenance, you must start with appropriate design choices that reduce the amount of maintenance. The methods used to highlight opportunities to reduce maintenance are based on failure mode and effects analysis (FMEA). A simple way to understand the approach is to consider it as a series of answers to ‘what-if’ questions used on each part of the equipment. There is no one maintenance strategy for all situations and all companies! Rather you require a blend of maintenance management strategies that are right for your operation and for the age of the equipment. You will always require an amount of preventative maintenance, as well as an amount of predictive maintenance when equipment ages, along with root cause analysis to eliminate non-random failures. To this is added appropriate training, occasional overhaul shutdowns, replacement of old technologies with new, and so on. The choice of the appropriate maintenance strategies is what strategic maintenance planning is all about. Strategic maintenance planning should also recognize when it is necessary to change the maintenance strategy mix.

CEO

MACHINE TOOLS WORLD SEPTEMBER 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

Contents

Shirish Dongre

CEO

Vol 4 Issue 04 | SEPTEMBER 2018

COVER STORY

Shekhar D.

Editor Shilpa Dongre

Assistant Editor Shweta Nanda

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

Digital Marketing Kailash P.

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

Dutch Tech Tools: Marking growth through innovation

Online Division Ganesh Mahale

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

Mr. Abhijit Nag, (Director- Sales & Marketing) | Mr. Shubhojit Nag, (Director- Operations) Dutch Tech Tools Private Limited

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

Head Office : Divya Media Publications Pvt. Ltd., 3rd Floor, Harmony Tower, N.S. Road, Thane-400 602. Maharashtra Tel: +91 22-25380574/75, Telefax: +91-22-25418254 E-mail: shekhar@divyamediaonline.com Website: www.mtwmag.com Printed & Published by Shirish Dongre on behalf of DIVYA MEDIA PUBLICATIONS PVT LTD., Printed at Anitha Art Printers 29/30, Oasis, Next to Vakola Market, Santacruz(E), Mumbai-400055, published from 303/304, Harmony Tower, N.S.Road, Court Naka, Thane West, Thane-400601. Editor : Shilpa Dongre

MACHINE TOOLS WORLD SEPTEMBER 2018

BUSINESS NEWS

Shift to Smart Factories

Schmersal launches new generation of position switches

Seco partners with MachineMetrics to Offer Manufacturing Analytics

Elesa+Ganter is pleased to introduce you the new General Catalogue 048

Winjit launched its Industrial IoT version of its product IoTSense at the Automation Expo 2018, Mumbai

Step into the Digital Reality at EuroBLECH 2018

Mastercam India appoints Green Apple Solutions, Pune as Reseller & Gold Certified Compliance Partner

Rollon : The linear motion leadership

TAKING A GLOBAL STEP AHEAD

We delight our customers by providing economic solutions to their grinding process

ANCA Motion unveils the new LinX M-Series at IMTS 2018

IN FOCUS

Contents COMPANY PROFILE

Vol 4 Issue 04 | SEPTEMBER 2018

TECH TRENDS

We give strategic advantages to our customers from dustries

Speed up on-machine measurement with SupaTouch technology

Absolute precision in automotive production

60 “FIBRO has committed to Make in India”

WireDress® - When grinding receives an unprece-dented dimension

102

CASE STUDY

PRODUCTS SHOWCASE

106

EFFICIENT AND ULTRA-DYNAMIC: SIMULTANEOUS MILLING & TURNING

KING CUT PRO – The Large Gantry Type CNC Cutting Machine

92 Fixture and Tooling solution for Auto component

Blaser Swisslube’s Synergy 915 pays for itself at Dantal Hydraulics

107

Steady Volt Servo Voltage Stabilizers

107

Nexgen Refrigerated Air Dryers

108

New transmission elements

96 14

MACHINE TOOLS WORLD SEPTEMBER 2018

Measuring with speed and precision

98 109 Rotary Ball Spline

Editorial Board

Editorial Index A

Ador Welding

72, 106

ANCA

B Bettinelli Automation

Blaser Swisslube

C CNC India Mr. Arun Mahajan General Manager

Mr. A.P. Jayanthram Consultant

AMT- The Association For Manufacturing Technology

Grob Machine Tools India Pvt. Ltd.

Mr. GK Pillai Managing Director & CEO Walchandnagar Industries Ltd

D 44

108

Effica Automation Ltd.

Renishaw Metrology Systems Ltd.

Bettinelli Automation Components Pvt. Ltd.

Mastercam

Meech

Micro-Epsilon

P Phillips Machine Tool

Precision Camshafts

Renishaw

62, 98 46

Elesa+Ganter

Schmersal

ELGi

SCHUNK

EuroBLECH 2018

Seco Tools

26 76, 109 34

Shavo Technologies

Mr. Rupesh Paparaju Director,

Rollon India

Elesa and Ganter

Ms.Samina Khalid Marketing Manager

Dutch Tech Tools E

Mr. Arjun Prakash Managing Director

HEIDENHAIN

FARO

FIBRO India

108

Solitaire Machine Tools

Stratasys India

STUDER

38, 80

Superslides & Ballscrews 109 U

GEM Equipments

107

Unity Controls

GROB

Grundfos

Winjit Technologies

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 SEPTEMBER 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

107 40

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BUSINESS NEWS

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

MACHINE TOOLS WORLD SEPTEMBER 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.”

BUSINESS NEWS

Shift to Smart Factories In an industrial setting pumps never work in isolation and are always a part of a larger system. Grundfos has invested heavily in the R&D of its products. It was 7 decades ago when they came up with their first pump, solely built for the purpose of moving liquid from point A to point B. Further developing on the technology, they introduced the E-Solution pumps, whose integrated controls enabled the pumps to adapt to changing demands. This helped further

smoothen the pumps and make them more energy efficient. Fast forward to 2007, Grundfos pumps were the first company to couple IOT technology with their pumps, leading to what is now called - Grundfos iSolutions. Years of R&D and expertise in the pump industry, the iSolution greatly improved on several aspects. Focusing on intelligent communication between components like the drives, measurement & control systems, the Grundfos iSolution pumps have enabled the end-users to enjoy benefits like user-friendliness, great savings, and extended customization. It is the constant innovation by companies such as these that drive the move towards

smarter factories. Another aspect of smart factories is about how clean they are in terms of energy efficiency and anti-pollution measures. At this point in time, the capability of an industry to balance its environmental and business interests is crucial. A green factory not only entails a sustainable way of production, but it starts at how the facility is built (i.e.) the materials used. Also, it must take into account the energy consumed

by the secondary processes of the factory. For example, temperature control is an important system in a factory, but that does require the temperature control system to function round the clock, as the load varies at different times. Using an intelligent solution like the Grundfos iSolution Temperature Control system ensures full control of temperatures with fewer components and a complete overview of the systemâ&#x20AC;&#x2122;s performance.

Schmersal launches new generation of position switches PS product range offers varied applications thanks to modular design The Schmersal Group launches a new generation of position switches. The benefits for the user: The new PS product range offers varied applications, as all the position switches can be used both as complete devices and as modular units. Type 1 position switches in line with ISO 14119 are for the position detection and monitoring of moving parts on machinery and plants as well as for lateral or pivotable protection equipment. The new range is suitable for a wide range of applications across all individual disciplines of machine and plant engineering - both for automation and safety applications and for lift engineering. The protection types

MACHINE TOOLS WORLD SEPTEMBER 2018

IP66 or IP67 create the prerequisites for using the position switch in unfavourable environmental conditions.

Fewer variants - more flexibility The modular design of the PS range with consistent components across all models reduces the number of variants, reduces storage costs

and increases availability. All the position switches in the PS116, PS2xx and PS3xx ranges available within the modular system can be chosen both as complete switches with actuating element or as basic switches. Depending on the application, the basic switches can be combined with the necessary actuating element, which can be selected from a range of possible

versions. This achieves the greatest possible flexibility in application and at the same time reduces the number of different switches available. All actuating elements can be rotated in 45Â° increments, allowing adjustment to the defined direction of motion at any time. The connection terminals are also rotated around 45Â°, which makes connection easier and significantly reduces installation times. Switching elements with up to three contacts guarantee a redundant shutdown with an additional signal contact.

For more information, Website: www.schmersal.com

Fixturing solutions for Automobile Components, Heavy Parts and Welding Applications for over 25 years

Fixtures for Automobile Components

Fixtures for Heavy Parts

Fixtures for Welding Applications

We have all inhouse facilities for Designing, Manufacturing and Testing of the above type of fixtures CNC INDIA TOOLS & SERVICES (P) LTD. th nd A-320, 7 Main, 2 Stage, Peenya Indurstrial Area, Bangalore -560058 Ph: 9880215189/9845079769 Email: enquiry@cnc-india.com Website: www.cnc-india.com

BUSINESS NEWS

ANCA Motion unveils the new LinX M-Series at IMTS 2018 ANCA Motion designs and manufactures flexible control systems, specialising in high precision solutions for CNC machines. Unique to ANCA Motion is the LinX M-series linear motor which is housed within a slim body, is highly energy efficient and delivers precision CNC applications or high-speed automation systems every time. An early adopter to new technology, ANCA Motion will also reveal its Single Cable Motion System that adopts the Hiperface DSL protocol technology by using a single cable to simplify machine integration, reduce waste and offer improved diagnostics. Naveen Nadesan, ANCA Motion Marketing Manager said: “There is a clear trend for companies to use energy in a more efficient manner.

Replacing a pneumatic cylinder with a tubular linear motor reduces energy costs achieving a relatively short payback period of 6 to 12 months. The LinX M-Series linear motor therefore provides a unique benefit to OEMs seeking higher performance, accuracy and reliability in their machines.” Two LinX motors will be displayed in a V-structure parallel

robot (V-Bot) arrangement showcasing high-speed pick and place application; and high precision contouring around various shapes. The LinX M-Series is fully compatible with standard pneumatics accessories such as mounting plates, linear guides and couplings. ANCA Motion’s Single Cable Motion System adopts the

Hiperface DSL protocol technology connecting the drive to a servo motor using a single cable. The Hiperface DSL encoder technology offers significant savings in cabling; and high accuracy and precision with improved diagnostics. Naveen concluded: “ANCA Motion offers a wide range of control systems and havemore recently been working largely with laser cutting businesses, providing a complete motor solution for their machines. At the stand we will have interactive display panels and videos of laser and cylindrical grinding applications to demonstrate the breadth of our technology. Excitingly, the LinX M-series V-Bot demo unit will be unveiled at MWCS in Shanghai which is the week after IMTS.”

Breakthrough FARO 8-Axis FaroArm sets new standard FARO has introduced the FARO 8-Axis FaroArm system. After more than 30 years of continuous innovation in portable measurement arms, FARO® once again drives the industry forward. This comprehensive, solution combines either the portable Quantum FaroArm®, Quantum ScanArm or Design ScanArm® portfolio products with a functionally integrated, yet physically separate, 8th axis. The 8th axis is a complete rotational axis identical to and a natural extension of all FaroArm® products. It plugs directly into the FaroArm® and results in a seamlessly integrated, high accuracy additional axis that requires no additional setup time or effort. Moreover, unlike a turntable, the 8th axis is completely transparent to the measurement software, so no software updates or upgrades are needed. This innovative functionality enables the

MACHINE TOOLS WORLD SEPTEMBER 2018

part to be rotated in real time relative to the Arm versus requiring the Arm to be moved around the part. The 8-Axis system is ideal for addressing a range of non-contact measurement and design challenges, including point cloud comparison with CAD, rapid prototyping, reverse engineering, and 3D modeling of free-form surfaces. The extended reach of this system via the easy to use part rotation functionality allows the user to scan, measure and digitize features on both small and large parts with a single Arm

position. As a result, this process is up to 40% faster relative to a standard 7-Axis Arm system. The operator is now able to focus with minimal distraction on the actual scan or measurement of the part since reaching around the part is no longer required. Also, this allows complex objects to be digitized, not only faster, but also more comprehensively. “We are excited about the 8-Axis system as another FARO first, which enables a new standard for both inspection and design efficiency,” stated Simon Raab, Ph.D., FARO’s President and CEO. “Based on our engagements over the last two years with both inspection and 3D design professionals, we are confident that we are uniquely addressing their core pain points including speed and productivity, ease of use and end to end cycle time in the most creative and easy to implement manner.”

State-of-the-art car engines perform best with state-of-the-art Auto Cables. • Thin wall insulation • Higher current carrying capacity • Withstands temps. from -50°C to 150°C • REACH & RoHS certiﬁed

Email: rrkabel@rrglobal.in | Website: www.rrkabel.com | Follow us

BUSINESS NEWS

Phillips & EOS conduct seminar on the impact of Additive Manufacturing India’s leading Machine Tool Solutions provider Phillips Machine Tool India &the global leader in 3D Printing solutions, EOSpartnered to organize a seminar on Additive Manufacturing today at Imperial Palace Hotel, Rajkot. The seminar wasconducted to explore the possibilities of Additive Manufacturing in the Investment Casting industry. Titled ‘How Will Additive Manufacturing Impact Investment Casting?’ the seminar focused on educating attendees aboutdigitizing the pattern making process thus building efficiency and agility to react to the industry needs . Additive Manufacturing or 3D printing is one of the disruptive technologies changing the entire manufacturing industry scenario with improvement in process and productivity. “Through this seminar, we aim to provide a detailed understanding of using Additive Manufacturing in investment casting. We want more manufacturers to realize the potential of digital transformation, especially in a city

like Rajkot that contributes so much to the manufacturing sector in India. By using AM technology, they will be able to enhance their manufacturing processes and improve overall business performance.” says Anand Prakasam, Country Manager, EOS India. “To further catalyse the process of integrating AM, we not only provide our customers with cutting edge technology, but also support them with the expertise of how to utilize AM technology effectively,” he added. Some of the key advantages of using Additive manufacturing in investment casting include the reduction in the number of process steps and

lead time, increase in efficiency; a better option for the manufacturing of complex parts; more cost effective as it is a tool-less process, higher degree of accuracy and wider range of materials can be used. “We are happy to partner with EOS in this path breaking technological seminar which is especially relevant to the vibrant city of Rajkot and its innovative industrialists who are always ready to embrace the latest manufacturing techniques and use these to grow their businesses exponentially on a global level.” Terrence Miranda, Managing Director, Phillips Machine Tools India.

Seco partners with MachineMetrics to Offer Manufacturing Analytics As part of a global initiative to ensure the continued success of its customers, Seco Tools is expanding their customer service capabilities through a partnership with MachineMetrics. MachineMetrics’ manufacturing analytics engine will provide Seco and its customers a technological resource for their advancement into Industry 4.0. “Seco has always been committed to providing our customers with the best products and services available. Partnering with MachineMetrics will allow us to not only continue to help our customers learn about themselves but will transform our ability to help them improve their machine tool utilization and production capacity.”

MACHINE TOOLS WORLD SEPTEMBER 2018

said Ben Alexander, Business Manager Online Services at Seco Tools. Seco plans to use the MachineMetrics Industrial IoT platform and its manufacturing analytics applications as a cornerstone in their expansion into new technology services. With data provided by MachineMetrics, Seco can apply their extensive experience and engineering capabilities to the continuous improvement of their customers by helping them make data driven decisions to improve their efficiency and bottom line. Leveraging Seco’s experience in tooling with MachineMetrics’ data collection capabilities will help both Seco and MachineMetrics

customers gain a deeper understanding of what’s happening with their tools in real-time. These insights may include predicting tool life, preventing tool breakages, and feed and speed optimization. “This partnership offers an exciting opportunity for both MachineMetrics and Seco Tools to demonstrate the value of data-driven manufacturing and analytics to Seco Tools users around the world,” says Bill Bither, CEO of MachineMetrics, “Together, we can uncover industry-first insights into machine tool and tooling optimization that will enhance the availability and reliability of machines for customers.” With the MachineMetrics

Production Monitoring application, Seco will enable their global customers to gain visibility into their production using an easy to use, doit-yourself, completely customizable manufacturing machine monitoring system. As a cloud-based platform, MachineMetrics allows manufacturers to collect, monitor and analyze data from any and all types of machines, from anywhere and with any Internet-connected device to track OEE performance, identify production bottlenecks, take action with real-time notifications, predict and prevent costly downtime events, measure process improvements, and enhance shop floor communications.

The Art of Grinding.

A member of the UNITED GRINDING Group

S33 The reasonably priced for individual requirements.

If you don’t know today what you’ll be grinding tomorrow, then the S33 will impress you with its universality and flexibility: it can be retooled from grinding between centres to live spindle grinding in the record time of under 2 minutes. You can grind even complex workpieces in a single clamping, as well as utilizing the distance between centres with each grinding wheel. This is made possible by the new wheelhead with two motor spindles. www.studer.com – The Art of Grinding.

United Grinding GmbH · India Branch Office & Technology Center · No. 487, D1 & D2A, 4th Phase · KIADB Main Road · Peenya Industrial area · 560 058 · Bangalore · India Phone +91 80 30257 600 · sales.in@grinding.ch · www.grinding.ch

STU_Inserat_S33_210x297mm_IN_18.indd 1

10.07.18 08:44

BUSINESS NEWS

Elesa+Ganter is pleased to introduce you the new General Catalogue 048 A new single volume of 2.120 pages for over 60.000 product codes, divided in 18 functional groups: the General Catalogue 048 is always at your hand! New products, range extensions and all the traditional standard products for a total of 1.330 series to offer you the widest range of standard machine elements for the

mechanical industry. Designers and engineers can now find complete product datasheets with information about materials, standard executions, standard colour options, types of assembly and accessories to choose the right components. Technical drawings and tables show all dimensions and codes

available as standard. Technical Data section, included as an appendix, presents all technical information about Elesa+Ganter products: laboratory tests modes, international standards and chemical resistance tables make the new General Catalogue an out-and-out working tool.

Diving Equipment Market anticipated to grow at a CAGR of 4.07% In 2017, the mining, oil & gas segment generated the highest revenue share in the global professional diving equipment market. Among major regions, North America was the highest revenue generating market, holding nearly 32% of the market share, in 2017. â&#x20AC;&#x153;The U.S. dredging industry is continuously investing in building dredges with increased capacity for complex operations while maintaining the highest environmental and safety standards for dredging operations. It invested in the manufacturing and delivery of four vessels that represents a value of more than $310 million in new vessel construction in the United States.â&#x20AC;? The dredging segment garnered a significant share of the overall professional diving equipment market and is anticipated to grow

MACHINE TOOLS WORLD SEPTEMBER 2018

with the highest CAGR of 4.49% during the forecast period. The dredging sector is witnessing an increase in the number of dredging activities across the globe, with various developing and developed nations investing heavily in the sector. The dredging market is gaining pace in the European region, as global contractors are seeking opportunities to order new & large equipment for attractive prices, due to the overcapacity in shipbuilding. As per the International Association of Dredging Companies, Europe

accounted for more than 20% share of the total turnover of dredging contractors in the open markets, in the year 2017. In addition, the Malaysian dredging industry is also investing in building and cleaning dredges with an increased capacity for complex operations while maintaining the highest environmental and safety standards for dredging operations. Deck decompression chambers are gaining importance in professional diving, as decompression is a crucial aspect in the complete diving process.

Decompression allows the divers to adjust to the normal surface pressure after long durations of underwater diving. Market players are focusing on introducing decompression chambers that are light in weight, transportable, and small in size. Moreover, deck decompression chambers are being widely used in diving centres, military, and superyachts among others. These chambers are gaining demand in military and navy, as decompression illness has caused several fatal accidents in the recent past.

BUSINESS NEWS

Step into the Digital Reality at EuroBLECH 2018 EuroBLECH 2018, the 25th International Sheet Metal Working Technology Exhibition, takes place from 23 – 26 October 2018 at the Hanover Exhibition Grounds in Germany. Around 1,550 exhibitors from 40 countries will present the complete spectrum (link: https:// www.euroblech.com/2018/english/event/ exhibition-profile/) of intelligent solutions and innovative machinery for modern production in sheet metal working through numerous live demonstrations at the exhibition stands.

The digital transformation is currently playing a major role in the industry, which enables an

increased efficiency and thus a higher level of automation and predictive maintenance. These developments are reflected in this year’s motto for EuroBLECH “Step into the digital reality” since Industry 4.0 and the relating Smart Factory have become major topics in sheet metal working. Tickets for EuroBLECH 2018 and further detailed information about the exhibition are available on the show website www. euroblech.com.

ELGi’s compressor business registers a 15% growth in Q1 ELGi Equipments Ltd., manufacturer of air compressors, recently announced the results for the first quarter ended 30th June 2018, posting a PAT of 21.6 crores for the quarter, compared to Rs.16.5 crores in the same period in 2017-18. Sales for the quarter was Rs.261 crores as against Rs.235 crores in the corresponding quarter in 2017-18. The consolidated PAT for the group for the quarter ended 30th

June, 2018 was Rs.18.5 crores as compared to Rs.13.6 crores during the corresponding period in 2017-2018. Consolidated sales for the group was Rs.413 crores for the quarter ended 30th June, 2018 compared to Rs.372 crores in the corresponding quarter in 2017-2018. The company’s compressor business in the domestic market grew by 15% over the corresponding quarter in 2017-18 on the back of increased demand in

most of the business segments the company operates in. The company has performed well across the international markets too, barring some of the Gulf countries and Africa. The company’s automotive business has registered a 17%

growth over the corresponding period in the previous year, which is in line with the industry growth. The recent acquisition of F.R. Pulford & Son in Australia will serve as a catalyst for further growth opportunities in that region. “We expect the trend to continue in the second quarter, save unforeseen circumstances,” says Dr. Jairam Varadaraj, Managing Director, ELGi Equipments in a press release.

STUDER wins user satisfaction award in China The Swiss grinding machine manufacturer, Fritz Studer AG, wins a user satisfaction award in China. This prize was awarded by the “AI Automobile Production” magazine during the Chi-nese Engineering Fair CIMES in Beijing. In total, 38 products and solutions for the automotive industry won awards. Which products are particularly innovative? Which solutions are smart? Which machines reli-able? Renowned users of the automotive and supplier industry were able to give their favour-ites a vote. The “AI User Satisfaction Award” is awarded every two years by the Trade Maga-zine “AI Automobile Production”. This summer, 38 products used in vehicle technology achieved an award. This includes the solution for precise grinding of CVT shafts and pulleys on the

MACHINE TOOLS WORLD SEPTEMBER 2018

Rolf Grossenbacher, Sales Manager Fritz Studer AG, receives the “AI User Satisfaction Award” at the CIMES in Beijing.

STUDER S41. The precise grinding of CVT shafts and pulleys is a classical application of the STUDER S41. The machine can be equipped with grinding wheels for external and internal cylindrical grind-ing. A

self-developed groove-grinding unit, as well as a CNC-controlled Y-axis allow the ma-chining of all ground surfaces in one clamping. With the combination of In- and Post-process measuring, high precision with no scrap parts can be achieved. Fit for Industry 4.0: The STUDER software for an MES system realizes real-time process monitoring and ensures complete traceability of all workpieces. With this project solution, STUDER was able to inspire the users and fulfil the wish of Editor-in-Chief Gong Shujuan: To motivate the industry to offer users even greater efficiency, quality and better cost-effectiveness. For more information, Website: www.studer.com

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SPECIALS

BUSINESS NEWS

Winjit launched its Industrial IoT version of its product IoTSense at the Automation Expo 2018, Mumbai Winjit Technologies, a pioneer in providing smart IoT solutions by innovating concepts based on real-time data, was a part of the automation expo at Bombay exhibition centre from 29th August to 1st September 2018 where it launched its Industrial IoT version of its product ‘IoTSense’. The industry 4.0 enabling platform, which is an award-winning full-stack IoT platform built using open standards and is one of the most versatile, scalable IoT platforms. For the manufacturing domain, IoTSense can be deployed for the rapid transition to industry 4.0 standards. It has won the NASSCOM Emerge 50 Award, 2017 for the Most Innovative Product and Business World Leadership & CIO Award, 2017 for the Best IoT Implementation. The full-stack comprises functionality to fetch data from industrial sources like PLC, sensors etc, manage and group industrial assets, monitor and alert exceptions in real-time, perform real-time

analytics at the shop floor level, and provide inputs to 3rd party applications like PPC and ERP. The system can start delivering value in less than a week. Winjit also showcased its automated machine learning product, ‘PredictSense’, which is an

automated machine learning platform built on an open API structure using efficient algorithms. It helps you to solve complex real-time business problems with its high-power algorithms in a very less amount of operational time. It builds predictive models which in turn helps you take precise and optimum business decisions. Commenting on the participation & the launch of industry version of IoTSense, Mr. Ashwin Kandoi, Director & Co-Founder of Winjit said, “We are delighted to be associated with this landmark event as it provides us with an excellent platform to launch our new products, showcase our company, our industry expertise and our solutions to the industrial sector. The industry 4.0 version of our product is aimed at bringing value to customers in the industrial sector.” For more information, Website: www.winjit.com

Stratasys India Launches Award-Winning F123 Series Stratasys India, a subsidiary of Stratasys Ltd. (NASDAQ: SSYS), a global leader in additive technology solutions launched the awardwinning Stratasys F123 3D Printing Solution in India. The series consists of F170, F270 and F370 printers that are adaptable to all engineering environments be it office, lab or classroom, to facilitate rapid 3D prototyping. The F123 delivers engineering-grade quality and repeatability. It accepts up to four different materials, in 10 different colors, to support a wide range of prototyping and tooling applications. For example, the F123’s new Fast Draft Mode leverages PLA material to quickly produce conceptual prototypes at a low cost per part. Productiongrade ASA and ABS are ideal for producing strong, stable, repeatable parts, and for even stronger, impact-resistant parts,

MACHINE TOOLS WORLD SEPTEMBER 2018

there is super-tough PC-ABS. “The Indian manufacturing industry is transforming. The integration of on-demand manufacturing solutions represents a leap forward for 3D printing in manufacturing and production environments. To keep pace with the fast-changing Industry and evolving customer base requires new levels of innovation in 3D printing. The new F123 series is easy to operate, all-in-one rapid prototyping solution for concept verification, design validation and functional performance” said Rajiv Bajaj, Managing Director, Stratasys India. The F123 series has been designed by BMW Designworks, one of the world’s leading industrial design firms, and Stratasys, to blend in with any office environment. The enhanced user experience includes a sleek touchscreen interface, remote monitoring on portable

devices, practically noiseless operation, and the integration of GrabCAD Print to eliminate any wasted time on file conversion and STL preparation. The F123 Series is described as an “end-to-end rapid prototyping solution”, allowing users to start with fast and economic draft models and move through the design cycle to verify form and functionality, using production-grade materials for strong and repeatable parts. Having a machine like this readily available within a design team gives product developers the ability to work through all the necessary stages of product substantiation to shorten lead times and reduce costs before moving onto full-scale production.

BUSINESS NEWS

Mastercam India appoints Green Apple Solutions, Pune as Reseller & Gold Certified Compliance Partner Mastercam India announced the appointment of Green Apple Solutions, Pune as their authorised reseller and Gold Certified Compliance Partner (GCCP), for the India region. Under the agreement, Green Apple Solutions will sell and support Mastercam products and will also take up end-user soft audits and counselling for license compliance, in the India region. Anubhab Hazra, CEO of Green Apple Solutions commented, “CAM software business is very different from CAE and CAD business; there is a greater emphasis here on support, than I have ever seen in the other two domains. This means that we need to have a team that not only has expertise in the software, but also in various allied

domains. Experienced professionals are what makes this business successful and I’m very pleased that my company and I will be working with seasoned professionals backed by a robust Global CAM brand such

as Mastercam.” He further added, “Many users fail to recognise the benefits of using legal software and risk their reputation as well as reliability, by using pirated software. We specialise in soft-audits and

counselling, a proven method that helps us become a friend and a trusted advisor of errant licensees, as we help them achieve more and better.” Vineet Seth, Managing Director – South Asia and Middle East, for Mastercam APAC, said, “We welcome Anubhab and team Green Apple to the Mastercam fraternity. Having worked with Anubhab, while he was with a former reseller of Mastercam, we know that he understands the CAM business and we’re positive that his team will help us increase our reach, while retaining the high quality of support, that we’re so well known for. We wish the Green Apple Solutions team, every success, going forward.”

IMTMA’s summit showcases competitiveness and sustainable growth in manufacturing The 12thedition of Indian Machine Tool Manufacturers’ Association’s (IMTMA) National Productivity Summit got underway . The summit was inaugurated by M M Murugappan, Executive Chairman, Murugappa Group and V Sumantran, Independent Director, UCAL Fuel Systems. Also present were P Ramadas, President, IMTMA, and V Anbu, Director General & CEO, IMTMA. The two-day summit, held on 24 -25 August 2018, will enable the delegates to learn about the best shop floor practices through pre-summit plant visits, insights from prominent industry experts on productivity gains, and case studies. The National Productivity Summit has been organized to serve as a learning and knowledge sharing platform with interactive sessions and networking opportunities to usher in a fresh perspective on manufacturing as technologies

MACHINE TOOLS WORLD SEPTEMBER 2018

surrounding Industry 4.0 gain wider acceptance across Indian manufacturing units. In his opening address, Murugappan said, “India is poised to be one of the largest manufacturing economies in the world as Industry 4.0 gains wider acceptance and reshapes the manufacturing as whole rendering real-time control of entire manufacturing value chain.” Elaborating further he said, “Across India today, companies are in the process of digitizing their day to day operational functions to achieve efficiency and boost revenue growth and Industry 4.0 will usher in an era of transformative manufacturing in India.” He also emphasized on the importance of having the right talent and cash flow to make a business successful. In this backdrop he explained the philosophy of the Group – Recruit for Attitude and Train for Skills. P Ramadas, President, IMTMA, said, “It is

imminent now for companies in India to enhance competitiveness in manufacturing by reducing costs and improving productivity by building a sustainable competitive advantage especially around technologies surrounding Industry 4.0. Summits like these are platforms that address learning and best practices requirements of manufacturing industry and raise its competitiveness.” The summit also featureslive case study presentations on some of the best practices in manufacturing by leading manufacturing companies. The IMTMA - ACE MICROMATIC Productivity Championship Awards 2018have been organized to recognize and reward outstanding efforts from the shortlisted case studies of companies who have excelled in achieving superior performance with cash prizes worth INR 10 lakh.

COVER STORY

Mr. Abhijit Nag, (Director- Sales & Marketing) | Mr. Shubhojit Nag, (Director- Operations) Dutch Tech Tools Private Limited

Dutch Tech Tools:

Marking growth through innovation Q. Please brief us about companyâ&#x20AC;&#x2122;s Indian & global reach? Dutch Tech Tools was founded with the prime motive of being a globally recognized player from India for manufacturing New Age Solid Carbide Round Cutting Tools and primarily exporting as we are based in a Special Economic Zone Over the short history of the company, we have established distributor and dealer network in over 22 countries to sell our branded tools was highly critical for us; firstly to be confident on our products and more importantly to showcase India as a quality abled producer of Carbide Cutting Tools. Having seen success amidst the global

MACHINE TOOLS WORLD SEPTEMBER 2018

giants, over the last 2 years, we launched our products in India to cater to the ever growing needs of the Indian market. We have started focusing more and more onto the India market as it still imports vast amounts of cutting tools which we believe is our biggest competitor and look to position ourselves in order to reduce dependency on foreign products. Very importantly, we also focus on SMEs â&#x20AC;&#x201C; as it is them that support the big framework of manufacturing network in India. Most of the sales happens through dealer network to them, which is something we have been developing in India in the recent past. In Export Markets, we have well estab-

lished distribution Network in Europe and our new upcoming markets are South East Asia and the Americas.

Q. Please also highlight the latest initiatives in cutting tools industry domain? Newer challenges faced by cutting tools is the machining of new age and so called difficult-to- cut materials. They are mostly heat resistive materials, and the usage of such materials in the Aerospace and Defense Sectors are increasing; hence initiatives taken by cutting tool manufacturers are channeled towards providing solutions for these. Machining such materials also lead to

COVER STORY www.mtwmag.com

advancements in the machining methods. For example a growing trend in machining difficult metals is by Trochoidal milling / Dynamic Milling which uses high speeds while maintaining a low radial depth of cut and a high axial depth of cut. The reduced radial engagement of the cutting edge decreases the amount of heat produced in the cut while also decreasing the cutting forces and load on the spindle. The reduced radial forces allow for greater accuracy during production and make it possible to machine finer and more precise features on a part.

Q. What is future prospect for cutting tools industry?

Q. What are the market opportunities for your company’s products in India?

Q. Is there any plans for expansion & new investment in terms of product development or new technology adoption to cater the demand of the industry?

Automotive, General Engineering as well as Capital Goods Industry form the major market for machine tools in India. In addition to these, the Aerospace and Defense sector is growing as well. India being a prominent global importer of cutting tools ; it was crucial that focusing purely on performance, quality, precision , consistency as well as being in sync with this ever growing industry was the only way to be successful in India, since there are numerous well established players- however mostly foreign entities. This is where, Dutch Tech Tools comes in as providing you superior performance tools engineered and manufactured with the latest machinery and coatings. Our USP is tools with very well engineered geometries to machine a wide range of materials and perform in a much reduced time. We hope to penetrate the Indian market more with our tools now.

Market opportunities for any cutting tool is very vast as it is used in diverse industries as mentioned earlier. Globally all these sectors are on a rise and will continue to play a prominent part in the economies of the world. Hence, the prospects of the cutting tool industry seem to be quite positive. More importantly, with the economy and the fiscal policies being supportive of manufacturing sectors, the tool industry stands to benefit in this environment.

Continuing with the above point, there are regular advancements made in each of the manufacturing sectors which then promotes advancements and innovation in our tools to match up to their level of expectation. Our infrastructure is already at par with global leaders, with numerous highly precise Swiss Tool and Cutter grinders, Quality check equipment from Germany and Switzerland and very importantly one of the best oil filtration system. Recently, we have added another high end quality check equipment from a renowned German company. Everything on a cutting tool is based on few critical factors- quality, consistency

and cost effectiveness! All our R&D, Innovations and engineering are channeled to cater to these qualities.

Q. What is the top line product range & Is there any plans to launch new products? In the short history of our company, we have made huge strides in terms of product offerings of various Drills and Endmills made from Solid Carbide to machine a wide range of materials. In collaboration with our Coating partners, all our tools now come with advanced and highly sophisticated coatings which prolong tool life and tool performance. Our Drill ranges start from 0.40 mm upto 20.0 mm for drilling lengths from 3xd to 40xd. In Endmills, we also start from 0.20 mm and offer up to 25.0 mm in various configurations. Most of our tools are Vibration and Chatter free cutters designed to machine at high depth of cuts thereby reducing production times of the user. This is the only way to be cost effective for a user and not focusing purely on the cost of the tool. Currently, we are focusing on launching what we call is our ‘Extra Cutting Edge’ range of End mills – which are end mills capable of High Efficiency Machining as well as Multipurpose End mills- i.e. they can effectively perform multiple operations such as Slotting, Plunging, Ramping, Trochoidal Milling – all with one end mill.

Q. What is your vision for your company? To be the partner of choice for best in class Round Cutting Tools.

SEPTEMBER 2018

MACHINE TOOLS WORLD

IN FOCUS

Rollon : The linear motion leadership Mr. Vikash Poddar Country Manager India Rollon India Pvt. Ltd.

Q. Would you like to briefly introduce the Rollon Group and his global strategy? The Rollon Group is a global company specialized in the production of components for linear motion. Rollon is having worldwide presence, the companies headquarter is in Italy (Milano) and the global sales activities are organized by our German Branch in Dusseldorf. Furthermore, our presence is very strong all around Europe and US market, today we are focused on India, China, Japan, Korea, Russia and Brazil, because our interest is developing the international market. Rollon is the global leader for linear motion products in many different industrial sectors, especially the company is ranked first globally in markets like railway, warehouse logistics and aerospace industry. The strong point of Rollon

MACHINE TOOLS WORLD SEPTEMBER 2018

Group is its ability to provide both standard and “customized” solutions to satisfy customers requirements for an industry or a specific application. Rollon’s global strategy is strongly focused on emerging countries so in this direction, in March 2014, Rollon India Pvt. Ltd has been opened in Bangalore. The idea is to accommodate all the demand of our Indian customers with a local office, local people and a complete logistic centre, with the purpose of handling the requests with very short delivery times. The main segments are industrial machines, railways, transportation, defence, special vehicles, medical equipment and industrial automation.

Q. What could you tell us regarding to the development and the quality policy of the Rollon Group? Rollon has become the international point of reference in all sectors for many different applications. Customers can count on a high-quality product that is both trustworthy and enduring. One of the most appreciated characteristic is the self-aligning capacity offered by our rails, in fact this is clearly demonstrated by

the reduced costs associated with surface preparation and installation. Rollon success is determinate by at least other two factors: firstly, our capability to develop applications that are ever increasingly specific and diversified based on the reference market, right up to making customized products, in some cases even codesigned with customer, and secondly our worldwide network of assistance centres. Every manufacturer or exporter of Rollon products may make use of the specialized assistance service provided by our team of engineers. They can also find our products in their own countries, avoiding extended waiting times and benefiting from the technical assistance whenever required, for a truly all-round technical support service as it happens in India.

Q. What is the function of R&D activity in your company? The Rollon’s commercial approach on international markets are based on innovation and competitiveness so the constant involvement of the R&D department is remarkable in looking for solutions dedicated to the specific application of its customers in the manifold industrial sector and in all the major countries in the world.

Linear solutions global provider.

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.

IN FOCUS Although our sales with customized products hits 35%, we keep improving our products in order to develop new to satisfy the requests and to offer a fulfilling system solution, not just products.

Q. What are the major technological trends that are leading your linear motion solutions? There is a worldwide growth of linear motion market. The main engines are the automation of industrial processes, robotic movements and the global industrialization. We are keeping finding new applications and challenges to evolve and to produce new options. The use of Rollon linear rails affords many solutions for multiple linear motion applications for industrial machines. The lateral sliding of protective devices, the movement of control panels or the movement of tools in machining centre are a few examples of linear rails. The potential of Rollon products is to avoid misalignment, most of all on the rails. Many of our products are built on a fundamental value that is the spirit of Rollon’s attitude: ‘C’ profile rails housing different types of sliders operated by rolling elements such as ball bearings. The rail-slider has a very compact configuration and enhanced uses of increasing spaces available: this manufacturing principle is essential to guarantee the ability of Rollon’s components to offer more benefits than other solutions available in

the market. Moreover, internal circuit guarantee appropriate and high quality protection from possible shocks and dirt. To intensify rails’ weight capacity and duration the raceways of almost the entirely Rollon linear and telescopic rail are subjected to an induction hardening process. Furthermore, to expand rail’s sliding abilities some products undergo a grinding process.

Q. What are the market opportunities for Rollon products in India? We are very optimistic regarding the opportunities for machine tool industry in India and consequently for the solutions proposed by Rollon, especially for our strong industrial markets like railway and automation projects. The linear rails, telescopic rails and actuators made by Rollon ensure proper function and improved performance of machine tools. What industrial machines should assure is adequate efficiency in the production process: especially machining centres, cutting machines, painting machines, and machines for processing wood or marble must be capable to provide a proper implementation on an extended period, often with challenging cycles and critical conditions (presence of liquids, process residue, contaminants or corrosive substances). Procedure complications or machine interruptions create a lack of efficiency and additional costs. Every element must sup-

ply the proper functioning of the machine, guarantee an extreme accuracy and simplicity during the assembly and in replacement phases, keeping the maintenance down.

Q. Which Rollon products are particularly suitable for the Indian market? Our production range has a three main lines: the linear line that contains linear caged ball bearings and recirculating ball bearings rails, with different profiles and kind of sliders. The telescopic line with full and partial extraction telescopic guides, accessible in several rail profiles and characteristics like load capacity, inflexibility and proper functioning. The actuator line with linear components available in many extremely load capable and accurate typed of belt and ball screw driven models and arrangements. At this time the Indian market is particularly developing in the automation, logistics, defense and medical sectors: this is why the telescopic rails, the seventh axis system, the actuator line (uniline system and smart system) are widely used.

For more information: ROLLON INDIA Pvt. Ltd. 1st floor, Regus Gem Business Centre 26/1 Hosur road, Bommanahalli Bangalore 560068, INDIA Tel: +91 80 67027066 Fax: +91 80 67027004 info@rollonindia.in www.rollonindia.in

MACHINE TOOLS WORLD SEPTEMBER 2018

IN FOCUS

TAKING A GLOBAL STEP AHEAD Solapur-based Precision Camshaft Limited, a leading manufacturer of camshafts for the automotive industry, has recently been in the news for its acquisition of two companies that will help it generate a bigger footprint across the globe. The company is headed by Yatin Shah, Chairman and Managing Director. Huned Contractor reports years the company has established strong business relationships with marquee global OEMs. A majority of its revenue comes from export of camshafts to various OEMs directly and indirectly. The company has a long-term relationship with several global OEMs such as General Motors, Ford Motors, Hyundai, Maruti Suzuki, Tata Motors and Mahindra and Mahindra. It has supplied more than 60 million units of camshafts over about ten fiscals and has serviced various customers across different geographies including the United States of America, Brazil, the United Kingdom, Germany, Austria, Hungary, Russia, South Korea, China and India.

caters to its domestic customers from this manufacturing facility. The EOU unit of PCL has four foundries and one foundry at the domestic unit. The total manufacturing capacity is 13.38 million camshaft castings per annum. PCL has state-of-the-art machine shops which enables it to achieve standards agreed upon with its customers. It specialises in 3 and 4 cylinder chilled iron camshafts, with machining capacity to produce over 2.22 million camshafts annually. PCL also has the capability to manufacture fully machined camshafts as per customer requirement for locomotive application made out of rolled steel bar route.

Joint Ventures Manufacturing Infrastructure

Mr. Yatin Shah, Chairman & Managing Director Precision Camshafts Limited

recision Camshaft Limited is one of the world’s leading manufacturer and supplier of camshafts, a critical engine component, in the passenger vehicle segment, based on estimated global market share by volume according to the ICRA research report. It supplies over 150 varieties of camshafts for passenger vehicles, tractors, light commercial vehicles and locomotive engine applications from its manufacturing facilities in Solapur, Maharashtra. The company was set up in 1992 by first generation entrepreneurs Yatin Shah and Dr. Suhasini Shah, who have over 20 years of experience in the critical engine component manufacturing sector. Over the

MACHINE TOOLS WORLD SEPTEMBER 2018

Precision Camshaft Limited has two state-of-the-art manufacturing facilities – an EOU unit and a domestic unit – both situated at Solapur. The EOU unit consists of four foundries and two machine shops and products manufactured at the EOU unit are primarily exported to its overseas customers. The domestic unit consists of one foundry and one machine shop and

In order to strengthen business operations in Asia, PCL has entered into two joint ventures with NSPCL, the first, Ningbo Shenglong PCL Camshafts Company Limited, for machining of camshafts and the second, PCL Shenglong (Huzhou) Specialised Casting Company Limited, for setting up a foundry in China. The machine shop at Ningbo, China commenced production in April 2013.

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01_MTW_Monthly_Magazine_190x250mm.indd 1

www.grobgroup.com

15.02.2018 10:20:47

IN FOCUS and Czech border, MFT manufacturers critical components in its state-of-theart and cost-competitive manufacturing environment. The dynamic and young team led by Guido Glinski has indepth knowledge of machining and is committed to growing the company. This move will also help MFT expand its global footprint. It will allow them to get better access to the development departments of the German and European car manufactures. This will enable them to actively shape the disruptive changes in the automotive industry and prepare themselves for the challenges in the future development of the conventional powertrain and become part of the alternative drivetrain technologies.

Technology and Innovation PCL continues to invest in technologies, designing capabilities and research and development activities. The company uses different technologies for engineering and manufacturing operations, including shell sand molding process technology, special AI203 ceramic sand care technology and GBQII process technology which gives it a cost-competitive advantage among competitors. It also has a dedicated design and development team of engineers along with a well-equipped inspection laboratory and a calibration laboratory. The company has also entered into an exclusive agreement with EMAG, a German machining and tooling process company, for transfer of certain knowhow and technology in order to strengthen its foray into assembled camshafts and expand business operations in the European market.

Acquisition of MEMCO PCL acquired Nashik-based precision component maker MEMCO Engineering last year so that the synergy would help it further strengthen its industry leadership and diversify into a new product range. MEMCO is a financially strong company with an annual growth rate of 18.5% over the past four years and has the capacity to produce 10.7 million precision components. MEMCOâ&#x20AC;&#x2122;s key products

MACHINE TOOLS WORLD SEPTEMBER 2018

include fuel injection components for conventional and CRDi diesel engines, brake components, high-pressure diesel injector connectors for naval ships and high-precision instrumentation components.

Footprint in Germany In March this year, PCL announced its second acquisition with the taking over of German precision machinist MFT Motoren und Fahrzeugtechnik GmbH (MFT) through its wholly owned Dutch subsidiary, PCL (International) Holding. This acquisition is value-accretive which will open up synergetic opportunities for the company through new product offerings and will establish a global brand presence. MFT will not only complement its relationships with current OEMs in that region but will also help in enhancing its customer base. With MEMCO and MFT on board, PCL is gradually progressing towards attaining its goal of transforming the business profile, while the key focus area continues to be its legacy business. MFT enjoys long-term relationships with marquee global customers like Volkswagen, Audi, Opel, Westfalia, Hatz, Suzuki, etc. MFTâ&#x20AC;&#x2122;s key products include balancer shafts, camshafts, bearing caps, engine brackets and several non-engine prismatic components. Located close to the Polish

Acquisition of EMOSS Mobile Systems Netherlands PCL has recently acquired 51% equity shares of EMOSS Mobile Systems Netherlands for Rs 58 crore. The acquisition will pave the way to mature electrical mobility markets such as Europe, North America and Australia. The electric vehicle market has grown significantly over the past decade with a special emphasis on the commercial electric and niche services segment. PCL with its experience in delivering topof-class products to customers across its global network will leverage this advantage to the EMOSS business as well. PCL is looking at capturing a significant share of the commercial electric vehicle market globally.

New Contracts In the recent past, PCL has won a global contract from General Motors with aggregate value of Rs 580 crore over the lifetime and a global contract from Ford Motors with an aggregate value of Rs 550 crore. Both programs are on track and will start serial production in FY18-19. In addition to this, PCL has been recently awarded with new contracts for fully machined camshafts from Ford, General Motors, and Mahindra and Mahindra with aggregate value of Rs 275 crore over lifetime.

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IN FOCUS

We delight our customers by providing economic solutions to their grinding process: Ashok Sheth Vadodara-based Solitaire Machine Tools Limited is a leading manufacturer of Precision Centerless Grinders, with a standing and reputation spanning nearly three decades. Solitaire focuses on designing and manufacturing centerless grinding machines of superior quality, high accuracy and superlative performance. The company is also recognized for timely delivery, installation services, training and after-sales technical support, reveals Ashok Sheth, Chairman, SMT in an interview with P.K. Balasubbramaniian. Excerpts: Mr. Ashok Sheth, Chairman Solitaire Machine Tools Limited

Q. You are a prominent name in Centerless Grinding. What precisely is your niche? We have been in Centerless Grinder business of manufacturing and remanufacturing since 1980. The association with Cincinnati Milacron and its grinders made us aware of quality requirements and need to provide solution for the customer rather than supply the grinder. Also we have consistently focused on this small niche part of the grinding sector. The later association with Bocca & Malandrone, Sunebo of Italy for the past 10 years has brought their advanced features like Hydrostatic Slides, Double supported spindles and Vibration free concrete base. These are slowly being recognized by manufacturers of precision components.

grinders to customers, who were importing new grinders from USA, Europe and Japan. They found that indigenous grinder was of same quality and durability. Over the years, we kept on evolving design and features to improve productivity and quality for customers.

Q. How comprehensive is your range of manufacture today? We can grind components from 1mm diameter to 200 mm diameter. We have supplied grinders to grind small drill bit of 1 mm weighing about 5 grams to rear Axle of Volvo truck weighing 250 kg. We are working on a new grinder to grind parts as small as 0.2 mm diameter. We are launching Centerless Grinder with 5 Axis CNC and with Twin Grip supported wheel width of 300 mm, especially to meet requirement of shock absorber industry and manufacturers of precision shafts and small crank shafts. It will be dispayed at IMTEX 2019.

Q. You pioneered the technology some three decades ago. What is the level of sophistication Centerless grinding has attained over the years?

Q. You say your machines are designed to give â&#x20AC;&#x2DC;superior quality, high accuracy and top performanceâ&#x20AC;&#x2122;. How do you substantiate this statement?

We are not Pioneer of this technology, but we brought features, which were not being offered in India. We offered

We would say that our customers substantiate this statement. We have ground parts with roundness below 1

MACHINE TOOLS WORLD SEPTEMBER 2018

micron, surface finish below 0.03 Ra, and cylindricity below 2 microns. We have ground small pins at the rate of 30 pins / second, Steel bars at 6 meters / minute feed rate for example while still meeting their stringent standards.

Q. What must be the total headcount of machines you have supplied so far? We have manufactured and remanufactured over 1000 grinders in India in the last 30 years. Our US associate plant in Chicago has supplied close to 1400 grinders since 1980.

Q. Who are your major customers? Our major customers are automotive component manufacturers. Most of our customers in thisfield are MNC plants in India. Many of vehicle manufacturers have recognized Solitaire as reliable source of Centerless Grinders and have been advising their vendors to use our grinders. Other customer base in Engineering industry for Precision components like Hydraulic spools, Crank shafts, Ceramic Parts, Graphite and Aluminium components etc.

Q. Could you enlighten us on your manufacturing facilities and wherewithal? We have complete manufacturing

IN FOCUS

facilities comprising Horizontal Machining Centers, Vertical Machining Centers, Horizontal Boring Mills, Slideway Grinders, Cylindrical grinder, Surface grinders, Super finishing machine and all other allied equipment. We also have quality control facilities to inspect ground components with Cylindricity tester, Roundness tester, Surface finish tester, Profile Projector and all other related inspection equipment. We also have 150 vendors to manufacture components as per our drawings.

Q. What’s your export performance? You have also got some Awards we believe. We have exported 25 to 40 % of our sales every year for past six years. We have received EEPC Star Performer award for past 5 years in a row.

Q. Of late, there have been innovations in software for better flexibility and precision in CNC controls. Have you embraced these? Software for efficient working and ease of operation is an evolutionary process. Each grinder is customized with software to meet customer’s

MACHINE TOOLS WORLD SEPTEMBER 2018

requirement. Also all safety interlocks are provided to ensure safety at all times. We are servicing grinders supplied in South America through internet.

Q. Do you also do re-engineering and retrofitting of grinders of any make? What are the benefits the end customer can derive from this activity? We do Remanufacturing and CNC retrofitting in addition to automation for Cincinnati Centerless Grinders of any model or any age. We have remanufactured Cincinnati grinder as old as 1939 (close to 78 years old) and brought it back to grinding parts meeting customer’s requirement. The cost compared to new machine could be around 50 % to 60% and customer can still use the asset which is owned by them.

Q. Service is crucial in your line of business. What’s your service setup and response time? We try and train customer’s maintenance personnel in ways to look after the grinder and do the work themselves as far as possible. This saves time as well as cost for them. All required spares are offered with quick

delivery. The training to customer’s staff is free at our plant. Also during commissioning, training is given for operation and maintenance. In case required, our factory trained personnel visits and takes care of servicing.

Q. How do you delight your customer? We delight our customers by providing them economic solutions to their grinding process. We provide them various options and the advantages to make educated decision on their procurement of the grinder. All features and options are discussed in details before placement of order.

Q. What are your future thrusts? We like to work on improving quality and productivity for components being produced on our grinders. For example, we grind a small set of components at 10 metres/ minute and now we are targeting to improve the same and try to reach 15 meters/ minute. In the past, one of our customers was grinding a component in one second and with joint efforts, they were able to bring it to 0.8 seconds per part. That is 20 % increase in productivity. Our focus will be on such accomplishments.

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 SEPTEMBER 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

Machine tool probe technology at your fingertips

Whether you are programming, configuring or maintaining your probing systems, Renishaw smartphone apps provide assistance in a simple and convenient format. With touch interaction and intuitive design, our range of apps provide significant benefits to machine tool probe users and integrators. Available globally in a wide range of languages, our free-of-charge apps are perfect for both new and experienced users.

For more information visit www.renishaw.com/smartphoneapps

Renishaw plc New Mills, Wotton-under-Edge, Gloucestershire, GL12 8JR United Kingdom T +44 (0)1453 524524 F +44 (0)1453 524901 E uk@renishaw.com

www.renishaw.com

COMPANY PROFILE

“FIBRO has committed to Make in India”

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

e, FIBRO India, the 100 % own subsidiary of FIBRO GMBH, Germany have been present in the Indian market for more than the decade serving Indian engineering industry. We started as ‘FIBRO India Standard Parts Pvt Ltd’ in 2008 with rented place at Pirangut, Pune. We started manufacturing guide pillars, oil less wear parts with German precision to the to Die & Mould making industries. Over the period of time, our standard parts like guide pillars, bushes, die sets, cams, gas springs etc. have received recognition and appreciation from the global customers. We have grown in Indian market due to the support and encouragement received from our esteem clients, suppliers, friends and well-wishers. As a result, we moved to our own new location on 7th March 2013 to meet ever growing needs in terms of quality and quantity of our customers like you. Though FIBRO has direct presence in many countries across the globe, this is the first manufacturing unit outside Germany. This new plant has the built-up area of 2000 sq.m. to accommodate the capacity enhancement in the near future to cater to the global market. We enhanced our manufacturing capacity by adding equipment and machineries to reduce the

MACHINE TOOLS WORLD SEPTEMBER 2018

lead time Again in 2014, Rotary Tables division of FIBRO GmbH decided to join hands with FIBRO India for their business in India. As a result, we changed our name to “FIBRO INDIA PRECISION PRODUCTS PRIVATE LIMITED” so as to indicate that FIBRO India is not restricting its business only to standard parts activity. Recently, ‘Make in India’ initiative has boosted the manufacturing in India. This has opened the doors to manufacture new innovative standard parts and Rotary Tables to support the various manufacturing sectors across the industry. FIBRO GmbH has committed to ‘Make in India’. It has been our experience that the products manufactured at FIBRO India are globally competitive as we are supplying those standard parts made in house to the major FIBRO subsidiaries across the globe. Hence to meet this increased Global demand, FIBRO has decided to expand the manufacturing facilities in India. As a result of this initiative, we have acquired adjacent land for setting up of new manufacturing unit. We expect that within a year, new FIBRO India Plant with increased production capacity will be ready to invite you for Grand Inauguration! Our USP is ‘German Precision at Indian costs backed by 60 years of worldwide rich experience in Tool & Die industry’ Here in India, we are manufacturing standard parts like Oil less guide elements, CAM slide units, spring plungers etc, for domestic as well as global market. And along with standard parts, FIBRO, the pioneer in manufacturing Rotary Tables, having started in 1958, offers a wide range of rotary tables used for automation as well as metal cutting applications. Our range for Automation includes FIBROTOR – Cam driven, FIBROMAT – Heavy Load Positioning, FIBRODYN – High speed direct drive rotary table. And the range for Metal cutting includes FIBROPLAN – NC Rotary Table, FIBROMAX – Heavy duty NC Rotary

table with twin drive, FIBRODYN – NC rotary table with direct torque drive, FIBROTAKT – Precision Rotary Tables with Hearth face gearing. Recently, we started representing reputed European brand - HEMA Maschinen- und Apparateschutz GmbH for their unique product range like machine back walls, telescopic bellows, safety windows etc. For more than thirty-five years, HEMA has been manufacturing protective systems for the world’s machinery building sectors. Through consistent further development, HEMA Group expanded their production to several sites in Germany and abroad for most efficient service to the customers worldwide. Products offered by HEMA are mainly -

• Protection and window systems First range of products - bellows for the protection of linear guides - HEMA engineered the SAMURAI range of product, lamella protected bellows and aprons and also complete backwall systems. In addition to spiral springs other products such as telescopic steel covers, roller systems, machine safety windows. VISIPORT® Spin windows and LED lighting systems completes the range of offers. • Clamping and Braking Systems Within the last ten years HEMA also enlarged second sphere of competence which newly includes pneumatic and electromagnetic clamping and braking systems and also manual and mechanical clamping systems. With this partnership, FIBRO India has broadened their product offerings & will be representing HEMA for Indian Market henceforth.

For more information, Website: www.fibro.com

TECH TRENDS

Speed up on-machine measurement with SupaTouch technology

ou might think that minimising probing cycle time on a machine tool would be as simple as just increasing the feedrate; unfortunately, it’s not as simple as that. Based on its years of metrology experience, Renishaw knows that to minimise probing cycle time whilst maintaining machined component accuracy, intelligent optimisation is needed. SupaTouch – an optimisation routine within Renishaw’s industry standard Inspection Plus macro software – intelligently optimises on machine probing cycles, leading to a cycle time reduction of up to 60% on CNC machine tools. During 2018 Renishaw will introduce a new version of Inspection Plus, with updated SupaTouch technology, at IMTS, USA; AMB, Germany and JIMTOF, Japan. New usability enhancements that have been added to the optimisation routine give users full control of probing cycle feedrates. Optimise probing cycles automatically SupaTouch technology intelligently determines the fastest feedrates a machine tool can achieve whilst ensuring repeatable measurement. Its smart in cycle decision making technology implements the quickest probing strategy (either one touch or two touch) for each measurement. Smart decision making continues during component measurement. If a probe is triggered during machine acceleration or deceleration phases (which may happen due to variation in the positioning of the workpiece) the

MACHINE TOOLS WORLD SEPTEMBER 2018

measurement result will be inaccurate. After detecting these inaccurate measurements, SupaTouch technology automatically commands the probe to remeasure the surface at a more appropriate speed to ensure accuracy is maintained and no machine alarms are raised.

The many proven benefits of Renishaw’s established Inspection Plus software are enhanced with SupaTouch technology. With this software, users can significantly improve cycle times and on-machine measurement results, maximising the productivity and profitability of their machine tools.

Minimise cycle time and maximise productivity SupaTouch technology eliminates the need for manual optimisation of on machine positioning feedrates, measurement feedrates and strategies. When compared with traditional software cycles, it provides a significant measurement time reduction of up to 60% on CNC machine tools.

For more information, Website: www.renishaw.com

TECH TRENDS

Absolute precision in automotive production

In the automotive industry, there are measurement tasks which require simultaneous detection of several measurement values or three-dimensional detection of measurement objects within short cycle times. For example, when assembling the windshield, a scanCONTROL laser line sensor is used to detect detailed distance values.

he automotive industry is the sector where most industrial robots are used. Therefore, the requirements regarding cycle time, degree of automation and repeatability are increasing. In production and joining processes from the shock absorber to the front spoiler and the lights, many steps must be carried out during which different parts are joined. Previously, the production processes were rigid. Now, these are controlled in real-time by state-of-the-art sensor technologies. Meanwhile, the tolerances of the gap sizes have halved and are now between 0.5mm to 2mm. In order to achieve these tolerances, all working steps must be carried out accurately. The joining processes in production automation for example require precise assembly. This is why robots have now taken over most of these processes. In addition to the opticalvisual impression, the correct and long-life function of all parts must be ensured. Squeaking doors are not acceptable and windows must be tight and installed flush. In parallel, perfect appearance and functionality of the vehicle must be achieved

MACHINE TOOLS WORLD SEPTEMBER 2018

using as little material as possible. For these tasks, robots are perfectly suitable as they work continuously and reliably without psychological and physiological impairments, while operating quickly and accurately. Furthermore, they also take over many tasks that previously would have involved heavy manual labor for employees. Laser sensors and laser scanners from Micro-Epsilon are used in these applications for intelligent robotics. They detect measurement values in real time and can directly transmit these to the PLC. The result is improved quality control based on extremely high accuracy, process optimization, cost savings and material savings. Marriage of engine and car body optoNCDT laser point sensors, for example, monitor the â&#x20AC;&#x153;marriageâ&#x20AC;? of the car body and the engine. Car body and engine, i.e. the entire drive train, are joined together in so-called marriage lines. Therefore, the drive train is moved into the production line on a frame. At this point, the car body is suspended from a device

Important parameters of quality are homogeneous gap sizes of cockpit elements and the center console. Depending on the inspection scenario, a single scanner applied on a robot arm can measure different gaps in static or dynamic mode.

and is swiveled from above by a robot in such a way that the car body is above the drive train, which is then lowered onto it. Laser triangulation sensors mounted on the device measure the distance between the car body and the engine. Now, the

TECH TRENDS car body must be placed exactly onto the drive train and fastened accordingly. High precision cockpit positioning The cockpit in the car includes hundreds of individual parts and weighs up to 100kg. During its installation into the vehicle, it must be positioned precisely. Therefore, a rectangular frame of metal struts with two grippers is mounted on the outsides on a robot arm. The gripper grabs the cockpit on both sides and moves it horizontally in the direction of the vehicle, which is fed into the assembly line on a conveyor belt. Shortly before reaching the vehicle, the robot inclines the cockpit side to be mounted slightly downwards. In this position, the cockpit is swiveled into the passenger compartment over the robot through the opening, which is intended for the driver door and then turned horizontally again. Typically, four optoNCDT laser sensors are used for this measurement task which are installed in the four corners of the metal frame respectively. They are fixed both on the top and the bottom, i.e. in the four corners of the metal frame, which is equipped with the grippers. The sensors measure reference points in the vehicle interior in real time. These can be prominences and depressions. The four sensors ensure that the cockpit is properly aligned in all directions (x-, y- and z-axes). When all sensors

Laser scanners from Micro-Epsilon enable measurements on almost all industrial materials, largely independent of the surface reflection.

have detected their respective reference marks, the robot is stopped in order to move the cockpit forward into exactly this position relative to the car body, to dock it on and to fix it in place. For the entire process including the fitting of the cockpit, an extremely short cycle time of less than one minute is required. Furthermore, the sensors must operate independently of the surfaces, as different reflections occur due to the multitude of different surface paints used – from dark to bright colors and from mat to shiny appearances. Strengths of the laser point sensors Considered as one of the best in their class, optoNCDT laser point sensors are used for displacement, distance and thickness measurements. The Real-Time Surface Compensation feature (RTSC) enables the sensors to operate regardless of

Micro-Epsilon’s laser scanners accurately position the vehicle.

MACHINE TOOLS WORLD SEPTEMBER 2018

materials and colors. The extremely small measurement spot size also enables the measurement of very small objects, while simultaneously providing high accuracy measurements down to the micrometer range. Measurement data is generally available in real time and so can be used to automatically correct and control the production process. Depending on the model, Micro-Epsilon’s wide product range of red and blue laser scanners covers measuring ranges from 2mm to 1000mm and measuring rates from 2kHz to 49.14kHz with resolutions down to 0.03µm. High precision laser sensors from Micro-Epsilon are used in high-tech areas such as automotive industry and 3D printing, where aircraft components are also produced. Car windows In the automotive industry, measurement tasks in which the simultaneous detection of multiple measurement values and three-dimensional detection of measurement objects within short cycle times are required. For example, when installing the windshield, a scanCONTROL laser line sensor detects detailed distance values in all axes. In the installation process, the sensor is mounted onto the robot, which fits the window into the vehicle. When the windshield is placed on the car, the scanner detects the complete profile and vicinity of the windshield while all necessary values are determined with a single run in quick time. It can be determined whether the windshield is placed straight and centered or whether it fits perfectly in every plane. The results, which are in this case the gap and flushness, are directly

TECH TRENDS www.mtwmag.com

generated in the sensor head and output to the PLC. Another measurement task concerns the adhesive, which is already applied before the windshield is fitted into the chassis and also detected by a laser scanner. Therefore, the scanner is directly mounted onto the robot that applies the adhesive beading. Here, the sensor moves along the adhesive bead to create a 3D image. It reveals whether the adhesive quantity is sufficient, whether it is applied evenly and whether the bead is applied in the correct places. All detected measurement values are stored separately. If an error occurs in the process at a later point in time, these measurement values can be used for analysis purposes. Gap inspection When assembling a vehicle, numerous gap and flushness measurements are necessary. This includes, among other things, the position inspection of airbag

Robot axes must be calibrated at regular intervals. Micro-Epsilonâ&#x20AC;&#x2122;s induSENSOR (LVDT) displacement sensors carry out this task. Mounted on robot axes, these gauges detect the zero point via a probe tip when the axis is turning.

Considered one of the best in their class, these laser point sensors are used in displacement, distance and thickness measurements. Due to the RTSC real-time surface compensation feature, the laser-optical measuring system operates almost regardless of material and color.

stitching. The scanner detects the contour of the stitching while being guided by a robot arm and evaluates several features synchronously. The laser scanner continuously inspects the distance between the stitching and the separating point between the single stitches and outputs the evaluation directly as 0 (NOK) or 1 (OK) via the Ethernet interface. Beyond that, the height

difference between two single components is directly inspected in order to immediately recognize any faulty assemblies that might impair the safety. Another measurement task involves gap monitoring in car interiors. Important parameters of quality are homogeneous gap sizes of cockpit elements and the center console. Depending on the inspection situation, a single scanner applied on a robot arm can measure different gaps in a static or dynamic mode; alternatively, a special frame on the robot arm is used that enables the scanner to detect a number of different gaps in the interior in static mode within fractions of a second. The sensor evaluates these measurement values and sends a signal to the control system if the values measured lie within the tolerances defined by the customer. Other gap inspections also concern the car body, e.g. when measuring gaps in doors or when assembling body trims. Website: www.micro-epsilon.com

SEPTEMBER 2018

MACHINE TOOLS WORLD

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 SEPTEMBER 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.

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TOOL & PROCESS MONITORING Genior Modular can monitor real time and track quality from row to finish part providing and using various sensors and control information. This solution allows machines and components to communicate and optimizes the manufacturing process. Marposs is the partner you need to make Industry 4.0 a working reality.

MARPOSS INDIA Pvt. Ltd.

147, Sector 7, IMT Manesar 122 050 - Tel. +91 124 4735700 | sales@in.marposs.com

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 SEPTEMBER 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 SEPTEMBER 2018

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 SEPTEMBER 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.).

TECH TRENDS

Intelligent 24V powerhouse with PROFINET certification

With the intelligent SCHUNK EGL PROFINET parallel gripper, the competence leader for gripping systems and clamping technology SCHUNK has been exploiting the potential for highly flexible applications for users in the diverse Industry 4.0 environment

he world’s first universal gripper with integrated electronics,certified with the highest standard of category C, uniting power, diversity, and intelligence. Its high-performance PROFINET interface creates the optimum conditions for real-time process regulation and maximum performance. With a variable gripping force between 50 N and 600 N, the compact gripper covers an extremely wide range of components. In force-fit gripping, it can handle a wide range of parts up to 3 kg alternately – circuit boards in the electronics industry as well as components in the assembly of consumer goods or in mechanical engineering.

MACHINE TOOLS WORLD SEPTEMBER 2018

The finger position, the closing speed, and the gripping force can be freely programmed within the maximum stroke of 42.5 mm per finger. In order to shorten the cycle time, the fingers can also be pre-positioned wherever necessary with a speed of up to 150 mm/s. Interactive commissioning assistant The complete control and regulation electronics are installed inside the EGL PROFINET in space-saving fashion, which makes it possible to utilize it in a decentralized manner; thanks to its 24 V DC operating voltage, it can also be used in mobile applications. Due to standard plus

connectors, certified PROFINET interface and commissioning assistant, the gripper can be integrated into installations quickly and easily. The latter guides the operator step-by-step through the entire commissioning process – from the configuration of the hardware, through the incorporation of the GSDML file right up to the programming of the PLC. Integrated test functions make it possible to check each procedure. Furthermore, a diagnosis interface allows access to the most important process and status data of the gripper. A solid aluminum housing, stable guides and a brushless servomotor ensure a high level of robustness and long-lasting and reliable operation with minimal maintenance costs. In the case of a power failure, an electrically activated brake ensures that the position of the gripper fingers is held and no referencing is required. Besides the version with PROFINET interface, the gripper is also available in versions with PROFIBUS DP and CAN.

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TECH TRENDS

FARO Design ScanArm 2.5C brings color to 3D Scanning FARO has announced the first arm-based solution to include high resolution, 3D color scanning capability. This exciting introduction includes full color 3D scanning as standard, out-of-the-box functionality in the new FARO Design ScanArm® 2.5C

he Design ScanArm 2.5C is compatible with the FARO 8-Axis FaroArm® system, which effectively doubles the arm reach and substantively improves the ease of use, is specifically designed to address design challenges across a range of industries including Computer Graphics, Industrial Machinery, Auto Manufacturing and Engineering Services. A color 3D representation is the perfect baseline for product visualizations and special effects. This innovative leap forward enables parts and objects to be reconstructed and visualized as vividly as they appear in the real world. The true-to-life functionality not only allows design professionals to proceed with an even higher level of confidence but also, as a result, accelerates the completion of important projects. Faster end to end project cycle time is also supported and enhanced by rapid scanning color capability of up to 240,000

MACHINE TOOLS WORLD SEPTEMBER 2018

points per second. Consistent with the FARO commitment to optimizing ease of use through advanced ergonomics, the Design ScanArm 2.5C, like its predecessor the Design ScanArm 2.0, is available in three highly maneuverable arm lengths—2.5m, 3.5m and 4m. This ensures that end users can select the option that optimally fits with the specific design objectives for their projects. Furthermore, hot swappable batteries ensure that the user can bring the scan to the project rather than needing to bring the project to the scan. Greater Efficiency with 3D Color The DSA 2.5C significantly exceeds the baseline expectations that FARO documented from prospective users during an exhaustive product development process. Not only do the vividness and sharpness deliver spoton representation of the color of the

real-world object, but now finer details including texture, and even text, can be clearly extracted for product visualization, computer graphics or identification of key features during the product design or reverse engineering processes. Finally, greater efficiencies can be realized as full color can be captured in a single scan, removing any need to take pictures or apply texture in the post scanning process. “FARO continues to be laser focused on optimizing the productivity of design professionals,” stated Thorsten Brecht, Senior Director Product Design. “By integrating exceptional quality color into the design process, we have created a best-in-class 3D reality experience by allowing users to capture more information, in true-to-life detail richness and color, in less time than ever before. The DesignArm 2.5C is yet another example of FARO pushing the boundaries of innovation and accepting the challenge to lead the market.”

TECH TRENDS

WireDress® - When grinding receives an unprece-dented dimension

f.l.t.r. Michael Klotz (Project Leader Development STUDER), Alfred Mair (Head of Grind-ing Technology Fischer AG), Emine Elezi (Head of Marketing Fischer AG), Philippe Schmider (STUDER Sales).

Completely new possibilities in grinding with metal bonded CBN and Diamond wheels: This is made possible by WireDress® from STUDER. Not only does this innovative, electro erosive integrated dressing technology save massive downtime, it also enables sintered metal bonds to be dressed with the highest precision in the grinding machine at full wheel speed. Fischer AG in Herzogenbuchsee, manufacturer of high-precision spindles, has been using this technology for several months and cannot hide their en-thusiasm.

lfred Mair, Head of Grinding Technology at Fischer in Herzogenbuchsee, faced a challenge. The aim of Fischer AG was not only to increase productivity, but they also reached their limits in the grinding of exotic materials such as titanium and hard-to-machine hard materials under the increasing quality demands from the customers. He could not solve the problem with a conventional grinding machine. What next? The solution was found by Mair at STUDER. Here the CNC universal cylindrical grinding machine S41 is

MACHINE TOOLS WORLD SEPTEMBER 2018

manufactured. Specifically de-signed for large workpieces, it has a length between centres of 1000/1600 mm and a centre height of 225/275 mm. It processes workpieces with high precision up to a maximum weight of 250 kg, just as effectively as small and medium-sized workpieces. But the key for Fischer is the fully integrated WireDress® dressing system. “We had high hopes that we could use metal-bonded grinding wheels for a measurable and reproducible highest quality, have a higher productivity, more universal machining options as well as reduced tool costs,” Mair explains his

expectations. Expectations exceeded STUDER configured the S41 with WireDress® based on additional wishes of Fischer AG. Thus, the machine received a special high-speed external grinding motor spindle, an innova-tive proprietary product of Fischer AG, in which the axial growth is particularly small. In addi-tion, the spindle is tapered at the rear end, avoiding possible collision situations. This is a spe-cific benefit for face/shoulder grinding with the spindle at an angle. The S41 is supplemented with a fully automatic workpiece magazine

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TECH TRENDS and handling system, which ensures fully auto-matic series production of the high-quality precision components in a stand-alone operation. The conclusion of Mr. Mair after a solid introduction time of the machine: “I am blown away”. Three to five times faster than with conventional technology, with absolute reproducibility, ground in a tolerance range of less than 1μm! I have never seen anything like that! I am ex-tremely impressed. “ The secret behind it But how does this dressing technology work? Michael Klotz, project manager for develop-ment at Fritz Studer AG, explains it this way: “It is a well-known fact that metal-bonded grind-ing wheels are much more durable and dimensionally stable when machining difficult-to-machine materials and ultimately enable higher productivity. The problem with this is that metal bonds can only be dressed to a very limited extent using conventional methods in the grinding machine. In addition to this there is a high dressing tool wear associated with a low cutting ability. This is neither an operator-friendly, nor a high quality and process consistent dressing method”. That’s why the “best” bond – the metal bond - is rarely used. “STUDER has developed, along with technology partners, the machine-integrated WireDress® dressing technology. Here, the dressing is done at full wheel speed.

In contrast to conventional me-chanical or external EDM dressing, WireDress® dressing occurs by a modified wire erosion in the grinding machine, where the grinding oil serves as a dielectric. The dressing process is contactless and wear-free. The grit itself is not dressed, the metallic bond around the grit is removed. Depending on how deep the grit is embedded in the bond, it either falls out or remains with original sharpness in the bond. The grinding wheel receives a high grain clearance for maximum cutting capability, lower grinding forces and low burning risk. You can now harness the capabilities of metal bond with WireDress®. Using a bond with a high dimensional stability, almost any profile can be precision-contoured in the μm range. Long dressing intervals can be achieved. Yet another plus: the accurate processing of sophis-ticated or smallest geometries that was neither economical nor possible before, now becomes feasible. Compared to grinding with ceramic-bonded grinding tools, significant increases in productivity in the range of at least 30 percent is realistic, with resin bonds, even more is pos-sible. With a sintered metal bonded grinding wheel, you can even go beyond the limit - you can just re-dress it in the machine again. With a conventional grinding wheel you can only go over the limit once. “Maximize these limits without fear - that also makes greater profit-

Manufacturing hall of Fischer AG with the STUDER S41.

MACHINE TOOLS WORLD SEPTEMBER 2018

STUDER S41 with WireDress® dressing unit.

ability possible,” adds Michael Klotz. Several factors for success “If you have the right technology, the process is peanuts. In the past, you had to feel your way, today everything is process-stable. This also has the advantage that you can calculate the costs more clearly, “explains Mair. He also knows that the right technology is not just about the machine. What other factors also contribute to reproducible manufacturing in the absolute range of less than 1 mu? “A fully air-conditioned hall, which among other things also ensures the thermal stability of our spindle, the right tooling, state-of-theart measuring tech-nology, optimized cooling and, of course, highly trained and motivated staff,” says Mair. Conclusion For Fischer AG, the investment in the S41 has paid off with WireDress® technology. The productivity could even be increased by 70% for certain materials. Mair states further: “I am convinced that if this technology gets around in the professional circles, STUDER will be flooded with orders.” Another advantage that should be of interest to engineers and design engineers in particular: not only can straight forms be dressed, but also very fine profiles, which was previously not possible with metal-bonded grinding wheels. This opens completely new design possibilities for engineers, and even unimaginable horizons.

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CASE STUDY

EFFICIENT AND ULTRA-DYNAMIC: SIMULTANEOUS MILLING & TURNING An extremely impressive machine concept providing the option of milling and drilling without re-clamping and – above all – a high level of process safety with maximum accuracy for workpiece machining. Impressed by these benefits, the services provider HETEC located in Breidenbach, Hessen, has become a loyal GROB customer in the field of milling.

tuttgart, AMB Trade Fair in September 2010. Hans Rink, Head of Rink Werk-zeugmaschinen and

GROB Represen-tative for the Hessen region, mana-ged to persuade HETEC MD Friedhelm Herhaus to visit the GROB trade fair stand. Back then, Friedhelm Herhaus was rather sceptical about the size of GROB as a com-pany, as he couldn’t believe that he would really be taken seriously as a regional sup-plier of tool, die and machine manufactu-ring

Deep-hole drilling on a G550 – Use of extra-long tools without restrictions on the maximum part size

products from one of the world’s big-gest machine tool companies. But he soon

hydrau-lics-free, fully CNC controlled

He was much more interested in the

knew better.

machining center. Back then, he wasn’t

horizontal spindle position on the G550

interested in all the arguments for and

and that you could mill and drill with it

against hydrau-lics-free machine tools.

at the same time without having to re-

2010 saw him standing in front of a world first from GROB – the first fully

MACHINE TOOLS WORLD SEPTEMBER 2018

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21/09/17 5:46 PM

CASE STUDY clamp the workpiece or take it to a deep-

mum chip removal for both drilling and

hole drilling machine. An important

deep cavities. The question of the extent

HETEC team impressed by GROB technology

factor for tool and die construction, but

to which the GROB machine would

The more Friedhelm Herhaus and

for many mechanical engineers, too,

suit existing HETEC machine tools also

his tech-nicians got to grips with the

when they have to drill deep holes. The

needed to be clarified, and whether this

technology of the GROB machining

highly experienced Friedhelm Herhaus

type of GROB machine with its specific

centers, the more they could see the

had never seen milling and drilling on a

axis con-cept could be integrated in the

strength of these machi-nes. First the

single machine of this kind before. So it

HETEC en-vironment successfully.

benefit that – thanks to the special axis

initially got his interest, at any event. He

Friedhelm Herhaus could instinctively

concept – the entire length of the tool

found the travel and GROB kine-matics –

see the potential of the GROB machine.

can be used in each axis setting – even

the whole machine concept in fact – very

Fur ther discussions took place in

at maximum workpiece size. And the

appealing.

Mindelheim and Breidenbach – with

special tunnel concept means that the

long phone calls – and they finally

whole work area can be used, as the

Thorough preliminary research and intensive technical analysis

hatched the idea of deve-loping a

motor spindle plus tool withdraws into

“fantasy component”, for which the

the spind-le shaft, meaning that the

Nevertheless, the disinclination to opt

GROB machine concept minus re-

machine table can rotate and swivel with

for a GROB 5-axis universal machining

clam-ping and multiple clamping

the workpiece and clamping mechanism

center was strong. Basic issues needed to

would deliver rapid results. There was

without colliding a definite plus point.

be clarified first as to whether HETEC

also a requirement to create various

Something comple-tely new to the die

actu-ally wanted to implement the axis

contours on the GROB machine.

HETEC technicians. In Mindelheim

sys tem (with rotated Y axis). An axis

Chip removal with deep pockets was

for training during the initial and test

system that was totally new territory to

another major issue on the check list.

periods, the machine operators soon

HETEC at the time. But as he traveled

“We were really impressed by the

appreciated another benefit provided by

back from the trade fair, Friedhelm

assistan-ce we received from the GROB

GROB machines: The spindle is positio-

Herhaus called Hans Rink to discuss

technicians. Even at an early stage of

ned almost at eye level, giving a good

the machine’s axis symmetry and the

our collaboration, when we hadn’t

view of the machining tool.

machining technology for workpieces

even bought a machine yet, we quickly

From the first G550 to the G550 with

with long tools. He was increasingly

realized that GROB loo-ked after new

rotary pallet storage system (PSS-R)

persuaded, recognizing that workpieces

customers really well, the aim being to

After successful testing at GROB in

can be machined with long tools

find the best user solutions”, Friedhelm

Mindel-heim, the HETEC management

with the GROB machine and that the

Herhaus looks back to the time with

team finally took the decision to buy

horizontal spindle position enables opti-

fondness.

a G550. Particularly because the axis

GROB‘s automation solution – the rotary pallet storage system PSS-R

High-precision machining of complex part contours

MACHINE TOOLS WORLD SEPTEMBER 2018

CASE STUDY flexibility and improved spindle running times. And then came the GROB inhouse trade show in 2015. The HETEC management team were impressed by the benefits of a G550 with a rotary pallet storage system (PSS-R), purchasing one soon afterwards with a master computer. A major plus point in their eyes was the fact that, even with the GROB automation ap-plication, the machine operator still had a good view and access to the work area.

A solid partnership is formed At an early stage of discussions and the f.l.t.r.: Mr. Friedhelm Herhaus (CEO), Mr. Hans-Hermann Rink (GROB sales agency Hesse) and Mr. Tom Herhaus (HETEC machine operator of the GROB G550)

process of getting to know each other, HETEC dismissed fears of a David and Goliath situation. Both sides soon learned

concept allows for machi-ning deeper

of cooling and ejector bore with tool

to value each other as they looked for

cavities with good chip remo-val and

lengths of up to 650 mm in the same

the best solution. The GROB philosophy

drilling operations with deep hole

clamp.

of “nothing’s impossible” ultimately

drilling tools (Ø 8 x 650 mm) went

Continuing close collaboration

won the day. GROB acceded to nearly

without a hitch. The first GROB G550

between HETEC and GROB, allied with

all of the customer’s wishes, developing

was then in-stalled as planned for

a desire to introduce automation for

special solutions. The purchase of a G550

machining modelling components

die- and tool-ma-king processes with

seven years ago marked the beginning

with complex contours, high surface

typically long running times, led to

of a solid collaboration based on trust

requirements and parallel introduc-tion

the purchase in 2014 of a G350 with a

– something that HETEC had never

of cooling bores in a single clamp. La-ter

zero point clamp system and a pallet

before experienced in over twenty years

on, HETEC soon saw the machine’s ac-

system that made it possible to set up

of existence. HETEC are also really

tual potential at HETEC for machining

workpieces outside of the machine.

impressed by the GROB Ser-vice hotline

used in die and mold construction. The

Completed pallets were replaced by

and expert technical support. So it’s

G550 was ideal for machining the high-

newly fitted ones manually. But it was

no surprise that Friedhelm Herhaus is

strength, hardened steels typically used

also clear that simultaneously setting

really pleased with his Swabian Bava-

in this area. HETEC technicians were

up the workpie-ces while the machine

rian partners, buying more machines in

amazed by the option of full introduction

was running would result in greater

Mindelheim.

MACHINE TOOLS WORLD SEPTEMBER 2018

CASE STUDY

Fixture and Tooling solution for Auto component The Basics of fixture Design. 1. The fixtures are designed with 3-2-1

clamping with hinge mechanism. 3. Hydraulic clamping- Hydraulic

principle ie 3 points resting, 2 points

cylinders are used for Hydraulic

orientation & 1-point location of the

clamping fixtures.

component. 2. Components are located using a

4. The hydraulic power pack is the source for oil supply. Three types

round locating pin & oriented with a

of hydraulic supply can be used to

diamond locating pin.

operate hydraulic elements.

3. Hardened & ground rest pads should rest the components in a parallel plane.

Quick Release couplers (Off-Line)

ii. CPH-Continuous pressure holes (Rotary Joint)

4. Rough guides should be used to load

iii. TPH-Through pallet Holes.

the components into the fixture to

5. Hydraulic Power pack should be

avoid fouling in the fixture elements.

designed in such a way to meet the

Venkatesh Phadnis, Manager Projects & Fixture, CNC India Pvt Ltd

esign of fixture is the key to effective utilization of machine tools. Basics of fixture design if not

implemented correctly, results in poor productivity & quality problems. Set-up time and cycle time reduction, increased accuracy on components and deskilling the job setting operation are the obvious advantages of a good fixture design. A complete process of fixture design should be carried out from concept to finish which includes Pre-design activities like Design input, machine details, component drawings and conceptualization, process planning, accuracy consideration,

Types of clamping systems:

required clamping force on compo-

cycle time estimation, POKAYOKE,

1. Manual clamping - Usually strap

nent for machining. Offline system

3D modeling of parts and assembly

clamps, goose neck clamps and

Accumulator and non- return check

using popular design CAD tools and

swing clamps should be used for

valve should be used to avoid pres-

preparing the final manufacturing

manual clamping. Clamping of com-

drawings with complete BOM.

ponents can be done using torque

Fixtures are the work holding devices used to accurately locate/orient &

wrench for uniform clamping. 2. Pneumatic clamping - Pneumatic

secure (clamp). A part that is repeatedly

clamping fixtures should use pneu-

in a mass production set up.

matic cylinders with mechanical

MACHINE TOOLS WORLD SEPTEMBER 2018

sure drop during machining. 6. Air seat check should be used to ensure proper seating of components. 7. Coolant and Chip management â&#x20AC;˘ Proper slopes to be provided on the fixture base for efficient coolant &

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UNITY CONTROLS PVT. LTD

CASE STUDY chip evacuation. • Air and coolant flush to be provided for chip removal from component resting areas. 8. Tooling hole to be provided on the

13. Fixtures should be either base type fixtures or tomb stone type fixtures with quick change sub plate concept. 14. Indexing cradle type fixtures to be used with CNC rotary tables which

fixture to ensure the start point of the

are programmable as 4th axis on

NC program.

VMC’s to reduce number of setups

9. Fixtures should be positioned on the

for particular component.

machine pallet or table by using end

15. Multiple setup & multiple

butting pads or Tenon locations or centre location and orientation pins. 10. Hydraulic work support to be used

component to be loaded on tomb stone type fixtures. 16. Zero-point clamping system is

where required in cases of rough

provided to increase the machine UP-

for every fixture to ensure the

surface or profiled surface resting or

TIME and easy loading and unload-

approach of the tool in the set of

4th resting to achieve flatness and to

ing of sub /fixture plates.

avoid vibration on component while machining. 11. Internal hydraulic lines should be

CUTTING TOOLS

be confirmed by making the tooling

1. Basic tool design should be based

layout.

on machining process, design of the

nate external piping to avoid chip

component, machining process to

clogging.

be named as Op-10, OP-20… etc.

lar concept to machine multiple variants of components.

MACHINE TOOLS WORLD SEPTEMBER 2018

operation. 4. Tools GPL (Gauge plane length) can

provided in the fixture base to elimi-

12. Fixtures should be built with modu-

rical tolerances of the component. 3. Tooling layout should be prepared

(Operation -10). 2. Tooling plays the key role in maintaining the dimensional and geomet-

5. Fixture and Tooling validation will be ensured after achieving the cp & cpk parameters on the component All the parts manufactured have to undergo PPAP (Production Part Approval Process).

CASE STUDY

Blaser Swisslube’s Synergy 915 pays for itself at Dantal Hydraulics Achieving an annual total cost saving of INR 1.33 Mio with a higher coolant price per litre? Impossible? Not for Blaser Swisslube. They convinced Dantal Hydraulics to test their Liquid Tool. With outstandin results.

t their plant in Haryana, India,

“We are very happy with the new coolant

Dantal Hydraulics manufactures

from Blaser Swisslube, especially with the

customized hydraulic cylinder

tailored on-site customer service. I was

and hydraulic systems, aircraft hydraulic

very scepticalat first. The coolant price per

service trolleys and car parking solutions

litre of the new Synergy 915 is 47 percent

in India.Blaser Swisslube approached

higher than our previous coolant. But the

Dantal Hydraulics and was able to

Liquid Tool solution pays for itself”. After

introduce their philosophy of maximizing

the first success, two more machines were

profitability of machines and tools.

switched to the Blaser coolant.

Take a close look at all Parameters

A Desire for More

“Sandeep Kumar Bhat from Blaser

However, the potential has not been fully

Swisslube India explained to us in

exploited yet. With Dantal Hydraulics’

detailhow they first analyse the current

plan to invest in expansion, Blaser will be

machining processand structure their

at their side as a trusted coolant partner

testing accordingly”, said Mr. Yogesh

for further continuous improvements on

Tyagi, Deputy General Manager – Plant

the shop floor.

Engineering at Dental Hydraulics. Dental

The Liquid Tool by Blaser Swisslube

Hydraulics was curious and agreed on a test on their SIERRA during almost

suits perfectlyfor demineralized and

Productivity, cost-effectiveness and

two months. “We found good chances to

soft water applications “, said the Blaser

processing quality are factors that depend

improve tool costs and overall savings

representative.

on the selection and quality of the

for the skiving and burnishing process”

metalworking fluid to the highest degree.

said Sandeep Kumar Bhat. Based on his

An Outstanding Result

“With our extensive machining know-

experiences and the recommendations

The results from the testing were very

how, customized services and first-class

from the Headquarters in Switzerland,

promising. During the test phase, the tool

products, we can help our customers

the coolant Synergy 915 was selected for

costs were reduced by 22 percent. This

to fully exhaust the potential of their

the given machining situation at Dantal

resulted in an annual tool cost saving of

machines and tools and to convert the

Hydraulics. “Synergy 915 is a synthetic,

INR 1.33 Mio. Furthermore,the machine

metalworking fluid into a central factor

water-miscible, chlorine, mineral oil and

is cleaner and the foam disappeared

for success – a Liquid Tool,” says Marc

ester oil free metalworking fluid and

completely. A very satisfied customer:

Blaser, CEO of Blaser Swisslube.

MACHINE TOOLS WORLD SEPTEMBER 2018

19th Indian Metal-Cutting Machine Tool Exhibition with International participation

24 - 30 January 2019, Bangalore, India

CASE STUDY

Measuring with speed and precision A Madrid, Spain-based precision engineering business specialising in complex parts for aerospace and defence applications has invested in a Renishaw REVO® five-axis measuring head and probe system. The change has resulted in a reduction in inspection time by as much as a factor of 5, ensuring quality control and inspection keep up with its high-productivity CNC machine tools.

t’s true that in many ways making things is getting easier, at least as far as

He continues, “Depending on what the

synchronised head and machine motion when scanning, rapidly following changes

customer requests, we inspect between

in part geometry without introducing its

ple, machine tools are simpler to program

10% and 100% of machined parts. The

own dynamic errors. The CMM is able

and operate, rapid prototyping means

Renishaw REVO system, recently fitted to

to move at a constant velocity whilst

that product development is faster and

a Metris CMM, measures non-prismatic

measurements are being taken, without

cheaper than ever, and user-friendly CAD

surfaces very quickly, many of which

impacting accuracy.

software may even negate the need for

would be difficult or impossible to meas-

physical prototypes entirely. All of this as-

ure with touch trigger systems. In some

infinite head positioning and innova-

sumes that what you are actually making,

cases, such as a complex avionics chassis

tive tip-sensing probe technology, which

or trying to make, is relatively uncompli-

for the Typhoon, the REVO has increased

further improves measurement accuracy

cated. It’s a different matter, however, if

our inspection throughput by a factor of

by sensing close to the measured surface.

you are building complex multi-million

5; typically, up to 80% reduction in time

This combination of speed, flexibility and

dollar aerospace systems, like those engi-

per part.”

accuracy has proven to give exceptional

the technology is concerned. For exam-

neered by Mecanizados Escribano.

The key attribute of the REVO five-axis

REVO also benefits CMM users with

performance in a wide range of scanning

head is its ability to overcome the limita-

measurement applications, including circle,

specify all the options,” says company

tions of three-axis scanning methods,

helix, sweep and gasket scanning, plus, if

project manager Juan A. Humanes. “But,

where any attempt to rapidly move the

required, rapid single-touch routines.

having the best machines is only part of

large mass of a CMM results in inertial er-

the equation. Our customers demand very

rors caused by accelerations and decelera-

Expanding to meet increased demand

rigorous part inspection, which means

tions. Therefore, the only possible way to

Any visitor lucky enough to tour the

there’s always the chance that the metrol-

maintain acceptable accuracy in three-

Escribano factory can see the size and

ogy department can become a bottleneck,

axis scanning has been at the expense of

significance of the investment required

especially when the parts are complex and

measuring speed. However, REVO uses

for such production. Juan A. Humanes

“When we buy a machine tool we

machined to very tight tolerances.”

MACHINE TOOLS WORLD SEPTEMBER 2018

CASE STUDY www.mtwmag.com

(pictured right) reveals it to be between

For most precision engineering busi-

sure we can deliver exactly what they

€1million and €1.5million a year, and

nesses, the Metris and Renishaw REVO

most of the company’s CNC machines are

combination would be enough to cater for

A large proportion of Escribano’s

top-end, Japanese or Swiss-built multi-

their metrology needs. But Escribano isn’t

production is for the US defence sector,

pallet and multi-axis: Makino, Matsuura,

your typical workshop and its customers

which probably has more small, privately

Mazak; Sodick wire EDMs and CNC

are somewhat more demanding, leading

owned precision engineering companies

precision grinders from Jung. All of

to further investments in other advanced

than any other country on Earth so the

them are the latest models, meticulously

metrology systems such as a white light

question is; why would a US defence

maintained and configured to minimise

interferometer microscope for measuring

contractor choose to outsource some of its

set-up and non-machining time, mostly

roughness, and a contact profile meter

most complicated, quality-critical parts to

using Renishaw OMP40 spindle-mounted

capable of assessing the size and texture

a company in Spain, instead of one closer

touch probes and NC4 non-contact laser

of a part’s surface.

to home?

want, when they want it.”

“Some people might assume that we

tool setting systems.

Sophisticated expertise and technology

win business because Spanish labour costs

building and has designed and built a

The Madrid-based company is a rarity;

are lower than they would be at a similar,

new facility, where it will relocate in the

privately owned engineering workshops

US company,’ says Humanes. “But they

next few weeks. Until then, the two small

with the expertise and the technology to

would be wrong. If that were the case

rooms adjacent to the main workshop

deliver components and systems for such

the work would simply migrate to Asia.

that house the company’s inspection

sophisticated applications are few and far

The truth is we are competitive because

equipment will remain crowded. In the

between. No one at Escribano can or will

we invest in the best technology and we

larger of the two rooms, three DEA Global

talk about its customers or their products,

train people to high levels. We don’t just

Advance co-ordinate measuring machines

but Humanes is happy to discuss what

benchmark ourselves with competitors in

(CMMs) with Renishaw probes check

the company is equipped to do and how

Spain or Europe, we aspire to be the best

samples of parts for everything from ther-

it does it.

in the world.”

Escribano has outgrown its current

mal imaging cameras to components des-

“We specialise in machining complex,

General precision engineering may,

tined for the Joint Strike Fighter. Along-

5-axis parts in aircraft-grade aluminium,

thanks to the technology, be getting easier,

side the main metrology lab’ is a smaller

stainless steel, nickel alloys, copper and

but Escribano’s willingness to meet almost

room housing the company’s largest

titanium,” he says. “The only way to be

any standard of engineering precision

CMM: a Metris LKV CMM equipped with

good at this kind of work is to make the

means that even during the worst reces-

the Renishaw REVO five-axis measuring

necessary investments in technology

sion in living memory – and the Spanish

head and probe system; part of a recent

and people. Our customers can choose

economy is suffering the effects as acutely

investment in inspection equipment that

between some of the best equipped sup-

as any country – this family-owned com-

totalled around €300,000.

pliers in the world, so we have to make

pany is still busy 20 hours a day.

SEPTEMBER 2018

MACHINE TOOLS WORLD

NSIC GROUND, AJI GIDC

BLOCK YOUR DATES Machine ToolsCutting

Phillips Machine ToolsForming

Laser Cutting, Welding & Marking

ENGINEERING & SOLUTIONS

Automation casting-forging, material handling & storage

Precision tools Testing & Measuring

DYNASCAN

INSPECTION SYSTEMS

Hydraulics & Pneumatics PNEUMATIC EQUIPMENT

Industrial Supplies Other major exhibitors

Lanyard Sponsor

Gold Sponsors

Diamond Sponsors

CNC Machine Tools

Organised by

Supported by

FEDERATION OF KUTCH INDUSTRIES ASSOCIATIONS

ENGINEERING & SOLUTIONS

Awards by

Concurrent Show

Hall 6 & 7

(M) +91- 98250 83530 | (E) amit@kdclglobal.com | (W) www.rmtsindia.com

A GLOBAL DISPLAY OF IN

CONCURRENT SHOWS

For More Details, Please contact: +91-98795 66567 SILVER SPONSORS

GOLD SPONSORS

CNC Machine Tools

Pioneer in Spring Machinery Since 2001

ENGINEERING & SOLUTIONS

ORGANISED BY

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• TEFC 3-ph asynchronous brake motor (0.09kW-130kW) • AC 3-ph brake (no rectifier) or DC brake on request • Oversized brake disc for higher brake torque, longer life and reduced maintenance • Fine and easy brake torque adjustment (as standard) • Very quick brake reaction time • Frequent START/STOP cycle applications • Manual brake release (as standard) • Hexagonal hole on non drive end of the shaft for manual rotation • Single speed or two speeds motors • All motors designed for inverter duty

• RS-RT worm gearboxes: 28 to 150 mm centres. One stage worm, helical/worm and double worm. • RD helical gearboxes: 50 to 2300 Nm. Two and three stages. • RN parallel shaft gearboxes: 180 to 3300 Nm. Two and three stages. • RO-RV bevel/helical gearboxes: 180 to 3300 Nm. Three stages. • RG precision planetary gearboxes: 10 to 230 Nm. One and two stages. • VR dry friction speed variators: IEC63 to IEC90 1 to 5 stepless speed range, 300 to 1500 rpm. • VS planetary speed variators: IEC71 to IEC112 1 to 5 stepless speed range, 200 to 1000 rpm.

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MGM-VARVEL Power Transmission Pvt Ltd Ware House No. G3 and G4 • Ground Floor • Indus Valley's Logistic Park • Unit 3 • Mel Ayanambakkam • Vellala Street Chennai - 600 095 • Tamil Nadu, INDIA • Phone: +91 44 64627008 • info@mgmvarvelindia.com • www.mgmvarvelindia.com REGIONAL OFFICE: KOHLI TOWERS • 4th Floor, Dapodi • Near Bharat Petrol Pump • Pune - 411012

PRODUCTS SHOWCASE

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

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

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

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

106

MACHINE TOOLS WORLD SEPTEMBER 2018

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

PRODUCTS SHOWCASE www.mtwmag.com

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

Following are some of its unique features:

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

• • • • • • •

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

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

Nexgen Refrigerated Air Dryers

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

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

SEPTEMBER 2018

MACHINE TOOLS WORLD

107

PRODUCTS SHOWCASE

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

Designed to performs

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

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

New transmission elements

ZCL Spur gears Technopolymer, pressure angle 20°

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

108

MACHINE TOOLS WORLD SEPTEMBER 2018

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

PRODUCTS SHOWCASE www.mtwmag.com

Rotary Ball Spline 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 the nuts. The Spline is capable of performing two modes of motions (rotational and linear) with a single shaft by rotating or stopping the spline nut. The rows of balls are held in a special resin retainer incorporated in the spline nut so that they smoothly roll and circulate. The balls recirculation in ball holder, prevent balls falling from the spline nut while assembling.

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

• High Positioning Accuracy The Ball Spline groove profi¬le is designed Gothic arch. By applied preload, the backlash in the rotational direction is eliminated therefore having higher positioning accuracy. • Compact Design Spline nut and the support bearing is integration structure. The Spline nut is designed lightweight. Therefore, the highly accurate and compact design is achieved. • Easy Installation The spline nut and the support bearing are integrated, thus the Rotary Ball Spline can easily be mounted simply by securing it to the housing with bolts. • Support Bearing The support bearing of the Ball Spline has a contact angle of 45°, thus it has the average force of axial and radial direction.

Application Robots, Transporting equipment, Wire winder, ACT(Auto Tools Change)…etc.

Base plate joins clamping force blocks with quick-change pallet system

For Product Enquiry Contact SCHUNK INTEC INDIA PRIVATE LIMITED No 80 B, Yeshwanthpur Industrial Suburbs, Bangalore – 560022, India Ph.: 080-40538999, Fax: 080-40538998 Email: info@in.schunk.com Web: www.in.schunk.com

Starting now, pneumatically actuated SCHUNK TANDEM KSP plus clamping force blocks can be directly joined to the SCHUNK VERO-S quick-change pallet system via standardized base plates. The manually controlled SCHUNK ABP-h plus basic plates can be supplied with compressed air both on the bottom and side connections. An integrated pressure maintenance valve ensures that the clamping force blocks remain securely clamped even if the compressed air supply is interrupted. This means that the clamping force blocks can be used on a wide range of 3, 4 and 5-axis machines. The current pressure is displayed on a pressure gauge integrated into the base plate. SCHUNK ABP-h plus base plates are available in two sizes, one for TANDEM KSP plus 100 and 160, and one for TANDEM KSP plus 250, with drilling patterns for one, two or for small sizes also for three clamping force blocks. The vise on the base plate can be turned by 90° as required for the respective application. Centering takes place using KSP plus fitting screws.

SEPTEMBER 2018

MACHINE TOOLS WORLD

109

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MACHINE TOOLS WORLD SEPTEMBER 2018

PRODUCT INDEX A AC / DC Geared Motor AC Linear Servo Motor Actuator Actuator Line Air Compressors Alloy Wheel Machining Solutions Aluminium Profiles Angle Encoders Auto Cables Automation Products B Ball Transfer Units Ballscrews Bevel Gear Boxes Boring Bars Brake Motors

87 87 95 47 29 63 87 81 31 73

87 95 90, 91 43 105

C Cam Driven Systems 75 Cartridges 43 Casting 65 Centerless Grinders 77 Circuit Identifiers 85 Clamp Meters 85 Clamps for Linear Guides 87 CNC Grinding Machines 37 CNC Horizontal Boring Machine 63 CNC Lathe 63 CNC Machines 9 CNC Machining Centers BACK PAGE Cnc Metal Cutting Machines 49 CNC Smart Mills 63 CNC Solutions 13 CNC Turning Center 19 CNC Vertical Machining Center 19 Coatings INNER IFC Consumables 73 Continuity Testers 85 Contouring Controls 81 Current Testers 85 Curvic Coupling 87 Cycloidal Gear Boxes 90, 91 D Deep Hole Drilling Solutions 39 Digital Inverter technology 17 Dimensional Measurement Systems 67 Double Column Machining Centers 63 Drill Tap Center 63 Drilling Solutions IFC Drills 24, 25, INNER GATEFOLD E End Mills INNER GATEFOLD Endmills 24, 25 Energy Absorption & Vibration Isolation 79 F Face-Mill Cutters

Fixtures Flex Clamps Flexible Couplings

27 85 87

G Gas Flow Products Gas Management Gear Boxes Gears, Racks & Pinions Grinding Machines Grooving Tools Ground Resistance Testers

79 79 105 87 35 43 85

H Harmonic Filters High Pressure Filtration Hydraulic Press Hypid Gear Boxes

93 79 89 90, 91

I Indexable Ball Endmill 43 Inserts INNER GATEFOLD Instrumentation Fittings & Valves 79 L Laser Sensors Laser-Line Scanner Lathe Machines Length Gauges Light Energy Management Systems Linear Actuators Linear Encoders Linear Guideway Linear Line Linear Motion Guides Lubricants M Machining Centers Mass Flow Controllers Megohmmeters Metal Forming Machines Metal Working Fluids Micro Boring Tool Milling Cutters Milling Machines Milling Solutions Moisture Meters Monitoring Solution Motion Toolpaths Motor Rotation Testers Multimeters

83 83 15 81 93 87 81 95 47 87 23

11 79 85 21, 49 23 43 FALSE COVER 41 IFC 85 69 IBC 85 85

O Oil/ Coolant Mist Cleaner Optical Micrometers Oxy-Fuel CNC Cutting Machines

87 83 73

P Photoelectric Light Barriers FRONT GATEFOLD Planetary Gear Boxes 90, 91

Plasma CNC Cutting Machines Plate Rolling Machine Position Displays Power Analyzers Power Conditioners Precision Air Moving Products Precision Ball Screws Press Brake Machine Pressure Control Solutions Probing Systems Project Engineering Solutions Pump Solutions

73 33 81 85 93 79 87 33 79 59 73 53

R Real Time Power Factor System Rotary Encoders Rotary Tables

93 81 57

S Safety Mats FRONT GATEFOLD Safety Switches FRONT GATEFOLD Screwiacks 87 Security Sensors FRONT GATEFOLD Shearing Machine 33 Side & Face Cutters 43 Slewing Ring 87 Solenoid Interlocks FRONT GATEFOLD Stabilizers 93 Static Elimination Solutions 79 Stepper & BLDC Motor 87 Surface Cleaning 79 T Tapping Machine 61 Taps INNER GATEFOLD Telescopic Line 47 Thermal Imaging Cameras 85 Threading & Grooving Solutions IFC Tool Holders INNER GATEFOLD, FALSE COVER T-Slot Cutters FALSE COVER Turning Solutions IFC Turning Tool Holders 43 Twist Drills 71 U U-Drills 43, FALSE COVER Ultra Isolation Transformers 93 Universal Endmills 55 Universal Machining Centers 51 V Vertical Machining Centers Voltage Detector

63 85

W Welding Equipments Woodruff Cutter

73 43

3-Phase Testers

SEPTEMBER 2018

MACHINE TOOLS WORLD

111

ADVERTISERS INDEX COMPANY NAME

PG. NO.

A ACE MICROMATIC GROUP

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ADOR WELDING LIMITED

ANCA MACHINE TOOLS PRIVATE LTD

APEX PRECISION MECHATRONIX PVT. LTD.

PG. NO.

COMPANY NAME

GEDEE WEILER PRIVATE LIMITED

GLOBE-TECH ENGINEERING EXPO - 2018

104

PARAGON MACHINERY CO. LTD.

GP PETROLEUMS LTD.

PRECISE CUTTING TOOLS

GROB MACHINE TOOLS INDIA PVT. LTD.

PRECISION MOTION INDUSTRIES, INC. ( PMI )

GRUNDFOS PUMPS INDIA PRIVATE LTD.

BIRLA PRECISION TECHNOLOGIES LIMITED

CNC INDIA TOOLS & SERVICES (P) LTD.

CNC SOFTWARE, INC.

INSIDE BACK COVER

HYUNDAI WIA INDIA PVT. LTD.

RAJKOT MACHINE TOOLS SHOW - 2018

100

RAJSHAKTI MACHINES (INDIA) LLP

RAVISON'S CORPORATION

RENISHAW PLC

ROLLON INDIA PVT. LTD. - INDIA

RR KABEL LIMITED

I IMTEX - 2019

DOWEL ENGINEERING WORKS

INTEC - 2019

DUTCH TECH TOOLS PVT. LTD

24 - 25

J JYOTI CNC AUTOMATION LTD.

HEIDENHAIN OPTICS & ELECTRONICS INDIA PRAIVATE LIMITED

IMTOS - 2019

PG. NO.

Q QVI INDIA PVT. LTD.

BETTINELLI AUTOMATION COMPONENTS PVT. LTD.

97 101 102

S 19 SCHMERSAL INDIA PVT LTD

FRONT GATEFOLD

SHAVO TECHNOLOGIES PVT. LTD.

SOLITAIRE MACHINE TOOLS LTD.

ELECTROTHERM (INDIA) LTD.

ELGI EQUIPMENTS LTD.

MARPOSS INDIA PVT. LTD.

EMUGE-FRANKEN INDIA PVT. LTD.

MEERA CASTING

EPPINGER TOOLING ASIA PVT. LTD.

90 - 91

MGM-VARVEL POWER TRANSMISSION PVT LTD

105

EURO BLECH - 2018

103

MICRO-EPSILON INDIA PRIVATE LIMITED

MITSUBISHI ELECTRIC INDIA PVT. LTD.

UNITED GRINDING GMBH

MMC HARDMETAL INDIA PVT. LTD.

INSIDE FRONT COVER

UNITY CONTROLS PVT. LTD.

F FACCIN S. P. A.

FATTY TUNA INDIA PVT. LTD.

FIBRO INDIA PRECISION PRODUCTS PVT. LTD.

FLIR SYSTEMS INDIA PVT. LTD.

T TRUCUT PRECISION TOOLS PVT. LTD.

NICOLAS CORREA, S. A.

GALAXIEE CONSULTANCY PVT. LTD.

MACHINE TOOLS WORLD SEPTEMBER 2018

OERLIKON BALZERS COATING INDIA PVT. LTD.

FALSE COVER

N 41

112

COMPANY NAME

WOHLHAUPTER / ALLIED MACHINE & ENGINEERING COMPANY

Y INNER INSIDE FRONT COVER

YG-1 INDUSTRIES INDIA PVT. LTD.

INNER 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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