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Editorial

Changing The Rules Of Manufacturing?!

epeat after me. It is an age of simplifying the process for making products. Even in this day and age of disruptive technology reeling us and around us, this reality is perennial. You cannot be on a denial mode…it is a straight path to being diminished. Adapt and imbibe, but, before that, accept the reality. This is the only way to be out of the ‘dinosaur club’…the extinct lot!

Hard hitting and hardly hit may be the mental framework for many manufacturers and machine tool fraternity about the additive manufacturing or 3D printing. Incidentally, this was also the differentiating mind frame between the dinosaurs and the agile adaptive creatures who survived even after an enormous asteroid hit the Earth way back. Back to present, the ability to produce highly complex designs with powerful computer software and turn them into real objects with 3D printing is creating new realities, unheard of and unimagined ever. As there are barely any economies of scale in additive manufacturing, the technology is ideally suited to low-volume production, as we talk. It also allows the mass customisation of finished parts. Freed of the constraints of traditional factories, additive manufacturing allows designers to produce things that were previously considered far too complex to make economically. That could be for aesthetic reasons…but engineers are finding practical applications too. For example, fluids flow more efficiently through rounded channels than they do around sharp corners, but it is very difficult to make such channels inside a solid metal structure using conventional means. A 3D printer, on the other hand, can easily do this.

Editorial Advisory Board Vikram Sirur President, IMTMA & Executive Chairman, Miven Machine Tools Ltd

L Krishnan Vice President, IMTMA & Managing Director, TaeguTec India P Ltd

Shailesh Sheth Media Chairman, IMTMA & Past President, IMTMA

M Lokeswara Rao Past President, IMTMA & MD, Lokesh Machines Ltd

N K Dhand Past President, IMTMA & CMD, Micromatic Grinding Technologies Ltd

R Srinivasan Past President, IMTMA & MD, RAS Transformation Technologies

A British firm recently printed a gearbox for a racing car with smooth internal pathways for hydraulic oil instead of drilled-out right-angle bends. The box not only allows faster gear changes, but is about 30% lighter. A Boeing F-18 fighter contains a number of printed parts, such as air ducts, for similar reasons. The technology, and possibilities that it brings along, has indeed come a long way. 3D printing was originally conceived as a way to make one-off prototypes, but as the technology is getting better, more things are being printed as finished goods. Currently, worldwide, around 28% of the money spent on printing things is for final products. Experts predict that this will rise to just over 50% by 2016 and to more than 80% by 2020. But it will never reach 100% (at least that’s the assumption as of now), because the ability to make prototypes quickly and cheaply will remain an important part of the mix. So, with this as a canvas, we are living in exciting times full of Questions Marks (?) and Exclamation Marks (!). In this very special edition dedicated to new-age technology in manufacturing and machine tools, the doubts, fears and apprehensions are paired with the possibilities, opportunities and realities. Optimise this new-age reality by investing your time to read through this edition…we have not even spared the cover page of this edition of the knowledge; it pops questions in the form of doubts that are at the top of your mind about additive manufacturing and provides you with the answers that exclaim the realities. Get ready for the future!

Gautam Doshi Advisor, IMTMA & Consultant, Productivity & Quality Improvement Services

S N Mishra Past President, IMTMA & Vice Chairman, Bharat Fritz Werner Ltd

Archana Tiwari-Nayudu archana.nayudu@infomedia18.in

July 2012 - MODERN MACHINE TOOLS

Contents Insights & Outlook History of Railway Manufacturing .................................... 104 Business Dynamics ............................................................. 110 Technology On Tracks ....................................................... 112 Railway Machining Technologies ....................................... 118

Facility Visit HMT Machine Tools Ltd .............................................. 100

Special Focus Additive Manufacturing

56 & 57

Insights & Outlook Railway & Equipment Machining

Strategy

102 & 103

Reducing Leaks .................................................................. 124

Top Shops Management ..................................................... 120

Energy Management Event Report AMTEX 2012 ...................................................................... 128

Tech Talk

Special Focus

CNC Machines................................................................... 130

AM In Space ...................................................................... 58 Optimising RP ................................................................... 60 Opinions And More ........................................................... 66

Geography Watch Delhi-NCR ......................................................................... 132

In Conversation With

Additive Innovations .......................................................... 70 AM Challenges .................................................................. 77

Guruprasad K Rao CEO, Imaginarium (India) Pvt Ltd ..............

Dr Rainer Ohnheiser President and CEO, Carl Zeiss .....................

AM Sustainability .............................................................. 80 One Q Many Views ........................................................... 82 3D Printing ......................................................................... 84 Tips & Tricks ..................................................................... 86 Desktop Additive Manufacturing ..................................... 90 3D Manufacturing .............................................................. 92

Looking For A Specific Product? Se Searching and sourcing products were never so easy. Just type MMT (space) Product Name and send it to 51818

eeg. MMT EDM and send it to 51818

Regular Sections

Turn to Page 142 for Latest TENDER Updates

Editorial ...................................................................... 17 Sarathi Sutras .............................................................. 23 News, Views & Analysis .............................................. 24 Technology & Innovation ............................................ 36 Event List .................................................................. 138 Products .................................................................... 149 List of Products .........................................................174 List of Advertisers .................................................... 180

NEXT EDITION HIGHLIGHTS Special Focus: Metal Cutting Insights & Outlook: Precision Cutting Special Supplement on Aerospace Machining

Cover illustration: Hemant Lambe

August 2012 - MODERN MACHINE TOOLS

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August 2012 - MODERN MACHINE TOOLS

Shailesh Sheth, an eminent authority, shrewd analyser of trends, brilliant strategist and considered by the industry as a “Guru”, to us, he manifests as ‘Sarathi’, accomplishing his timely purpose in the ever-evolving world.

ByMerchant Shailesh Sheth of Dreams

is the only way out of such precarious situations. It is apparent here was a time in history when our subcontinent that international MNCs have disturbed the natural state of had a 24.4% share of world GDP (in PPP, which has things for Indian manufacturers in domestic markets, urging them today reduced to under 6%!). Since then, it has been to extend their local ‘World Class’ mirage to beyond the shores of a long arduous journey through colonialism, independence, India. With globalisation in our backyard, Indian manufacturers industrialisation and economic liberalisation for India. Today, have had a chance to see that MNCs we find ourselves heading back Creating Indian MNCs are more than just about mammoth upwards, with a modern economy turnovers. Their sheer geographical fundamentally dependent not so spread helps them weather business much on the size and volume of its The age of the Indian MNCs is here. cycles around the globe, mitigating population but its worth per capita; This is one of the most visible outcomes risk from currency fluctuations by and nowhere is this more symbolic of India’s integration into the global operating in multiple currencies. and concentrated than in the economy. A key determinant of success It draws on a planet-wide pool of engines of growth of an economy, for Indian companies will be our ability talent, knowledge, technology and its MNCs. networks; thus, transforming once Yet the making of MNCs to strike global roots. local manufacturers into global is a road fraught with unique - Kumar Mangalam Birla leaders, iconic of the very best in challenges, and such jewels elude standard, quality and scale. the Indian machine tool industry, an industry that today, contributes a This last, scale, is a must for miniscule 1% to world machine tool production. The first step for any company aspiring to become an MNC. However, any such Indian manufacturers would be to think beyond India, to choose aspirations must be founded on core strategies such as identifying between being, as Kumar Mangalam Birla said, “a the unique value proposition of a company, branding true MNC or just an Indian company operating it in an effective and memorable way, recognising abroad.” The need for this is starkly apparent when opportunities that maximise the comparative advantages you consider that each of the 15 largest machine of a global firm over local manufacturers, knowing when tool companies in the world have a turnover greater to compete, cooperate & collaborate, and establishing a than the entire Indian machine tool industry ($875 sustainable balance between organic growth, mergers & million)! It only goes to show how far corporations acquisitions. There will be difficulties in establishing with global mindsets have gone. And it is a path our brand equity overseas since Indian companies are still companies can tread too! to receive widespread recognition. Sincere efforts need To begin with, our volumes are too low. China to be made in developing this equity in markets across produces 32 times more machine tools than India and 11 countries the world through reliable performance, reputable employment do far better than us in production. Manufacturers, comfortable practices and model corporate citizenship. Such MNCs would in gazing inwards, have not seized the opportunity to emerge be the vanguard of manufacturing for an ‘emerged’ India, from their domestic cocoons. These statistics also reveal a threat helping to consolidate a global identity for the nation’s machine to our industry in that each of the aforementioned 15 companies tool industry. has turnover volumes large enough to seriously damage primary It is time to shatter India’s image as a domesticated low-tech, domestic companies, numbers far above the minimum defensible high-volume producer of cheap machine tools, and to venture out volumes of our entire machine tool industry. If just 10-15% of on the tightrope between the macro and the micro, the global their turnover is invested in Indian markets, it could significantly and local. Thus, the new sutra ought to be to develop a genuine upset the balance and hopes of local manufacturers. Globalisation global leadership mindset in the Indian machine tool industry.

“Be a hero. Always say I have no fear. Tell this to everyone – ‘Have no fear’.” – Swami Vivekananda July 2012 - MODERN MACHINE TOOLS

News, Views & Analysis

Year 2013: A ‘Perfect Storm’

hile the current storm in the global economy has not yet subsided, American economist, Nouriel Roubini predicts a ‘perfect storm’ next year. Roubini highlighted the five factors that could derail the global economy: the worsening of the debt crisis in Europe; tax increases and spending cuts in the United Sates that may push the world’s biggest economy into recession; a hard landing for China’s economy; further slowing in the emerging markets; and a military confrontation with Iran. However, the Indian manufacturers seem to be ready and geared to face the

storm. Vikram Sirur, President, Indian Machine Tool Manufacturers’ Association (IMTMA), says, “There are still a lot of questions on how bad the economy really is. It is difficult to predict the situation in the future. There certainly is a slowdown in the global market, but the Indian industry has not yet entered an alarming situation. Though some sectors have suffered, others are still doing well. The automotive industry is growing reasonably well in terms of numbers. It is said that the Indian economy is like an elephant; once it starts moving, it is difficult to stop it. That is precisely what the industry promises.”

Intensity Reduced but Economy Still in Slowdown: BluFin

report from BluFin, a financial information company, points out that though the intensity of the downturn has reduced, the Indian economy is still facing slowdown. The BluFin Business Cycle Indicator (BCI), which tracks the business cycle in the Indian economy, fell marginally by -0.5% in July to 156.8 compared to 157.6 in the previous month. However, the BCI yearon-year growth rate improved from 1.8%

in June 2012 to 1.9% in July 2012. According to the report, the downtrend in July has primarily been caused by declining production of key metals such as aluminium, weak foreign trade and rising global commodity prices. All of these sectors have been affected by the international financial crisis. Interestingly, offsetting effects are beginning to appear at the component level, which have slowed the decline in the BCI to a great extent.

Chinese Eye German Machine Tool Group

hinese companies are eyeing German machine tool group MAG, a sign that appetite remains high among the Chinese companies for acquiring German industrial know-how. State-owned Shenyang Machine Tool (SMTCL) confirmed it is in talks to acquire Goeppingen-based MAG, while its competitors Dalian (DMTG), Quier Machine Tools and YierMT Group are also said to be looking at the asset. Apart from these groups, private equity investors such as Triton and DBAG are also looking at the group, which last year posted sales of €900 million ($1.1 billion). Chinese companies have already scooped up a number of German groups to gain access to technology, brands and worldwide distribution. In April, Xuzhou Construction Machinery Group (XCMG) agreed to buy a majority stake in privately held machinery manufacturer Schwing, following a similar deal a few weeks earlier, when car partsmaker Hebei Lingyun acquired car door latches specialist Kiekert. In January, Sany Heavy Industry said it would buy Schwing rival Putzmeister in a €360-million ($443.1 million) deal, and LDK Solar invested in solar group Sunways.

India’s First Machine Tool Industry Park to Come Up in Bengaluru

ndian Machine Tool manufacturers’ Association (IMTMA) recently signed an MoU with the Government of Karnataka for establishing a Machine Tool Industry Park for the Southern region. This is the first such endeavour in the machine tool segment. The initiative has already received an enthusiastic response from the industry. It will be developed to meet international standards, high infrastructural standards and facilities. “We want 300 acre of land from the State Government for this initiative, and things are yet to be finalised. We are also in talks with the Vikram Sirur, President, IMTMA , along with BS Sirsikar, Joint Director (Planning), Government of India to have similar parks in the Directorate of Industries & Commerce, North and West zones to cater to the industries of Government of Karnataka, signing the MoU the respective regions. Such parks will provide a for the first Machine Tool Industrial Park for common platform to machine tool manufactures, the Southern region. 24

MODERN MACHINE TOOLS - August 2012

vendors & customers, and help the industry grow,” said Vikram Sirur, President, Indian Machine Tool Manufacturers’ Association (IMTMA). The park is proposed to be located at Vasantha Narasapura Industrial Area, near Tumkur, where the Karnataka Government has offered land for the project. It will co-locate machine tool manufacturers and its supply chain companies & service providers in a modern industrial park. The project is expected to bring synergic benefits to the units and encourage an overall growth of the industry to meet the demand for machine tools in the future. The park is expected to come up in the next four years.

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News, Views & Analysis Tata Steel Turns to Asia, Africa for Growth

Eaton’s Supercharger Technology Wins Global Innovation Award

ndustrial manufacturer, Eaton Corporation, received Nissan Motor Co’s ‘Global Innovation Award’ for its supercharger technology. Eaton supplies its supercharger to Nissan’s Micra car, providing fuel economy, and environmental & overall vehicle performance benefits. Nissan’s COO, Toshiyuki Shiga, gave the award to Eaton and six other companies during the annual ‘Nissan Global Supplier Meeting’ in Yokohama, Japan. “The supercharger helps in making the Micra DIG-S one of the cleanest and most fuel-efficient gasolinepowered vehicles in the world. The instant response of our supercharger allowed Nissan to downsize the engine while still providing great performance and drivability,” said Jeff Schick, VP and GM, Eaton’s Supercharger Operations. This is an example how supercharger technology can benefit smaller vehicles. Eaton’s superchargers feature patented high-speed rotors driven directly from the engine’s crankshaft. The advanced rotor design pumps additional air directly into the engine’s intake system that, when mixed with fuel, boosts power. The supercharger design delivers high-power and low-end torque while providing vehicle manufacturers with the option of using a smaller, more efficient engine with no loss in performance or drivability.

he economic uncertainty in Europe has forced Tata Steel to focus on Asia, Africa and Latin America to look for growth prospects. In his statement in the company’s latest annual report, Chairman Ratan Tata said that while Tata Steel’s operations in India were expected to remain strong, its operations in Europe would continue to be under enormous stress for the next year or two until the Western European economy recovers. The sales volume of the company in Europe remained flat through the year. While India contributes 27% of the revenue, the UK accounts for 26% and the European Union (sans UK) 29%. Various measures and initiatives are being taken to reduce costs and underutilisation. However, the major concern comes from unprecedented increase in the prices of iron ore and coking coal, which would continue to affect the company’s European operations. “Steel plants are being closed or moth-balled to conserve costs and control over-supply,” he said, referring to the significant decline in steel consumption in the West due to prolonged downturn in the developed world, particularly the European Union. However, the demand for steel is still buoyant in Asia & Africa where growth rates and investment levels are higher than the West and where new sources of iron ore & coking coal are being developed.

Carl Zeiss Inaugurates its First Tech Centre in India

technology development process erman metrology giant, at Carl Zeiss. He added, Carl Zeiss, inaugurated “Our technology centre offers its new factory and demonstration, applications and competence centre at Bommasandra service support requirements for Industrial Area, Bengaluru. The the customers in India. It features tech centre offers customers the the latest CMM technology. opportunity to utilise & experience Our specialists in the tech centre the latest technologies, equipment are available to provide CMM & expertise from the core business measuring solutions, whether they groups of industrial metrology, are simple or complex.” microscopy and medical industries The customers can take under one roof. The centre will also benefit of equipments, such as offer round-the-clock assistance along with special training to Dr Rainer Ohnheiser, President and CEO, Carl Zeiss, inaugurates the 3D CMM, Roundness tester, new tech centre in Bengaluru. Surfcom 480A, & Contour customers on better utilisation of tester, and software like Calypso, Zeiss’ metrology machines and Calypso Planner & Simulation and BladePro. Apart from these, instruments. the centre will provide modular as well as customised fixturing Speaking during the event, Dr Rainer Ohnheiser, President solutions for quality assurance and inspection needs. and CEO, Carl Zeiss, said, “If you want to export, you have to have The tech center offers customers the opportunity to utilise global standards of accuracy. Carl Zeiss has products and solutions and experience the latest technology, equipment & expertise from that help you conform to global standards. Measurement is one of the core business groups of industrial metrology, microscopy and the critical activities that will be a foundation for progress”. medical industries under one roof. Wilson Thomas, COO, Carl Zeiss, further explained the 30

MODERN MACHINE TOOLS - August 2012

News, Views & Analysis Belgium Software Major, NUMECA, Expands its Reach in India

Guhring India Opens New Coating Facility in Pune

UMECA International, a Belgium-based major software and service provider entered the Indian market with its new branch office in Bengaluru. NUMECA specialises in Computational Fluid Dynamics (CFD) and optimisation solutions. NUMECA’s product strategy is based on the development of automated, integrated & customised software systems allowing optimal and rapid simulation, design & optimisation. The software is widely used in aerospace & defence, automotive, hydro engineering, marine, power & propulsion and wind energy industries. Professor Charles Hirsch, President and founder of NUMECA International, and a world-renowned expert on CFD said, “The opening of NUMECA India marks an important milestone for the greater consolidation of NUMECA’s presence on the world stage. An office in India will allow us to work closely with local customers and will significantly reinforce the company’s position in this strategic market.” The company is also considering setting up a global support centre and a full-fledged R&D team in India in future.

he tool-manufacturing major, Guhring, opened its new coating facility at the company’s service centre at Pirangut, Pune. The facility also marked the fifth anniversary of Guhring India’s Pune service centre. The PVD multi-coating facility will offer complete re-conditioning services with faster turnaround time to its customers. “This facility is for the benefit of our customers in Maharashtra, Madhya Pradesh and nearby areas. It will save a substantial amount of time for our customers as we provide both re-grinding and re-coating facilities from our Pune centre,” said Mukund Bharadwaj, Deputy CEO, Guhring India. The coating services available at this facility include ‘TIN coating’, ‘TiAIN coating’, ‘FIREX coating’ and ‘nano-FIREX coating’. The centre will also offer logistics services by collecting worn-out tools and delivering reconditioned tools. For the customers, this will result in consistent tool life resulting in cost reduction with 80% of the original tool life being ensured based on the machining conditions.

Gleason Opens Manufacturing Unit in China

leason Corporation expanded its reach in China by opening a new state-of-the-art manufacturing facility in Suzhou Industrial Park. The new factory brings together, under one roof, the company’s machine and cutting tool production, which were formerly located in separate facilities in the Suzhou Industrial Park. “This investment in our new facility along with the continued expansion of our technical staff in China is a strong statement about our long-term commitment to this important market,” said John J Perrotti, President and CEO, Gleason Corporation.

IMTMA Training Calendar for August , 2012 Date

Topic

Venue

August 02–03, 2012

Workshop on Machine Tool Testing & Performance Evaluation

IMTMA Technology Centre, Bangalore

August 03, 2012

Workshop on Measuring Productivity through OEE

IMTMA Technology Centre, Bangalore

August 07, 2012

Seminar on Cleaning of Machined Components

Pune

August 10–11, 2012

Seminar on Manufacturing Excellence through TQM Approach

IMTMA Technology Centre, Bangalore

August 13–14, 2012

Seminar on Design of Workholding and Fixturing

Gurgaon

August 23–24, 2012

Seminar on Design of Workholding and Fixturing

IMTMA Technology Centre, Bangalore

August 23–24, 2012

Seminar on Getting the Best Out of Co-ordinate Measuring Machines (CMMs)

Gurgaon

August 24, 2012

Seminar on Cutting Fluids and Swarf Management in Metal Cutting

Pune

August 28–30, 2012

Training Programme on Advanced Programming for CNC Machining Centres

IMTMA Technology Centre, Bangalore

August 28–29, 2012

Seminar on Latest Trends in Electrical Discharge Machining

Pune

August 29–30, 2012

Training Programme on Right Selection & Application of Tooling for CNC Machining Centres

Gurgaon

MODERN MACHINE TOOLS - August 2012

News, Views & Analysis

Dassault Systèmes starts R&D Centre with Chinese Engineering Institute

assault Systèmes, leader in 3D design, 3D digital and Product Lifecycle Management (PLM) and Shanghai Municipal Engineering Design Institute (Group) Co Ltd (SMEDI), a well-known Chinese state engineering institute, is planning to jointly open a new R&D centre in Shanghai, China, to develop industry solution for civil engineering and infrastructure construction professionals, based on Dassault Systèmes’ 3DEXPERIENCE platform. Dedicated to bridge projects, water supply & wastewater treatment installations, roads, rail systems, as well as open and underground buildings, the R&D centre will open in August 2012. Wei Tang, Chairman, SMEDI said, “By leveraging Dassault Systèmes’ 3DEXPERIENCE platform for civil engineering, we are confident of maximising our competitiveness & productivity and minimising errors in all our future projects.” “From the very beginning, our 3DEXPERIENCE platform has been inspired by our customers & partners, and what they have been telling us about their markets. This is why Dassault Systèmes has a long, successful history of partnering with key industry leaders to develop disruptive applications to harmonise human life in the urban environment of the 21st century,” said Dominique Florack, Senior Executive VP – Products and R&D, Dassault Systèmes. “Our partnership with SMEDI, one of the top players and most established civil engineering companies in China, will help us accelerate the development of world-class industry solution experiences for civil engineering in China and worldwide.”

GKN Driveline Trier Opens the World’s First Forging Flowline

KN Driveline has developed the world’s first forging flowline, GKN Driveline Trier (Germany). The total investment amount was around €20 million, and it is the largest ever made in the GKN Driveline Trier plant. The main machines of the line are an automatic vertical forging press and two cold-forming transfers presses Fagor of 500 tonne. The line is capable of forging up to 60 pieces/minute, each piece with maximum weight of 5 kg. “GKN Driveline Trier is an innovative system concept, the first of this kind in the world. This system shall involve a significant advance in safety, a fullyautomated process, resulting in an energy saving of over 15%, allowing us to be more responsive to our customers”, said Dr Roland Seidel, MD, GKN Driveline Trier plant. 34

MODERN MACHINE TOOLS - August 2012

Airbus to Invest $600 Million in the US

irbus plans to spend $600 million to build jetliners in Alabama. It will be the company’s first assembly plant in the US. The project is an attempt to grab a bigger share of the US market over its rival Boeing Co.

Italian Machine Tool Portray a Depressing Outlook

he Italian machine tool industry has still a gloomy future to face, as it saw a sharp decline in the secondquarter domestic orders and exports. UCIMU, the Italian Machine Tools, Robots and Automation Manufacturers’ Association, reported a 20.6% decrease in orders versus the second quarter of 2011. Consistently strong demand from other countries had kept the Italian machine tool builders afloat. However, UCIMU has warned that slack demand from the home market was a concern for its members and a dire sign for the country’s industrial sector in general. The Association reports that its index for domestic orders shows an 11.5% decrease for the second quarter of 2012, compared with that of 2011. This result demonstrates a domestic demand weakness that has drastically reduced its levels of investments in production technology. The group is standing by its recent forecast for a 12.3% annual increase in machine tool orders for 2012 versus 2011, made in conjunction with its annual meeting in June. With regard to the weak domestic demand, UCIMU is seeking an immediate and direct intervention from the Italian government to maintain its competitiveness.

RIL Gears Up to Invest in Aerospace Sector

eliance Industries Ltd (RIL) is expected to invest close to $1 billion over the next few years and hire around 1,500 people in its new aerospace division. The Mukesh Ambani-led company has applied for an industrial licence with the Department of Industrial Policy and Promotion to design, develop & manufacture equipment and components, including airframe, engine, radars, avionics and accessories for military and civilian aircraft, helicopters, unmanned airborne vehicles & aerostats. The company is also planning to undertake research and produce new aerospace technologies, materials, components & equipment, and test & carry out their certification. The company is also likely to join hands with global players to bring in sophisticated civil and military aerospace technologies into the country.

TECHNOLOGY & INNOVATION

Thermomechanical Analysis: Creating Better Realistic Systems

Simulating the Machining Process

ne substantial area where the simulation of metal-cutting production process can be applied is calculating the impact of the process parameters and cutting geometries of the tool on tool strain and wear & tear, chip shapes & chip break and burr formation & preventing burrs.

he disadvantage demonstrated by the lower simulation accuracy of temperature field calculations in comparison to static and dynamic characteristics analyses is no longer acceptable as far as modern machine tools are concerned. The increase in machining precision calls for an exact knowledge of the machine characteristics by as early as the development phase. In order to achieve greater precision in simulation as well as simultaneous short calculation times, substitution models for relevant sub-assemblies have been developed. For these models, parameter identification exercises based on measuring results are carried out

USPs

The technology increases machining precision with its guaranteed realistic heat transmission characteristics.

USPs

Temperature field on a HELLER machining centre.

in order to guarantee realistic heat transmission characteristics. In addition, they are supported by basic convection conditions relating to direction and temperature. Such measures help to create realistic systems that can be utilised to improve simulation accuracy for determining the temperature field.

Simulation is a very effective means to observe areas and processes that are only accessible to characterisation by measurement techniques. Simulation gurantees the proximity to real life conditions. The rate of rejection after production is minimal. It bring sdown the overall cost of production with better precision and accuracy in manufacturing.

This is where we can investigate a wide range of different materials including a whole series of metal and non-metals or homogenous materials and composite materials. Since the chip

Improving the Forming Techniques

ecent developments have seen hydroforming taking centre stage in the industrial production of components in the direct automotive suppliers sector. However, this is not the only industry where such techniques have made efficient production feasible. The automotive industry continues to be the driving force behind the expansion of this technique. The various applications of hydroforming in large-scale production indicate that this process has already established itself among the various forming technologies. The geometries that can be produced with the help of this technology find many applications in components for exhaust, axel & steering systems, even engine mounts and entire underbody structures.

USPs

A cost-effective way of shaping ductile metals into lightweight, structurally stiff and strong pieces Provides excellent quality to the surface of the formed parts All ductile and malleable materials can be used for hydroforming.

Along with reducing the amount of energy and materials required (lightweight construction), hydroforming permits savings in terms of joining operations (e.g., welding), the realisation of forms optimised for a specific application and new design concepts.

Simulation guarantees the proximity to real life conditions.

formation process is highly intricate, fundamental research coupled with experimental random sample tests is of major importance for models and determining model parameters. Even though we still cannot do without machining tests, we can reduce the required number of tests by making prior calculations. Courtesy: Fraunhofer Institute

MODERN MACHINE TOOLS - August 2012

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TECHNOLOGY & INNOVATION

Allow for Cleaner Cutting Edges

ngineers are constantly searching for methods for enhancing the cut quality, cut speeds, power levels, operating costs and ease-of-use of plasma systems. In the last two decades, a new category – high-definition plasma – emerged as a result of much research and development. The new high-definition plasma technology essentially works by forcing

USPs

High-definition plasma cutting can cut without producing any metal chips. It gives accurate cuts with cleaner edge than oxy-fuel cutting. It is five times faster than traditional methods. It has the ability to make precise cuts in variety of metals and thickness.

Form High-quality Joints

lectromagnetic forming is a technique where the impulse energy (i.e., the electromagnetic impulse) is used for forming sheet metal materials. This technology can be used for forming & cutting operations, joining processes & welding work using pipes,

the plasma arc through a smaller nozzle orifice. Such equipment takes advantage of the laws of hightemperature physics, allowing for cleaner cut edges while maintaining acceptable torch consumable (nozzle and electrode) life. The earliest high-definition plasma systems were limited in amperage (70 amperes maximum) and thickness capacity (0.95 cm Some high-def inition plasma systems can production pierce 75 mm-thick metals, sever 160 mm-thick ones, and thickness for steel), and were easily cut thin metal with a single torch. by today’s standards considered difficult to handle. They required the ability to production pierce 75-mm an expert machine operator to monitor thick metals, sever 160-mm thick ones, and adjust multiple parameters that and easily cut thin metals — including affect cut quality. However, over the gauge — with just a single torch. It is years, high-level engineering efforts for these reasons that high-definition by major plasma-cutting system plasma systems have now become metal manufacturers have lowered operating fabricators’ primary metal-cutting system costs and improved consumable life, cut of choice. quality and speeds. Some of these have also proven to be very versatile, with Courtesy: Hypertherm

USPs The greatest benefits of electromagnetic forming are: Forming without punches to go gentle on surfaces Short progress times Excellent reproducibility Low operating expenditures.

profiles and fast sheet metals. The key item for development in this segment is to lay out a tool coils while streamlining process layout. High-quality joints can be formed either by electromagnetic pulse crimping with a mechanical interlock or by electromagnetic pulse welding with a true metallurgical weld.

Overcoming the Limits of Serial Structure

arallel kinematics represents closed kinematic sequence. A platform is moved by means of independently acting drives. These drives can actuate, for example, a main spindle for machining processes, or a gripper for handling tasks. Parallel kinematics can be configured to satisfy a variety of requirements, and movements of up to six degrees of freedom (three rotational and three translatory) are possible.

USPs Parallel kinematics offers: High dynamics (speeds and accelerations) by low masses to be moved High stiffness by closed kinematic sequences Parts are mainly stressed by the tensile and compressive loads.

Parallel kinematics is able to overcome the limits of the serial structure of conventional structures. It allows improved repeatability and reduced inertial effects as compared to the traditional methods that are being used in manufacturing. Other important advantages of parallel kinematics are that it offers integration of accuracy-influencing components into the controller and has multitude of common parts & modularity & simple construction of frame. August 2012 - MODERN MACHINE TOOLS

TECHNOLOGY & INNOVATION Case Study: Hydrocarbon Cleaning

Reliable and Cost-effective Solution A

For effective removal of machining residues from parts after flat honing, lapping and polishing, nonhalogenated hydrocarbon process has come up as a reliable cleaning system. The process has clearly shown superior results in addition to tangible cuts in cleaning times & cost, and Stähli Läpp-Technik GmbH is successfully using this process.

s a manufacturer of flat honing, lapping and polishing systems, Stähli Läpp-Technik GmbH, Germany, markets machinery, consumable products and associated services. However, the focus of the company’s activities is contract machining and process development in the fields of flat honing, fine grinding, lapping, polishing and brush deburring technology. The operations handle parts of diverse materials such as tool steels, sintered metals, ceramics, engineering plastics, fibre composites and glass, which cater to the automotive industry, medical and micro-technology companies, the faucetry & furniture industry, manufacturers of turned and punched components and other manufacturing sectors. Given this diversity of materials, part geometries and dimensions, cleaning is a challenge which has been addressed, for a long time, with the aid of numerous ultrasonic treatment tanks and cleaning media. This involved huge labour costs; moreover, the cleaning result was not always perfect. Therefore, Stähli Läpp-Technik GmbH has resolved to invest in an automatic cleaning system.

Cleaning Trials Tipped the Scales For effective cleaning, one key criterion is that the system should be able to handle the broadest possible range of parts and materials, while providing the 42

MODERN MACHINE TOOLS - August 2012

the award of our contract and the equipment delivery date,” informs Robert Laich, Production Manager, StähliLäpp-Technik.

Forward-looking Equipment Design The hydrocarbon-based cleaning system operates fully under vacuum and uses a multi-stage process comprising cleaning, rinsing, steam degreasing and drying. For the specified treatment of each batch, up to eight different treatment Equipped with two flooding tanks programmes can be stored in the Universal 71C. The system uses a non- for coarse and fine cleaning, a halogenated hydrocarbon solvent for cleaning. high-performance injection flood washing step as standard and an ultrasonic system with a rating of 11 watts per litre, the unit can perform even complex cleaning tasks in a reliable manner under process conditions. Elaborating further, Uli Lars Bögelein, MD, Stähli Läpp-Technik GmbH, says, “We expect cleanliness requirements to become even more exacting in the future, specifically for automotive parts. The new cleaning system helps us be on the Parts are fed to the work chamber via a roller conveyor with an safe side.” The forward-looking design automatic basket covering feature. is also reflected in the machine’s ability to store eight freely selectable specified result and optimum drying in programmes in its controller. The every case. With this criterion, nondiverse parameters, such as rotating and halogenated hydrocarbon medium is swiveling movements in the cleaning & effectively capable of cleaning parts drying process, temperatures, ultrasonic made of virtually any material. “We characteristics and high-performance obtained the best cleaning results with flood washing, can be programmed Dürr Ecoclean GmbH. Moreover, it in any combination. As a result, the allowed us to clean parts at their Tech cleaning treatment can be tailorCenter during the interval between

TECHNOLOGY & INNOVATION

The work chamber is designed for batches up to 670 mm long, 480 mm wide and 300 mm high. An ultrasonic unit is fitted inside the chamber.

Basket rotation and swiveling movements support the cleaning and drying cycles.

covering device. Depending on matched to every part. “We are the programme, the cleaning cycle currently using four programmes takes between 8 minutes and 10 adapted in terms of degree of minutes to complete. “In this contamination and part material, short interval, we achieve a perfect and are highly satisfied with the cleaning result even with batches cleaning results. We have even of, say, 1,00,000 parts. Earlier, it created a programme for cleaning used to take a day or more for an the plastic transport containers for operator to clean a batch of this completed parts,” Laich adds. type,” Bögelein remarks. The vacuum drying technique Consistent with his preensures that even parts with During the lapping process, parts get contaminated with oil and complex geometry (e.g., bores, abraded particles. Such foreign matter must be removed with absolute investment analysis, Bögelein reliability. estimates the labour time savings blind holes and undercuts) will achieved at around 80 hours per emerge from the process fully week. In the time thus gained, dried. An integrated distillation through the cleaning process in bulk operators can now be assigned to the and filtration system removes foreign or arranged in part carriers. These production machines. Over and above oil & grease, particles and abraded containers facilitate an all-round this benefit, the company saves between matter from the solvent on a continuous exposure of the parts to the cleaning €1,500 and €2,000 on cleaning media basis, so that the cleaning fluid remains medium while also optimising the each month. available in unchanged quality for a long drying process and minimising time. carryover. Courtesy: Doris Schulz, DESIGNATION, Company. Batches measuring 670 x 480 x 300 DürrEcoclean Group is the leading provider of mm (L x W x H) are supplied by a Effective Cleaning at Reduced Cost industrial cleaning, automation and filtration solutions. The Group provides innovative custom-designed system feeder system, which comprises a roller Depending on part geometry solutions and services to automotive industry across conveyor and an automatic basket and sensitivity, the products pass the globe.

SEND US YOUR TECH INNOVATIONS! If you have any innovations, technologies or unique methods you would like to share with our readers from the industry, please write in at nishant.kashyap@infomedia18.in.

MODERN MACHINE TOOLS - August 2012

IN CONVERSATION WITH Guruprasad K Rao

Rapid prototyping offers the ‘fourth dimension’ in product design “Not only can you create exact digital models on virtual screens, but with prototypes almost like the real product, it provides an added dimension, the sense of touch. This tactile experience is unique to prototypes in AM and can be crucial in making key design decisions,” explains Guruprasad K Rao, CEO, Imaginarium (India) Pvt Ltd, the largest rapid prototyping and manufacturing centre in India. Tarun Tampi shares excerpts from an engaging conversation with a multi-faceted technocrat who happens to be a product designer, design educator, inventor, a researcher and leader. Q How do you see the growing field

of Additive Manufacturing (AM) today? AM is on the threshold of triggering a revolution in manufacturing. It is increasingly filling the need for on-demand components in highly specialised uses, like an individual’s surgical guide, which is unique and needed on a priority basis. I see it as increasingly dependable in lifesaving medical applications. The trend is moving from mass customisation to individualisation. The growth of additive technologies is bi-directional. There are mammoth machines being made in some countries, 46

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like in Belgium (some as large as swimming pools), as well as machines for micro-manufacturing, such as small machines to make miniature parts or those that people can use in their homes, are also being built. Therefore, modern additive technologies are such that the possibilities still seem limitless. For instance, architectural restorations are a very interesting application for AM as without even touching the object you can rebuild and restore parts of human history accurately and to the last detail. Would you not like to take back an absolutely accurate scaled model of the Taj Mahal, or any other monument?

Another exciting area is that of ‘co-creation’. Recently, we had an 8th standard student who, out of interest, learned CAD through us. We taught and guided him through, and he went on to build a 3D model of the Starship Enterprise from Star Trek! As a company exploring this emerging technology, we want to share and create a space for all those who want to experience the sheer joy of making things. For this, we are ready to work as ‘evangelists’ of this technology.

Q What are the current market

dynamics for the AM industry? How has it changed the approach

Guruprasad K Rao manufacturers have towards product design? The AM industry comprises of machine manufacturers, material manufacturers and end-users. Users, which mainly include OEM manufacturers, Tier I & Tier II suppliers, service bureaus, educational institutes and hobbyists, are major stakeholders, but have little control over the development of the technology or its costs. Looking at how AM has developed over the last few decades, two main things were clearly evident. One, the manufacturers consolidated their technologies and fine-tuned their additive machines, aggressively and possessively investing in their product to make it exclusive. Two, a lot of enthusiasts, hobbyists and amateurs are also driving innovation at the same time. The idea was ‘Can such a machine be made that can make itself?’ However, in reality, proprietary technologies and patents restricting innovations and developments in AM have been preventing enthusiasts from going ahead with experimentation. As such, OEMs have had a monopoly in producing these machines and their profits. Hence, AM has become very costly today. However, like any new technology, there is always something impeding its adoption; but this can be overcome. In Europe, the US and Japan, AM has really penetrated the markets and has certainly changed the way things are done. The idea is, if you have an idea, you can just go and try it out using RP! Designs are no longer evaluated by a limited mock-up or model, but by a fully functional model. It helps get things right the first time by enabling design validation before launch, and validation encompasses various stages like understanding the quality, reliability and appeal It is unpredictable, but RP helps bring in some predictability. On the whole, AM has definitely made life easier.

Q What is driving the trends in

innovation and development for AM in recent years? In recent years, AM has been heading

UP CLOSE

&personal

Your most challenging experiences in the AM industry? My first brush with AM technology was at IISc, Bangalore, where I was a student of design and fortunate to be assigned to operate and maintain an FDM system—Prodigy—made by Stratasys. The experience was exciting and gave me first-hand insights on the capabilities of the process. I remember when working for Tanishq in 1993, I had to evaluate RP technology for use in the jewellery industry. But at that time, the staircase effect was very bad and there were many other issues… organic shapes and designs were simply not possible then. I reported it was not suitable! Today, however, the layer thicknesses are becoming finer and finer. By 2003, most of the problems I had faced in 1993 were taken care of, as Viper machines and 3D printers began to enter the market in a big way. Today, it has become a defacto standard process in jewellery making. A message for aspiring rapid manufacturers in India? Aspiring rapid manufacturers should study and evaluate the technology as well as the market. The service providers can team up and learn from each other and can collectively represent their needs to the authorities, the government, institutions and/or the industry. In my opinion, RP service providers are directly contributing to the R&D of products, and hence, deserve tax rebates. We appeal to the government, DST, CSIR and policy makers to consider us as agents catalysing R&D and crucial members of a sound ecosystem for AM. Agencies like CII and FICCI should try to include this in their agenda to trigger the making of policies favourable for the growth and promotion of AM technologies and service providers.

in two directions. On the one hand, the machines are becoming large, measuring in metres, while on the other, they are becoming microscopic, measuring in microns. In addition, material choice is growing wider to cover metals, plastics and elastomers—from clear transparent ones to opaque. A recent addition to this is the increasing use of biocompatible materials. Besides, major AM manufacturers are also ensuring that their advanced machines are secure and have the performance of robust & professional production machines. They are also looking at lowcost desktop printers, which not only help educate and inform users, but also help penetrate the huge market.

Q What is the state of AM in

India? How has this technology developed in the nation and where is it headed? AM, in India, is still in its infancy and will play a significant role in the coming years. AM will provide impetus to product development in every field and will become a de facto standard process in New Product Development (NPD). AM can also help in reducing the carbon footprint of the companies by adopting eco-friendly additive processes since new regulations discourage wastage, use of industrial effluents, toxic materials and so on. AM began its journey in 1986 with stereo-lithography. From then on, people slowly started to work on these technologies. By 1996, India already had a few RP machines in use. Frankly, India is not typically an early adopter of new technology, and the market here is very cost sensitive. In retrospect, in the early 90s, AM technologies were very expensive, but a few large corporations in India had bought these machines for their own use. They had a lot of money and a lot of enthusiasm, but unfortunately, they were not ready to realise the scope of additive technology. Small companies, on the other hand, wanted to explore this technology, which gave rise to service bureaus. The competitive advantage for large August 2012 - MODERN MACHINE TOOLS

Guruprasad K Rao companies, their use of RP technology (which they preferred to conceal), became a huge advantage for service bureaus, who became the propagators of RP technology. Though, they used to offer fewer materials at that time, just like ABS. I can still smell the ABS! Yet nobody knew how to specifically apply the technology at the time. It was initially just used for very basic mock-ups used for form validation. Today, AM has long left prototyping behind and has advanced to manufacturing for production. As of now, in India, 50% of additive machines in use are FDM machines from Stratasys, the US. The technology has been neglected at institutes as well; early entrepreneurs who tried employing it commercially used poor business models. They did not really cater to anyone as service providers, which was where the scope lay. For AM, similar to incorporating PLM solutions, a manufacturing ecosystem needs to attain a certain digital maturity. Nevertheless, large corporations, such as Tata, TCS & Bajaj, were responsible for the entry of global manufacturers of RP technology into the Indian market. Today, 2D approaches are rapidly phasing out as 3D modelling takes its place—in areas as varied as classrooms to factory floors. You can call it the advent of ‘digital sculpting’, where anything you can think of or anything you find in nature can be designed and physically modelled.

Q What were your motivations

and ambitions in starting a rapid prototyping manufacturing facility in India? Imaginarium began its journey in 2009 with just a handful of employees and machines onboard. Today, we employ around 165 people. We began with a single Viper SLA machine and now, we have a wide range of machines and a variety of processes. We offer SLA, SLS, vacuum casting and 3D printing services. We have 3D printers, mostly from 3D Systems, 48

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US. They are dependable professional systems representing models from every generation. Today, we are the largest RP facility in India. We also have working satellite facilities in Surat and Delhi, and are looking to set up units in Bengaluru, Pune, Nashik, Aurangabad, Gurgaon, etc. Essentially, we want to be wherever there are manufacturing hubs so that manufacturers can easily access additive technologies. We are also planning to develop a training centre to create critical mass of skilled resource persons for additive design technologies. In terms of placing this technology in the cycle of product development, we enter the production cycle just after the embodiment design as prototype development. Subsequently, products go straight to tooling. Tooling is a risky & expensive business, and therefore, prototype development must be accurate, realistic & quick. Earlier, they would have handmade or CNC-made models. RP takes the risk out of the product development cycle. I like to think that we offer the ‘fourth dimension’ in product design. Not only can you create exact digital models on virtual screens, but with prototypes, like those we help make, we provide the additional sense of touch and feel. This tactile experience is unique to prototypes in AM and can be crucial in making key design decisions. Initially, for us as a company in RP, it was all about concept-selling, that in a way, began simply by word-ofmouth. We are a learning organisation, which strongly believes that a satisfied customer is the best marketing strategy. Further, there is also co-creation between the customer and the company. Given the plethora of applications for AM, we learn what the customer is looking for and what we can do for them. We are also open to selling, servicing and maintaining machines to clients interested in this technology. We have the knowledge and the means to provide support and maintenance to those using such machines. It is a dedicated offering to

every customer. We also give lectures at institutes to catch the imagination of young professionals. Additionally, we give seminars for the industry and interact freely with academia. We are planning a special interaction zone for this purpose where people can come, see, play and explore the possibilities in RP. We encourage people to come and see our facility to increase awareness about AM technologies, because, for me, everyone is a potential customer.

Q What barriers and challenges

lie in the way for AM to be increasingly adopted? Indeed, there are many challenges! Firstly, the technology is known only to a few businesses and designers. Secondly, it is very costly, making it more of a luxury in product development for most small manufacturers. Thirdly, AM technology is still not quite on the radar for policy makers, and hence, it lacks the government support it deserves and sorely needs. So, a greater awareness of its true capability, affordable machines and a supportive government policy are essential to its further growth. However, a problem is that manufacturers of AM technology might try to monopolise or restrict the usage of their machines to their materials, their accessories, etc., just like computer printer manufacturers are making their money on the ink, not the printer.

Q How can Direct Digital

Manufacturing (DDM) transform manufacturing? DDM is a concept of making anything directly from CAD into a working part. They essentially use composites and have the capability to use different materials. While a lot of research is being done worldwide, it is still far from commercialisation. Yet even for current RP and other additive technologies vital to manufacturers, we insist on proving to them that delayed design can be directly related to lost business, reinforcing our belief that in the industry today, you either innovate or perish. tarun.tampi@infomedia18.in

MMT Aug-2012 Ad Name:Ganesh Pg No. 49

MMT Aug-2012 Ad Name: Tungaloy Pg No.50

MMT Aug-2012 Ad Name: Tungaloy Pg No. 51

MMT Aug-2012

Ad Name:Ermaksan

Pg No. 52

IN CONVERSATION WITH Dr Rainer Ohnheiser

India needs to move fast in terms of productivity and accuracy Localisation of important products has helped us fit into the Indian market. It has also made us more competitive in terms of cost and prices. As a result, we can serve many companies that are just stepping into this technology,” asserts Dr Rainer Ohnheiser, President and CEO, Carl Zeiss, during an interaction with Suprita Anupam. Excerpts…

Q How do you see the recent demand

trends in Co-ordinate Measuring Machining (CMM) in India? In India, the demand for CMM is quite positive even though the country is being challenged by high productivity. As India is working towards improving its quality even further, CMM will prove to be a tool for quality, accuracy as well as moving the manufacturing process forward with regard to productivity.

Q Do you think Indian SMEs are willing or able

to invest to attain this level of accuracy and quality standards? Localisation of important products has helped us fit in the Indian market. It has also made us more competitive in terms of cost and prices. As a result, we can serve many companies that are just stepping into this technology. These companies could be privately owned or could be companies that are moving up to achieve greater accuracy.

Q Which are the prime market sectors with respect to

application that you deal with? Regarding the application, we fill all the ranges—be it singlepoint triangulation or other types of scanning. We provide state-of-the-art, world-class technology to various sectors, such as automotive and toolmakers. For instance, we provide leading scanning sensor technology with the most efficient software packages. Besides, our software application development 54

MODERN MACHINE TOOLS - August 2012

Dr Rainer Ohnheiser team can also cater to aspects pertaining to customisation. We also deal with application-based requirements.

Q If we talk about technology

in CMM, with multi-sensor measurement technology, we have already achieved certain level of saturation in terms of speed, accuracy and flexibility. What developments do you expect to see in metrology in the next five years? In India, so far, measuring tools and productivity have not been in sync with each other because of their different paces, i.e., conventional machine’s slow speed and weak accuracy. Apart from this, the multi-sensory technology incorporating touch trigger probes, Vision Metrology Systems (VMS) and laser technology, will also be a likely future trend. Considering that India is renowned for its software—from single point to the giga-byte—this is something where the country is

UP CLOSE

&personal

Your hobbies... I enjoy being with my family. I like to spend time with my children and discuss the cultures and traditions of different countries like India with them. Also, I enjoy playing sports. Being a professional means I have to spend a lot of time at work. To make work exciting, I enjoy taking up challenges that come my way. This makes doing business fun. Your interests… I belong to the 80s era and so, I enjoy listening to as well as singing songs of that era, including rock. Also, I like to read books that have some historical element in them.

already on the fast track. We will use this to ensure further upgradation.

Q What are the differences between

Indian and Chinese market trends? I think that the demand trends in both the countries are more or less very similar. For instance, both the countries have huge local markets that demand accuracy. Besides, both the markets have a high need for energy & efficiency and covering the energy availability across the whole country is a major concern for both the countries. Also, the big players in both the countries are well connected locally as well as globally. For example, companies like Tata, Mahindra, etc., are going global. However, as far as market is concerned, India has a comparatively wide range of private companies, smaller companies and entrepreneurial companies that must be taken into consideration if we want to expand our business further. suprita.anupam@infomedia18.in

August 2012 - MODERN MACHINE TOOLS

I I

News

• Stratasys Partners with Oak Ridge National Laboratory to Develop Additivie Manufacturing for Production Stratasys, a manufacturer of additive manufacturing machines for prototyping and producing plastic parts, has partnered with the Oak Ridge National Laboratory, the US Department of Energy to work on making Fused Deposition Modelling (FDM) a production-ready process. The aims are to develop in-process inspection for FDM systems that assure quality of parts & appropriateness for service and to develop carbon fiber-reinforced feedstock materials to create strong, lightweight parts. The overall aim of the project is to minimise the energy consumption in the US industry, commercialise innovative products rapidly and improve the worldwide competitiveness of the US manufacturing. • Swansea University Invests in Additive Manufacturing Technology Swansea University, one of the UK’s top research universities, has purchased an AM250 laser-melting machine from Renishaw, the global engineering technologies company. This machine allows the construction of fully dense, highly complex metal parts and structures that would not have been built using traditional subtractive manufacturing techniques. • Objet Sets New 3D Printing 100 Material Range Record A new, significant milestone has been reached in the world of 3D printing. The French company, Objet, announced that it now has the technology to use 107 different materials in 3D printing applications. Most low-level commercial 3D printers only focus on one kind of plastic or similar substance. But for industry-grade purposes, there needs to be a lot more flexibility. Objet has become the first 3D printing company to break the 100 materials barrier. “Considering that we had half this number just a few short years ago, this growth in material choice confirms our commitment to consistently deliver new and enhanced material properties to our customer,” says David Reis, CEO, Objet.

Emerging Technologies

• 3D Printer Used to Print Simple Drugs University of Glasgow has taken a commercially available 3D printer and adapted it to inject organic-based inks into tube-like structures to create the new home-grown version of a pill. Since most drugs are a combination of carbon, hydrogen and oxygen, a printer should be able to make any organic molecule. The printer not only controls the sequencing & exact calibration of inks, but also the shape of the pill & the environment in which reactions take place. The scale and architecture of the miniature printed ‘lab’ could be pre-programmed into software and downloaded for use with a standard set of inks. Researchers are currently trying to build simple drugs with a 3D printer that only costs £1,200.

Demand Trends

Made-in-space Parts Could Become the New Norm NASA is gearing its research towards identifying a mechanical component needing to be repaired/ replaced, designing the replacement part, fabricating it with additive manufacturing, finishing & inspecting it and working to demonstrate remote control of the additive manufacturing process. One technology highlighted by NASA is solid freeform fabrication, a process that could be used to support fabrication and repair of large space structures, spacecraft primary structure and replacement components. Only the total mass of replacements would need to be estimated instead of predicting which specific components might be needed. NASA is developing an on-demand additive manufacturing tool that will allow space explorers to build what they want, when and where they need it. 3D Printed Plane Parts Boeing Co. is working towards developing additive manufacturing to a point where they will be able to make an airplane wing without cutting or bending any metal. The wing would be formed, one razor thin layer at a time, by fusing powdered metal or other materials with a device resembling a giant office printer.

Industry Snapshot

Compound Annual Growth Rate (CAGR) for the additive manufacturing industry was 29.4% in 2011, according to Wohlers Report 2012. The market for all products and services in 2011 was $1.7 billion, and is expected to grow to $2.1 billion in 2012 and reach $6.9 billion by 2019. And this is when only around 8% of the potential market has been covered. Compiled by Tarun Tampi

SPECIAL FOCUS ADDITIVE MANUFACTURING 58

AM In Space Additive Manufacturing & The Final Frontier

Optimising RP Facilitating Robust Product Development

Opinions And More - Terry Wohlers, Principal Consultant and President, Wohlers Associates, Inc. - Dr Phil Reeves, MD, Econolyst Ltd.

Additive Innovations From Labs To Our Doorsteps: The Advent Of Additive Manufacturing

AM Challenges Overcoming And Understanding The Obstacles For AM

AM Sustainability A ‘Rapid’ Shift Towards ‘Prototyping’

One Q Many Views Additive Manufacturing: Can It Replace Traditional Manufacturing?

3D Printing The Future Of Manufacturing

Tips & Tricks Selecting RP Processes

Desktop Additive Manufacturing MOJO: A New 3D Printing System

3D Manufacturing Adopting Digital Prototyping

August 2012 - MODERN MACHINE TOOLS

SPECIAL FOCUS AM in Space

ADDITIVE M MA MANUFACTURING

The Final Frontier NASA is seriously looking into using Additive Manufacturing (AM), a 21st century technology, to build new parts or to replace and repair damaged tools or components…in space! Some say that if Apollo 13 had a 3D printer onboard, it would have radically changed the approach taken to fix the carbon dioxide filtering system. 3D designs could have been sent from ground control to space, where astronauts could directly use them to manufacture the required part in space itself! The possibilities of AM seem limitless as it finds itself emerging in numerous specialised applications. Tarun Tampi looks at how its application in space may be the most special of all…

f there are any doubts about whether AM is the future of manufacturing, they would fade in the light of the achievements of AM. NASA is committed to bringing a 3D printer onto the space station by 2014. Boeing has made over 20,000 parts using 3D printers that have been used in military aircraft, and there has not been a single part failure so far. When thinking of AM in space, few things immediately come to mind. The need for such technology is apparent as we attempt to support longer and longer human exploration missions. The aim is to gradually widen the radius of exploration by increasing the self-sustaining ability of such missions, reducing their dependence on maintaining a link for re-supply with the Earth. AM is one such solution for space exploration, because it provides on-demand chip-less fabrication of parts, tools, components, be it for replacement, maintenance or repair. Due to the nature of the way it uses material, every part it makes can be 58

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Guruprasad K Rao, CEO Imaginarium (India) Pvt Ltd Broadly speaking, AM is the automated production of a part while space manufacturing is the production of a part in space. AM, being a very lightweight system, is optimum for space manufacturing, since every additional gram put into space matters tremendously due to the high costs involved. However, not all AM processes can be used in space. 3D printing seems to be the most suitable. In the future, I see AM as an essential fixture in every space station, producing spares on demand. In space, you are manufacturing in a vacuum, there are no contaminants. You have 100% undiffused sunlight. Take a simple thing, like ball bearings. For these, you need a perfect ball. On earth, you cannot create a perfect sphere due to gravity. In space, you can. Crystal growth is also affected by gravitational pull. Electrical phenomena, flux, can also be affected by the Earth’s magnetic field. These effects are not there in space. The quality of the ball bearings, crystals, made in space will be fantastic. The change in the insulin grown will be dramatically different. Also, since AM uses exactly the same amount of material as in the final part, payloads would be economised; what comes down will be exactly what you had sent up. You send 100 g up, you get 100 g down. The spacecraft goes and comes with the same weight. AM has a lot of scope there. Liquid processes can probably not be used since they use liquids. Solid state process, like 3D printing, can be done. The quality of parts manufactured in space that are superior to comparable parts on earth will be the advantage for AM. Rapid injection moulding should also be possible.

AM in Space recycled to provide stock for more parts. It reduces the tremendous cost & time to transport and manufacture space parts, economises payloads & occupies smaller volumes than traditional machines. Certain AM processes have already been tested in zero-gravity facilities on the Earth. Now, there is an increasing push to test them in the ‘real world’, i.e., space. The International Space Station would serve as a test-bed for such experiments and demonstrations. One such process being considered is Electron Beam Freeform Fabrication (EBF), an additive-layer process using CNC techniques, an electron beam, a substrate and a wire feedstock to build parts. It is unique for its high energy efficiency and economy of material usage. The electron beam is very useful in that it can be modified and flexibly implemented in welding, deposition, machining, heating, etc. It can be applied for a wide variety of metals. If we look at just the manufacture of equipment and components for space

vehicles, infrastructure, etc., metallic parts made additively prove hugely beneficial. In rocket engine components, for instance, it reduces manufacture time from months to weeks and brings down costs dramatically. This same component can be made this way in space as well. But when we talk about what we mean by using manufacturing in space, we need to understand that additive processes will only have a comparative advantage if it builds such unique parts, or produces such properties, that cannot be done on Earth and exceed the quality of similar parts made here. The conditions in space have to be studied with respect to AM processes. Guruprasad K Rao, CEO, Imaginarium (India) Pvt Ltd, says, “In space, you are manufacturing in a vacuum, there are no contaminants. You have 100% undiffused sunlight. Take a simple thing, like ball bearings. For these, you need a perfect ball. On earth, you cannot create a perfect sphere due to

gravity. In space you can. And crystal growth is affected by gravitational pull. Electrical phenomena, flux, can also be affected by the Earth’s magnetic field. These effects are not there in space. The quality of the ball bearings, crystals, made in without these effects will be fantastic. The change in the insulin grown will also be dramatically different.” MADE IN SPACE, an AM start-up in the US, has pioneered and tested additive technologies (in zero gravity), like 3D printing, for use in outer space. They have demonstrated, proved and propagated the advantages of 3D printing from its reduced material wastage, its ability to build complex geometries to its immediate production time and reduced need for human involvement. They printed the first tool made in partial zero gravity, a scaled-down wrench. AM is being seriously seen as an ideal manufacturing technology for space. tarun.tampi@infomedia18.in

August 2012 - MODERN MACHINE TOOLS

SPECIAL FOCUS Optimising RP Creating prototypes today, does not require a specifically skilled or highly trained person. It is so easy that someone who is not related even remotely to the engineering field can create prototypes using highly advanced, state-of-the-art rapid prototyping technology machines. Rapid prototyping technology has advanced to such an impressive and surprising almost magical level that prototyping has not only become easy, but also fast and functional. Prototyping: The Ideal Approach

OLI NG

MODERN MACHINE TOOLS - August 2012

SIG

Product Development

Some areas where errors can occur and might go unnoticed in the virtual simulation & analysis include, product functioning and ergonomic constraints. It is difficult to understand if a product is operating smoothly & if the productâ&#x20AC;&#x2122;s hold and feel is comfortable & is not strenuous to operate. Such external details can be verified only when the product is validated physically, ie, only when you hold the physical product in hand and try to work with it. Here, it is important to note that the design factors are extremely critical as they can determine the success or failure of a product or brand. One of the ways to identify, address and, if detected, ensure that these areas of concern are rectified is to create a physical functional prototype of the product. This is especially true and largely

FACILITATING ROBUST

Identifying Glitches

The ideal approach to avoid the glitches would be prototyping all the smallest to the largest partsâ&#x20AC;&#x201D; right from small fitments, jigs & fixtures to large components, physically evaluate them and ensure they work in perfect tandem & coordination, individually as well as when assembled. This holds especially true & critical in multiTOTYPING body dynamics, where RAPID PRO the functioning of one component can hamper and impact the functioning of the entire product assembly & application. For instance, companies in hydraulics & pneumatics can actually applicable for companies in the test and physically validate product industrial machinery segment as they design by inserting & filling oil, water have to deal with the smallest to the or even, compressed air. largest parts and components that Moreover, rapid prototyping either go in the making of, or constitute helps identify errors in the physical an entire product. Therefore, they need functioning or ergonomics of the to be extremely cautious & ensure that components and products. This, in turn, the product, along with its tiniest to the saves the time taken for re-designing biggest parts and assemblies, is designed and reiterating the entire production to perfection & precision. Even the cycle, thereby saving significant costs minutest design error in the smallest required for repeating the process. After part or constituent of the product has all, the earlier the errors are identified the potential to cause huge product in the product development cycle, the design devastation and jeopardise the more time and costs can be saved in entire product launch & marketing product design & development. planning.

CONCEPT

SIM

he industry today is under continuous strain to produce robust products in the minimum possible time and cost. In this backdrop, how can one manage to get it right in the very first go? You might use the best CAD software to design a product. However, irrespective of the number of virtual simulations you may run to ensure that the product is sound, some design or functional glitches would appear only when you hold and operate the product physically in your hand.

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Optimising RP Timing & Quality are Critical For OEMs in today’s market scenario, where time required for production and timing of a product launch is critical enough to make or break a company. Therefore, the company has to ensure that they hit the market as early as possible. A product launch delay of six months can cost a company nearly 40% of their profit margin over the lifecycle of the product. So, when time is so expensive, companies have to take care that they invest as minimum time as possible to design, develop and launch a product. The old proverb ‘a stitch in time saves nine’ fits perfectly in this type of scenario. The earlier you prototype in the product development cycle, the sooner you identify the design fallacies and earlier you get them rectified. This subsequently saves you further damage control, fire fighting and rectification costs. The company also has to ensure that while concentrating on saving time, it should not lose focus on and compromise on the product’s quality. It is important to realise that hitting the market early can give it an ‘early movers’ advantage and boost the product’s initial sale. However, if the product is not good enough and does not match the high-quality requirements of today’s customers, then the product will enjoy a very short life and will soon become redundant. Besides, the ‘alert’ competitors will get an opportunity to spring into action and create competitive products of better quality at much more lucrative costs.

Benefits of Rapid Prototyping A Boost to Innovation: Rapid prototyping also helps boost innovation. Therefore, instead of using the traditional paper and pen approach, designers need to discuss designs and design concepts with the physical prototype of the product design in hand. This ensures that ideas are communicated better, thinking is stimulated and there is brainstorming. This facilitates a healthy and productive discussion on making the product better.

Advantages of Rapid Prototyping Rapid prototyping is essential and applicable for OEMs and suppliers alike. Some of its key advantages are: It helps identify design errors, such as physical product functioning & operation and ergonomic constraints, that otherwise would not be noticed in the virtual product design simulation and analysis. It detects the design errors early in the product development cycle, which saves significant costs and time that would otherwise be required for redesigning & reproduction. Discussing design ideas with the physical functional prototype in hand communicates the ideas clearly, stimulates thinking and boosts innovation. It can be used for Direct Digital Manufacturing (DDM) of actual components required in small quantities and for producing jigs & fixtures. DDM thus saves cost and time required for the development of tooling.

Direct Digital Manufacturing: For high-cost industrial machinery manufacturers, the quantity of machines produced by them is not very large. For small quantities, it is not viable to do full tooling for some aesthetic parts like front panel bezels, mounting brackets, etc. In such cases, small quantities of such components can be produced by rapid prototyping and can be directly used by them. This avoids all the costs and time involved in design and manufacturing of tooling. Similarly, rapid prototyping can also be used to directly produce jigs, fixtures and inspection gauges required during the manufacturing processes. This saves considerable costs and time. Such usage of rapid prototyping is

called Direct Digital Manufacturing (DDM). Save on Time and Costs: For suppliers who are under constant pressure from OEMs to produce fast and good quality components, prototyping would help address their concerns. This is because prototyping helps highlight the physical errors of the product early enough in the product development cycle to be able to make quick rectifications in less time & costs and facilitate the production. When OEMs give component designs and specifications to the suppliers, it is always a good idea to first do a physical prototype of a product and evaluate it thoroughly before heading to the final production stage. Prototyping helps in checking, maintaining & ascertaining the product quality, which saves extra time and costs that the company would otherwise have to incur in redesigning & reproduction.

Making the Right Choice Gone are the days when prototypes were created using wood, clay and thermocol. Creating such prototypes was a time-consuming process. Moreover, those prototypes were not functional and hence, physical validation of product functioning was not viable. Rapid prototyping is the need of the hour, without which one might be compromising on the product quality and incurring unnecessary extra costs in reiterating the entire product redesign and development process when the design errors are identified after the first trial batch of production. Doing away with traditional time-consuming, costly and inaccurate means & methods of making prototypes by adopting new advanced technologies that helps you build better and superior products in lesser time & costs would be a smart choice and an apt decision for progressive companies striving to stay ahead of time & competition! Author: Ravi Patil, National Manager, DesignTech Systems Ltd

August 2012 - MODERN MACHINE TOOLS

SPECIAL FOCUS Opinions and More

With additive manufacturing, almost anyone, located almost anywhere, can enter the product development and manufacturing business, says Terry Wohlers, Principal Consultant and President, Wohlers Associates, Inc.

Q Current Trends in 3D Printing

Technology We have seen that the producers of machines for Additive Manufacturing (AM) are making improvements to the software, mechanical systems and energy sources for speeding up the build process. Customers of these systems are streamlining the ‘front-end’ and ‘back-end’ processes to make the start-to-finish process more efficient. For example, cleaning & finishing the parts can require timely and expensive manual labour; therefore, companies are automating as much of it as possible. We document 19 trends in Wohlers Report 2012, a market study that we have been producing for 17 years now. One of the trends is that the technology is now being viewed as a serious method of manufacturing. Another is that much-needed industry standards are being developed by the ASTM International Committee F42 on Additive Manufacturing Technologies. Third is the dramatic advancement in metals. In the last 10 years, metal technology has developed from almost nothing to producing thousands of production parts annually.

Q Latest Technologies in AM One of the latest technologies is Ultrasonic AM (UAM) from Fabrisonic. The machines from the company produce fully-dense parts in a range of metals using ultrasonic welding (highfrequency sound), which produces little heat. Another up-coming technology is the growing number of RepRapinspired 3D printers that sell for as 66

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low as under $500 for a kit to more than $2,000 for an assembled system. ‘RepRap’ is an open-source development that started at the University of Bath, England. The original material extrusion technology was invented, developed and commercialised by Stratasys in the early 1990s.

Q Challenges Faced in Adopting AM Most AM systems were designed for prototyping, but not for manufacturing. Therefore, problems occur with consistency from system to system and among different parts made by the systems, so repeatability is of chief consideration. Moreover, some systems are not reliable. Material cost is also high and an obstacle to adoption, especially for manufacturing applications. AM materials cost about 50–100 times more than the equivalent materials for conventional manufacturing processes. Companies prefer systems that are reliable and are expecting advances in systems & materials technology. We have seen advances with some companies and systems, while with others it has been disappointingly slow. Without strong R&D and commercialisation, the industry will not progress at the pace expected by the user community.

Q Emerging Opportunities for the

Industry We see many emerging opportunities. With AM, almost anyone, located almost anywhere, can enter the product development and manufacturing business. As patents expire, less

expensive systems will become available that will bring prices of materials downward.

Q Adoption Rate & Growth

Prospects in India AM is an excellent tool for design validation and product refinement. Therefore, it serves as a good companion to CAD software, which is used extensively in India. Also, AM is being used increasingly for jewellery design & production and for the prototyping of automobile parts. The adoption of large, expensive AM systems has been slow in India. However, smaller, less expensive systems have been selling very well. As systems become faster & easier to use and as the price/performance ratio improves, sales are expected to become strong in India in the coming years.

Q Future Prospects According to Wohlers Report 2012, the Compounded Annual Growth Rate (CAGR) of AM was 29.4% in 2011. The market for all products and services in 2011 was $1.7 billion. We expect the market to grow to $2.1 billion this year. The AM industry is expected to record strong double-digit growth over the next several years. By 2015, Wohlers Associates believes that the sale of AM products and services will reach $3.7 billion worldwide, and by 2019, surpass the $6.5 billion mark. The future prospects for AM are exciting. We believe that it will eventually develop to become the most important, most strategic and most used manufacturing technology ever.

Opinions and More

A big advantage of additive manufacturing is that it can be used to manufacture personalised products at distributed locations, as it does not need tooling, says Dr Phil Reeves, MD, Econolyst Ltd.

Q Effects of Growing Demands for

Speed & Productivity on Additive Manufacturing (AM) AM has significantly improved speed and productivity since its inception. Something that would have taken 50 hours to build in 1985 now takes 10 hours or even less. The other big development in increasing the productivity is machine size; we can now fit thousands of small components into the chamber of a machine and leave that machine running overnight. For example, take a part the size of a wristwatch; we can now produce as many as 3,000 parts in one selective laser sintering machine at any one time. Even if the build takes 40 hours to complete, it is less than one minute per part, not far off from injection moulding cycle times. And remember, we can just as easily build 3,000 different small parts, as there is no cost penalty.

Q Chief Business Drivers in Adoption

Tool-less manufacture Ability to make personalised products Ability to change the shape of the supply chain and include the consumer in the design process.

Q Emerging Opportunities

Custom implants (hips, knees) to reduce surgery times and speed up healing Distributed manufacture, i.e., making products outside the conventional factory (in the shopping mall, on the shopping street, etc.) Home manufacture â&#x20AC;&#x201C; the sale and brokerage of digital data (iTunes for products).

Q Current Trends in 3D Printing 3D printing works for high-value, lowvolume components. As a result, we are seeing a lot of personalised products. Some typical examples include hearing aids and dental crowns. It is being used in the production of home furnishing, toys & games. It is also becoming a trend for small design companies and individuals to upload 3D printing data files onto the internet for others to buy either the product or data for home 3D manufacture.

Q Latest Trends As machine customers want reliable, robust and flexible machines that can be used everyday without failure, the latest trends in metallic AM are the production of lightweight efficient structures both in metals such as titanium and in very high-temperature alloys such as Inconel. In polymers, we are seeing the increasing usage of hightemperature materials such as PEEK, and sustainable polymers such as PLA & nylon 11.

Q Adoption Rate of AM in India To my knowledge, the current adoption levels are low in India. AM is being used to support product development (rapid prototyping). A number of global AM machine companies, including Objet, EOS, Stratasys and EnvisionTEC, are selling their technologies in India. For example, in Mumbai, machines are being used to make sacrificial patterns in the jewellery industry. Of course, it is now possible to make parts directly in gold, so perhaps we will see such technologies becoming established in India.

Q Challenges in Adoption The high cost of AM machines and materials makes the parts so produced expensive as compared to injection moulding, machining or casting. Therefore, it is important to find high-value applications where the geometric flexibility of AM can be used to the full. Other challenges in the way of adoption include the number of materials available (which are limited), the mechanical properties of the final parts (which may not be as good as other processes) and the accuracy of the parts produced (they will not be as good as machined parts of mouldings).

Q Market Size In 2013, we expect the global market for machine and material sales to be around $2.5 billion. However, the market for parts produced with the help of AM will probably be above $10 billion. The current growth rate is around 30% per annum year-onyear, but we have only penetrated around 8% of the potential market. It is going to be a $100-billion global market by 2020.

Q Into the future I expect to see much more complex technologies capable of printing â&#x20AC;&#x2DC;intelligent devicesâ&#x20AC;&#x2122;. Combining metallic materials with polymers and insulators to produce embedded systems, I also expect to see biological printers used for medical applications. Compiled by Nishant Kashyap nishant.kashyap@infomedia18.in

August 2012 - MODERN MACHINE TOOLS

SPECIAL FOCUS Additive Innovations

From Labs to our Doorsteps:

The Advent of

ADDITIVE

MANUFACTURING

Since their inception in the early 1950s, additive technologies have taken a series of baby steps into the world of manufacturing—to lay new foundations in uncharted territory. And often, between these small steps, there have been sudden leaps of progress— bolts of innovation that catalyse development and accelerate thought. From ultrasonic consolidation to electron beam technologies to Controlled Metal Build-up (CMB), Tarun Tampi highlights some of the leaps that are transforming additive manufacturing technologies from a motley crew of infant technologies into the engines of tomorrow.

he Additive Manufacturing (AM) industry has come a long way from the days when Rapid Prototyping (RP) was its primary forte. A host of special processes have now been developed catering to specific markets. From tooling, prototyping, scanning, direct part manufacturing to maintenance & repair, AM technologies are gradually establishing themselves as standard processes in production manufacturing. Guruprasad K Rao, CEO, Imaginarium (India) Pvt Ltd, says, “While one cannot replace the traditional routes to large-volume manufacture, RP and other AM technologies will more than complement them where very complex tooling is needed and quick tests for functionality or design are required or where tooling is impossible. We can expect an upsurge in the market, and RP & rapid tooling will closely compete with conventional tool & die making as a manufacturing technology. We can say that such technologies are the future of the next industrial revolution.” 70

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With increasing coverage from mainstream media, AM has gradually caught the fascination of manufacturers, scientists, students and hobbyists alike. With 3D printers selling for less than $2,000, it is a technology for the people, accessible to individuals in their homes and flexible in its uses; much like the advent of the personal computer, AM is a personal manufacturing unit for every ‘layer’ of society. With the expiry of patents and the increasing adoption of the technology by governments, private companies and individuals, all over the world, AM is truly carrying the future for manufacturing.

Ultrasonic Consolidation (UC) Also known as Ultrasonic Additive Manufacturing (UAM), UC involves ultrasonic welding of sequenced metal foils. It uses a rotating cylindrical sonotrode to join two layers of metal foil. It employs applied pressure and ultrasonic vibrations to create friction between two layers, thus resulting in a solid-state weld between the foils. This

occurs due to the unique feature in ultrasonic processing wherein a high level of the plastic flow of metal is obtained at low temperatures and pressures. This allows other materials and elements to be embedded into a metal object without having to worry about sensitive temperature or pressure criteria. It means that sensors, reinforcing meshes, optical fibres, shape-memory alloy fibres, etc., can be embedded quickly and without hassles into another metal object. CNC contour milling is then used to create the required shape from the material. It is inherently faster and more energy efficient (since it creates the weld in the solid state under low pressure with minimal melting) than other AM processes. UC processing benefits in several ways—welds are produced at half the fusion temperature of most metals and materials considered hazardous in powder form can be used, such as aluminium, magnesium and titanium. Additionally, the process requires no special environment for processing, like shield gas or vacuum,

Additive Innovations and there is no special preparation for foils prior to welding. The technique can also be used to bond dissimilar metals, thus allowing the manufacture of a range of composites that could be lighter and structurally better than the existing composites, with a wider range of possible geometries. The process has been pioneered by scientists and researchers at Loughborough University, and currently sees application in the production of tooling & smart structures.

Innovations for Application

Powder Bed Processes

Electron Beam Melting (EBM) Sometimes referred to as a ‘revolution in the art of manufacturing’, EBM, a process developed by Arcam in Sweden, uses very powerful but narrow electron beams to melt metal powder, layer by layer, in a high vacuum chamber. Multiple parts can be directly manufactured from a powder bed; these parts have 100% density and are extremely strong. Some of the end-users and clients of this technology include Boeing, NASA, Airbus, etc., apart from a host of research institutes and commercial service bureaus. The technology does not use any moving parts for beam deflection and optimises energy usage. Materials that have been used by the process to make parts include pure titanium (commercial), low-alloy steels, tool steel and iron. As compared to Selective Laser Melting (SLM), EBM has higher productivity due to faster scanning rates and full density deposition that requires no thermal post processing.

Liquid Curing Processes

Perfactory System This technology creates 3D resin models by projecting a sequence of digital masks onto a photocurable polymer using digital light processing. It uses a photopolymerisation process based on successive layers of masking and curing. Pioneered by Envisiontec GmbH, perfactory system uses Digital Light Processing (DLP), 72

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A German company Röders initially commercialised the process, but it no longer makes CMB machines. Fraunhofer Institute for Production Technology continues to work on improving automation in the CNC machining process and improve the translation from CAD solid model files. Currently, the Institute is working on CAD interface issues.

With printers selling for less than $2,000, it is a technology for the people, accessible to individuals in their homes and flexible in its uses; much like the advent of the personal computer, AM is a personal manufacturing unit for every ‘layer’ of society.

developed by Texas Instruments, ensuring reliability and accuracy in producing models with very short build times. Stereo-thermal Lithography (STLG) STLG, an innovative up-andcoming process, combines heat and ultraviolet (UV) radiation effects to cure liquid resin and form models. Unlike a single-photon polymerisation system, it uses two lasers; one, an infrared laser to heat & thermally initiate the resin, and the other, a UV laser to activate a photo-initiator. Thus, this hybrid Stereo-lithography (SL) process uses infrared and UV lasers to overcome the limitations in efficiency, accuracy and tenability of conventional SL processes. The Polytechnic Institute of Leiria, Portugal, has done extensive research in this field, particularly for application in processing thin-walled and hollow parts from polyesters.

Injected Powder Processes

Controlled Metal Build-up (CMB) CMB combines laser deposition welding and high-speed cutting in a single machine, where after every deposition, there is a machining step after each layer to control accuracy and surface roughness. The CMB process also has an optional wire feed system that can be used instead of powder feed. CMB also uses highpower diode lasers as the energy source for creating the molten pool. High-speed three-axis milling is performed after each built-up layer.

3D Scanning Apart from reverse engineering, 3D scanning is used extensively to create quick and accurate 3D models of objects, recreating them on a computer using CAD. With large amounts of 3D designs and data being generated worldwide, 3D scanning is a low-cost, easy tool to be included in any product development process. Bioprinting A core application of AM technologies is in the medical field— for making implants, prosthetics and other devices. Bioprinting hints at the brave new world where human tissue can be printed to form body parts and organs using a porous scaffold structure printed using AM. The body part is scanned and modelled using computer tomography. Conformal Electronics Since the limitations of conventional machining do not exist in AM, there are several areas where part designs can be further optimised to suit its application. There are several components, ranging from energy storage devices, like batteries, to sensors and electronic controls, where the electronic parts can be embedded in the housing or frame structure as the component is created. This greatly reduces manufacturing time and builds more holistic structures. However, this combination of AM technologies and printed electronics still requires further research and development. tarun.tampi@infomedia18.in

MMT Aug-2012 Ad Name: Korea Pg No. 73

MMT Aug-2012 Ad Name: Neway Pg No. 74

MMT Aug-2012 Ad Name:Wohlaupter Pg No. 75

MMT Aug-2012 Ad Name:Birla Pg No. 76

Courtesy: Imaginarium (India) Pvt Ltd

SPECIAL FOCUS AM Challenges

Overcoming and Understanding

the OBSTACLES for AM There is a rosy hue colouring the future of additive technologies, a sense of a budding revolution blossoming in the heart of manufacturing. Yet it is an optimism that, although, not unfounded, makes little of the grim challenges that lie in the way. Apart from establishing process, material, performance and quality standards conforming to international standards, an ecosystem for additive technologies and products also needs to be developed. There are many obstacles that remain, yet there are also those that have been overcome. Tarun Tampi takes noteâ&#x20AC;Ś

efore we look at the technical aspects of Additive Manufacturing (AM) in detail, we must take a broad view of the difficulties that AM faces as a revolutionary tool in the spheres of technology, business and culture. AM is not just a technology, it is also a fundamental shift from the way designing and manufacturing have usually been done till now. A majority of designers have grown in an environment of traditional manufacturing methods, influenced and limited in their design by conventional processes. This not only limits the kind of products that can be manufactured, but also makes manufacturers and designers reluctant to eagerly embrace additive technologies. AM is in a unique position where the technology is way ahead of the design

software available for it. Then there is the need to develop a wider variety of materials and properties for AM. The technology needs to be made suitable for industrial production to handle huge volumes, bulky parts under stringent quality standards. Businesses need to look less at AM as a means to effectively market products for broad applications, and more to leverage the unique capabilities of AM in specialised applications, like hearing implants. This would also allow a company to market products made with the help of AM in far more creative and knowledgeable ways. The additive technologies, undoubtedly, have the potential to change the future of manufacturing growth; all it requires is a shift in mindsets, a change in perception, particularly in India. Aditya Kumar,

Technical Director, Marco Polo (India), says, â&#x20AC;&#x153;There are two major barriers to the increased adoption of AM; a perception of high costs, ie, heavy capital associated with the technology, and the second is lack of education or awareness of the available techniques & capabilities of various additive machines.â&#x20AC;? Apart from these looming obstacles, there are technical challenges, such as challenges in material, equipment, cost, methodology and applications, that need to be overcome for AM to realise its potential.

Defining the Materials AM processes use material in a specialised form. To establish the standards of performance for products manufactured using AM and to develop a common understanding of the mechanical August 2012 - MODERN MACHINE TOOLS

AM Challenges Comparison of Prototype Attributes ATTRIBUTE

SLA

SLS

FDM

3DP

PJET

CNC

RIM

Quantity Complexity Surface Finish Material Choice Material Stability Colour Tolerance Speed

Developing the Materials

Price: Low Volume

Although AM uses an extensive Price: High Volume variety of materials and material Poor Fair Good combinations, there is still a need for more materials and greater PJET - Polyjet; RIM - Rapid Injection Moulding; SLA - Stero-lithography Apparatus; SLS - Selective Laser Sintering; variety. Since materials are FDM - Fuseo Deposition Modelling; 3DP - 3D Printing often specific to a particular type boosted by qualification procedures that that optimise structural as well as of AM process or machine, the relations will back the quality and specifications material properties. A step towards this between the process, material properties for AM machines worldwide. is Digital Prototyping (DP)â&#x20AC;&#x201D;software & product requirements need to be fully that digitally builds and tests a product understood and guidelines should be for fit, form & function, a precursor to created for developing new & improved Design Tools and Software the accurate and efficient development materials. This would involve the Solid modelling software is the need of of improved rapid prototyping software. use of predictive modelling, wherein the hour for AM. With the increasing the functional properties of materials adoption of the technology, the are mapped to make designing efficient software will be the interface between Understanding the Challenges and easier. the user and the product. Moreover, It is important for any manufacturer for 3D direct part production, solid or designer to understand exactly what modelling is necessary, with features AM technologies can and cannot Production Methodology do. Although many of the processes, The challenge here is to develop materials and techniques are in early monitoring systems, closed-loop feedback stages of development, research is being systems and in-process evaluation Dr Phil Reeves, MD, advanced at a rapid pace to overcome methods for AM processes. This would Econolyst Ltd limitations and iron out the kinks. Each enable reliable, consistent and uniform process varies in the material strength production of AM parts. For thermal of the products and the surface finish control, non-destructive early detection The high cost of AM machines and materials makes the parts so of the final parts since they vary in the and optimisation of machine performance, produced expensive when compared thickness of the additive layer. systems need to be introduced, verified to injection moulding, machining and tested for AM.

Machine Design The current nature of additive processes, controls and operations is that of closed architecture, inhibiting the flexibility and customisation in AM manufacturing. There is no common thread in control designs running through all the machines offered by a host of competing companies, each unique in its design language. Further, the inter-changeability and adoption of equipment & machines need to be 78

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or casting. For this reason, it is important to find high value applications where the geometric flexibility of AM can be used to the full. Other limitations or challenges include the number of materials available (which are limited), the mechanical properties of the final parts (which may not be as good as other processes) and also the accuracy of the parts produced (they will not be as good as machined parts of mouldings).

Evaluating AM Technologies When adopting such technology, there are certain factors one must consider in evaluating the various technologies available for a certain type of product. The AM industry is set to cross $3 billion in overall sales by 2016 and $5 billion by 2020, so the time to think and act is here. There needs to be an understanding of how to best balance the advantages and disadvantages of an additive technology to harness its manufacturing potential. tarun.tampi@infomedia18.in

Courtesy: ROTO LABS, INC

properties, the material properties must be tested, documented and maintained in a publicly available database that is certified internationally. This should also involve the classification and standardisation of emerging AM materials, with detailed specifications maintained by governing bodies and research organisations.

A ‘RAPID’ Shift towards ‘PROTOTYPING’

Design courtesy: Orion Racing Team, K. J. Somaiya College of Engineering Sponsor: Imaginarium (India) Pvt Ltd

SPECIAL FOCUS AM Sustainability

Sustainable product design incorporates economic imperatives, ethics & other socio-economic dimensions of sustainability, and uses ecological principles as methods of designing, thus aiming to achieve higher growth & productivity. Rapid prototyping has been proved to be a sustainable manufacturing process in the current scenario. Nishant Kashyap finds out advantages and the scope of sustaining rapid prototyping.

ustainability is mainly divided into three areas: environmental, economic and social sustainability. An ideal product is one that maximises all three areas, ie, it is good for the environment, is profitable for the company and is beneficial for society. The arrival of Additive Manufacturing (AM) technologies presents a number of opportunities that have the potential to greatly benefit designers and contribute to the sustainability of products. AM has removed many of the manufacturing restrictions that may previously have compromised a designer’s ability to make the product they imagined. Products can also be extensively customised as per 80

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the user’s demands, thereby potentially increasing their desirability, pleasure & attachment and therefore their longevity. As AM technologies evolve, more & more new materials become available and numerous material technologies are developed further, the field of product design is set to change greatly.

Prototypes: The Way Forward A prototype is a vital component in the product development process. It is the original specimen of a product: it is a copy or a preliminary version, which often may not be in the final version of the material that will be developed. Rapid prototyping has come to play an important role in the mould-

making process. With this technology, mould makers will save immensely by streamlining and making the prototyping phase more efficient. To remain competitive in the market, manufacturers are constantly searching to draw new benefits from prototyping that go far beyond the ability to assess the visual qualities of a design. Prototyping can enable the actual functional, assembly and performance testing. Functional prototypes help in detailed market research to assess the viability of a product before a decision is taken to move to full-scale production. These are made possible by prototypes that have the same or similar properties and materials as those of the production parts.

AM Sustainability Mass Customisation Parts can be immediately made in AM, as a long lead time is no more required to produce tooling, which greatly affects the new product time to market, and on the ability to easily produce model changes throughout the life of a product. It also has implications in stock control: since components can be made on the spot, companies may no longer need to hold stock of spare parts as they simply manufacture the parts when needed. From the design perspective, it also means that every component made can be completely different from the others in a production run without significantly affecting the manufacturing cost. This opens the door for mass customisation in which, though mass manufactured, each product can be customised as per the requirements of the individual customers.

Liberty to Design Due to traditional manufacturing technology restrictions, a product, which the designer may have originally envisioned as being aesthetic and having certain functionality, may need to be compromised so that it can be cost-effectively made. Most designers are quite familiar with the situation where manufacturing engineers simply say ‘it cannot be made like that’. The designers may then need to compromise their design to the extent that the product loses the essence of the designers’ vision. If this becomes the case, then one must ask if the product so manufactured becomes less desirable, and therefore, loses some of the longevity it may have had, had it been manufactured according to the designer’s original vision?

Design Considerations It should be noted that AM does not remove all manufacturing restrictions. It, instead, replaces them with a different set of design considerations that designers must take into account if they wish to use the technologies successfully. These new design

Phil Reeves, Econolyst Ltd

MD,

In metallic AM, the latest trends are the production of lightweight efficient structures in titanium and also in very high-temperature metals, such as Inconel. In polymers, we are not only seeing high-temperature materials such as PEEK (polyether ether ketone), but also sustainable polymers, such as PLA (polylactic acid) and nylon 11.

considerations are much easier for designers to both understand and comply with without affecting design intent in a major way. Enclosed voids, surface finish, strenth & flexibility and machine & material costs are some of the principal design considerations to keep in mind when designing for AM. Maintenance and Repair AM is increasingly being used for maintenance and repair of damaged parts, particularly for products where a long lead time or expense is associated with the procurement of new parts. The ability to repair metal parts to near-net shape has significant advantages over manufacturing new parts, particularly large parts where only a small portion has been damaged. AM also excels where traditional maintenance and repair approaches are not enough to replace worn or damaged parts. It provides a metallurgical bond to the base material as opposed to a mechanical bond; this reduces the heat-affected zone in the nearby material. It, thus, leads to a stronger bond with fewer nearby residual stresses, making it ideal for parts that have a high sensitivity to heat distortion.

The Trend It is only over the last few years that AM is being adopted by more and

more companies as a viable production technology. Many companies are using AM technologies as their main production process for manufacturing titanium hip implants. As new polymer & metal materials are developed and the speed & precision of the machines further increase, more AM machines are likely to find their way into mainstream production lines. Dr Phil Reeves, MD, Econolyst Ltd, says, “In metallic AM, the latest trends are the production of lightweight efficient structures in titanium and also in very high-temperature metals, such as Inconel. In polymers, we are not only seeing high-temperature materials such as PEEK (polyether ether ketone), but also sustainable polymers, such as PLA (polylactic acid) and nylon 11.” AM enables the creation of parts and products with complex features, which could not have been produced easily via subtractive or other traditional manufacturing processes. Injection-moulded or die-cast parts, for example, must be removable from the die in which they are made and must, therefore, be designed in such a way that this can be done. The metal part could not easily be machined or cast because there is no way of removing the internal part of the die from the component or of machining the interior surfaces. AM, on the other hand, does not suffer from these particular restrictions. The complexity of the part does not affect whether it can be made or not, or even its cost. It allows for components of almost any complexity, freedom in design and increased flexibility in the features & functions of the end product. AM allows rapid development of sustainable products and is being increasingly used to produce lightweight components. It also helps to save a considerable amount of material, energy & cost for the production. AM is, therefore, considered as a sustainable manufacturing approach driving the rapid development of new products. nishant.kashyap@infomedia18.in

August 2012 - MODERN MACHINE TOOLS

SPECIAL FOCUS One Q Many Views

Additive Manufacturing:

Can it replace traditional manufacturing? Additive Manufacturing (AM) has been gaining huge interest in the global manufacturing arena. And because of the numerous advancements made in this technology, AM has dispelled many preconceived notions and has emerged as a technology to manufacture parts having intricate designs with an increased rate of production. But can this technology ever completely replace conventional die and mould manufacturing? Debarati Basu talks to the industry to find outâ&#x20AC;Ś SC Kalyanpur, President, Tool and Gauge Manufacturers Association (TAGMA) Indian manufacturers have not yet understood the methodology of AM. So, it is a fairly early stage for Indian manufacturers to adopt this technology. From a global context, while the technology is being used in countries like the US and Germany, mass acceptance is still awaited. The greatest advantage of AM is that it does away with the mould-making process, which is a painful and expensive affair. However, this technology cannot be of much help for mass production. Hence, conventional methods still need

to be relied upon. Additionally, there are various factors like cycle time, production capacity, etc, which needs to be considered before adopting this new technology. Besides this, cost is another factor that determines the adoption of this technology. If the overall cost comes down globally, the technology will certainly get an enthusiastic response from the industry. As of now, the Indian industry is still in the learning phase of this technology; adopting it will come much later.

Guruprasad K Rao, CEO, Imaginarium (India) Pvt Ltd AM will become a more frequently adopted process for product development, custom parts, replacement parts, repair parts and, in that sense, it will increase its presence. However, it will not replace conventional manufacturing in which the parts can come out in a fraction of a second and in the millions.

As of today, the speed, cost and volume of conventional manufacturing cannot be matched by AM. New technologies have replaced old ones. I see hybrid manufacturing to be the future, where AM will be just as relevant as conventional methods today.

Aditya Kumar, Technical Director, Marco Polo (India) Both the techniques will coexist in manufacturing. For example, if a simple box needs to be made without any features, it would be rather costly and time consuming if it has to be made using AM. Similarly, a complicated component, such as a turbine shaft or a complex auto component, could be made much faster and cost effectively using AM. AM will not replace conventional manufacturing to a great extent in the near future. Even today, in the US, AM is being increasingly used for medical implants using titanium, but its use is not so widespread for manufacturing plastic components. The closest

Verdict 82

technique for rapid manufacturing is SLS (Selective Laser Sintering), but even this is constrained because of the lack of cost-effective good materials. Some materials may have excellent properties, but would be very costly, and some notso-expensive grades may not meet the specifications required for final part production. However, this technique can probably be used for complicated requirements in very small quantities, where tool costs would be prohibitively expensive and the component in question would be relatively a non-load bearing component.

Although the Indian industry is yet to adopt AM technology in full swing, manufacturers are fully aware of the potential that the technology holds. AM may not be a complete replacement to conventional methods, but it will certainly enhance the manufacturing technology to take it to the next level of speed, precision and quality of manufacturing.

MODERN MACHINE TOOLS - August 2012

Courtesy: Imaginarium (India) Pvt Ltd

SPECIAL FOCUS 3D Printing

3D printing and rapid prototyping technologies have become more and more prominent over the past few years, with newer materials and processes expanding the capabilities & lowering the cost to a point where small businesses and even individual consumers can now afford to create their own 3D objects. Nishant Kashyap analyses the usage and changes of this technology in the manufacturing industry.

The Future of

D printers are less costly variations of Rapid Prototyping (RP) technology that are positioned as a design tool to create inexpensive models early in the design process. Physical models produced on 3D printers allow the design team to review the concepts. This, in turn, ensures that the company gets better feedback, thereby resulting in a better product. 3D printing also offers companies the scope to achieve real-time collaboration on a global scale. In recent times, the use of 3D printing has significantly increased with most of the industry adopting this technology at their shop floors. Additionally, 3D printing has also made inroads into various households for personal use. According to ABI Research, the global market for 3D printing systems, services and materials will grow to reach $782.6 million by 2013. 84

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According to Dr Phil Reeves, MD, Econolyst Ltd, “3D printing works for high-value, low-volume components. As a result, there is a flood of personalised products (typical examples include hearing aids and dental crowns, medical implants and surgical guides). Moreover, it is also being used for the production of lamps, furniture, toys, games and artefacts.” He further adds, “Additionally, there is a trend for small design companies and individuals to upload 3D printing data files onto the internet to purchase either the product or the data for home 3D manufacture.”

Sectors Where 3D Printing can be Used Engineering: Engineers always need to create prototypes of the products or designs they are working on. Earlier, the process of creating prototypes would

take weeks and required the use of a lot of manpower as it involved the cutting & piecing together of paper, wood and other materials to create the prototype. But now, thanks to 3D printing, engineers only need to create a 3D graphic image of the design they are working on and have it made using a 3D printer. Architecture: Just like engineers, architects too need to create mock-ups of their designs. 3D printers allow them to come up with these mock-ups in a short period of time and with a higher degree of accuracy. These 3D models also make it easier to visualise a design. Jewellery: The jewellery industry was one of the first industries to use 3D printing in their ‘investment casting’ process. However, instead of metal printers, they use wax here, i.e., the

3D Printing piece of jewellery is sculpted or printed out of wax. Plaster is then poured on either side, while molten metal is poured onto the wax, which melts, leaving behind a metal version of the wax sculpt in the plaster. The jewellery piece is then finished and polished by a jeweller. Many independent jewellers have been using high tech printers in their businesses. Medicine & implants: There are many medical cases where surgical procedures can be a ‘touch-and-go’ phenomenon. They can be so complicated that a single error can fatal for a patient. In the light of this, 3D printing has turned out to be a boon. Many surgeons have now started practicing upon the 3D renderings of the part of their patient’s body before actually performing on them. This not only boosts their confidence, but also increases their chances of success in an operation. Additionally, rapid prototyping has several uses in the medical sector including making models of actual bones so that surgeons can practice complicated procedures upon

Advantages of 3D Printing

3D printing can help you quickly fine tune designs Identify design errors earlier Reduce travel to production facilities 3D printing provides a highly cost-efficient means of production Cut traditional prototyping and tooling costs Less waste compared to traditional manufacturing methods A variety of resins and waxes can be applied to the completed model. A two part urethane can be added to the model Product can be manufactured in home

Machining vs 3D Printing Dr Phil Reeves, MD, Econolyst Ltd 3D printing works for high-value, low-volume components. As a result, there is a flood of personalised products (typical examples include hearing aids and dental crowns, medical implants and surgical guides). Moreover, it is also being used for the production of lamps, furniture, toys, games and artifacts.”

them. It also them in conducting cutting-edge stem cell research. Prototypes: 3D printing technology has found major applicability in product development prototyping. These machines allow designers and engineers to test ideas for dimensional products at a low cost before committing to expensive tooling and manufacturing processes. Components manufacturing: In some industries, 3D printing has replaced traditional manufacturing to produce a gamut of products. The technology is being successfully used for manufacturing small components in every industry. Gradually, as the demand from automobile, aerospace, medical equipment, electrical, energy and other such industries grows, companies will use 3D printing to manufacture bigger and more complex components. Aerospace components: Aerospace giants are looking at the possibilities of using 3D printed components in aircraft to replace existing machined or welded parts with lightweight organic structures. Besides, the move to 3D printing greatly reduces restrictions on manufacturing parts. 3D printing will find immense applicability in the manufacturing of lightweight aerospace components with the growth in the demand for larger, faster and cheaper printers. This growth opportunity, in turn, will trickle down to other industries and consumers as well.

3D printing is a form of manufacturing technology that can be used to create entirely unique products, just like the products in the machining world. However, 3D printing has certain advantages that machining does not. For instance, 3D printing works much quicker than traditional machining methods (barring CNC cutting). Similar to machining, there is a wide variety of materials available in 3D printing. However, there is a critical difference between the two. While machining involves the cutting, drilling, milling, deburring, etc., of a block of material to create the final product, 3D printing allows to develop highly intricate shapes that cannot be created through machining. Moreover, hollow sections can be easily made in 3D printing applications, unlike in machining. This is because the process often involves a layer-by-layer powder-based system—or a system that uses support material.

Into the Future 3D printing is expanding its horizons—a trend that is likely to continue in the future. Some of the most promising areas include medical applications, custom parts replacement and customised consumer products. As materials improve and costs reduce, other applications that we can barely imagine today will become a reality. Perhaps the greatest area of growth for 3D printing is in the medical field. However, its growth in other avenues such as consumer durables, electrical & electronics, aerospace and other engineering component industry cannot be ruled out. 3D printing holds the promise to create less complex components and may also help produce cutting-edge final products. The manufacturing industry may see the rise of rapid prototyping to the extent that it will replace several machining operations for the better. nishant.kashyap@infomedia18.in

August 2012 - MODERN MACHINE TOOLS

TIPS & TRICKS Selecting RP Processes

‘Understanding & Selecting Rapid Processes for Prototyping’ Rapid prototyping is a unique process by which designs can be converted from 3D CAD to physical parts without using a mould. This is the beauty of additive manufacturing. It is a relatively young technology, and one of the first commercially available systems was developed only in the early 1990s. Over the years, this technology has grown by leaps and bounds, and today there are more than 30 different techniques for rapid prototyping, each technique having its own speciality in terms of materials, speed & accuracy. Based on rapid prototyping techniques, a number of secondary technologies have been developed, such as vacuum casting for plastic components and vacuum investment casting for metal castings. These techniques use patterns made using rapid prototyping, and are very popular processes for making multiple replicas in very short lead times and comparatively lower tooling costs as compared to conventional tooling. In the current scenario, it becomes very important to clearly identify the reason for prototyping, whether it is aesthetic, fitment or functional. Once this has been established, the next step is to ascertain the available lead time on hand, and, of course, the available budget for the project. Needless to say, functional prototypes normally are more expensive and take the longest lead time to manufacture. It is essential for the user to be very clear in the project requirement so that the correct prototype sample is made in the available time. This would ensure that the project requirement is met and the prototype sample actually 86

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Courtesy: Marco Polo (India)

Classification of Prototypes

adds value to the product development process. Many times, people try to compromise on lead time & cost, and also wish for a functional prototype. Such situations lead to the failure of the sample and subsequently the confidence of the user in rapid prototyping. Aesthetic prototypes: They are generally required by companies selling consumer products, such as fast-moving consumer goods, home appliances and home electronics. These are mostly made using 3D printing technologies or by subtractive manufacturing using CNC milling. A variety of materials such as wood, foam and plastic are used for subtractive manufacturing. Prototypes for the purpose of fitment: Such prototypes, in most cases, are those that are made once the aesthetics have been taken care of.

This is the second stage of prototyping in product development cycle. Some popular techniques that are used for these are Stereo-Lithography Analysis (SLA), Selective Laser Sintering (SLS) and Fused Deposition Modelling (FDM). Functional prototypes: These prototypes are manufactured once the mechanical design has been finalised and the product is ready for tooling. Prototypes are made at this time, so that any issues relating to final fitment and functionality could be fine-tuned to avoid costly re-working once the tools were made. Normally, functional prototypes are required in larger numbers prompting the use of vacuum casting. In this process, a rapid prototyping master pattern is used to make silicone moulds. Once the moulds are made, polyurethane material is used to manufacture the parts. These are ‘mimic materials’ and are equivalent to most thermoplastics. In case large quantities of parts are not required, it is easiest to make these parts by subtractive prototyping using CNC milling of a plastic material that is closest to the required material of choice. In cases where large quantities of parts are needed in actual material of choice, there remains no choice but to make soft tools, and use these tools in the actual injection moulding process to manufacture the prototype samples.

Aditya Kumar, Technical Director, Marco Polo (India)

Selecting RP Processes Stereo-Lithography Apparatus (SLA) This is an additive manufacturing technique that uses a laser beam to selectively cure a photopolymer resin that is epoxy-based. The layer thickness is maintained at +/- 0.1 mm. Advantages Disadvantages High accuracy at Material tends to be brittle and features +/- 0.1 mm/100 mm such as snap fits cannot be checked for multiple cycles Very good finish Comparatively more expensive than other additive techniques Can be used for basic fitment and aesthetic check Can be used as a master for vacuum casting

Selective Laser Sintering (SLS) This is an additive manufacturing technique that uses a laser beam to selectively inter a polyamide resin that is in powder form. The layer thickness is maintained at +/- 0.15 mm. Advantages Disadvantages High strength parts Surface finish is not as good as SLA and secondary operations are needed Can be used for basic functional testing Accuracy at +/- 0.15 mm/100 mm Lower cost of parts compared to SLA Can be used as a master for vacuum casting

Vacuum Casting The master pattern may be manufactured using SLA, SLS or CNC methods. Silicone rubber is used most commonly. Parts are made using dual component polyurethane by the process of cold casting under gravity in vacuum to ensure bubble-free parts. Advantages Disadvantages High strength parts Actual material and process cannot be replicated Can be used for functional testing Part cost is high compared to injection moulding Material equivalent to thermoplastics Tool life is maximum of 20 pieces Very fast turnaround times Accuracy +/-0.10 mm/100 mm

CNC Machining This is a method of subtractive prototyping where a block of material can be cut directly based on CAD data using the milling process. Advantages High strength parts Can be used for functional testing

Disadvantages Lead time is more compared to SLA/ SLS Cost for critical components may be higher as compared to SLA/SLS

Material almost same as production intent Accuracy +/-0.05 mm/100 mm tarun.tampi@infomedia18.in 88

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SPECIAL FOCUS Desktop Additive Manufacturing

MOJO:

A NEW 3D PRINTING SYSTEM By lowering the threshold to adopt additive technologies, manufacturers of equipment like 3D printers, are making it possible for companies of any size to access and incorporate digital manufacturing for industrial production purposes. With new 3D printers, like Mojo from Stratasys (US), less than $10,000 away, companies, across any industry, can harness such technology not just to make prototypes, but also to make fixtures, functional tooling and end-use parts, more easily than ever before.

he number of manufacturers producing end-use parts through additive manufacturing is relatively small, but the number of manufacturers seriously considering doing this is large. What will it take for some of these companies to add this direct digital production to their capabilities? A 3D printing system from Stratasys promises to make additive manufacturing much more accessible to companies like these by lowering the threshold for adopting the technology. The company’s new ‘Mojo’ is a desktop 3D printing system that is priced at less than $10,000, can be leased for less than $200 per month, and includes features aimed at making 3D part-making more intuitive and seamless than other 90

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approaches to production.

The Mojo Like other 3D printers from Stratasys, the Mojo unit builds parts through Fused Deposition Modelling (FDM)—a process that creates resilient plastic parts out of thermoplastic materials comparable to those of injection moulding. Applications of FDM, therefore, extend beyond prototyping to include functional tools, fixtures and end-use parts. An injection moulder uses FDM to make short-run mould tooling where the quantity is too small to justify a steel mould, and enduse production parts in cases in which the quantity is too small to justify moulding. The Mojo system now brings the potential for precisely this type of partmaking to the desktop, provided the part

can fit within the unit’s build envelope of 5 × 5 × 5 inches. A software interface developed for this system simplifies 3D printing, Stratasys says. The print wizard imports the CAD model and steps the user through decisions related to orientation and scaling, as well as the number of pieces to be built in the cycle. A hardware innovation intended to further simplify the process is the integration of material spool and print head into a single package (the ‘QuickPack’ engine). Thanks to this design, the company says loading material into the Mojo unit is a straightforward step that is similar to snapping an inkjet cartridge into an office paper printer. Courtesy: MMS Magazine

SPECIAL FOCUS 3D Manufacturing

es ani d, p com buil n. y a w ed to uctio d e s h g t ing u o prod ign, an tal n i g e i t des in dig ng. han g is b sign c D i A s e e i otypin om d k to C bilities factur r a t oftw l pro ss, fr ect lin possi manu s a ysis Digit proce its dir ds the of 3D l a n n e an e. rld nd factur ise th avily o t expa ng wo a i ling manu optim lies he re tha merg l e d mo and and ing re softwa n the e D e r 3 vat ulate factu e-art owth i o n m in t, si anu e-of-th y to gr m s te itive , stat s ke i Add refore uring the nfuact ma

oftware are fundamental to Digital Prototyping (DP), wherein a part can be entirely designed, thoroughly simulated, tested and rendered, all digitally, thereby ensuring economy of design, preventing waste parts or redesign, and optimising manufacturing time. Such CAD modelling software must be specifically suited to 3D Additive Manufacturing (AM) processes, must be easy to use and must build on databases of design information. In the following examples, software from Autodesk, like Inventor and AutoCAD have been extensively used to overcome industrial design and manufacturing challenges–testaments to the potential of today’s software and designers.

Marin Bikes Marin Bikes is a small bike company 92

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whose focus on superb mountain bike engineering has garnered it a worldwide reputation over the past 20 years. Jason Faircloth, Product Manager, Marin Bikes, explains how a company as small as Marin Bikes is able to take on, surpass its large competitors and stay ahead of the curve. Unite a team of talented

Embracing 3D design and digital prototyping helps Marin Bikes maximize its resources and boost creativity.

designers with the industry’s best digital tools, and the secret to their long-lasting success becomes clear. “Obviously, one of the biggest challenges we face as a business is our size. We have limited resources and limited staff,” says Faircloth, adding, “The tools that we use to address this issue are the keys that allow us to maximise the return we get from each employee. As we started to move from a 2D to a 3D environment, the software lets us easily and quickly work with complicated 3D shapes, simple tube shapes and complicated suspension designs where you have to ensure clearances are maintained and tolerances are kept in check,” he says. Before they started working with such software, the designers had no way of finding points of potential liability, or of seeing compression details, say, where the loads transmit through the frames, without creating costly and timeconsuming physical prototypes. Being

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3D Manufacturing

August 2012 - MODERN MACHINE TOOLS

Courtesy: Pi Mobility

Courtesy: Glaze Tool & Engineering Inc.

job number to track labour costs from able to accurately initial concept to completed product. work with complicated Using digital prototyping software, suspension designs Glaze Tool designed and manufactured where designers a press feed at one-third the normal have components development cost, which decreased the interacting with client’s production time of automotive each other was window seals by 75%. Forkert explains accomplished by that the original machine was handfed creating digital four strips of cut-to-length rubber. prototypes that help The press would mould the corners, them simulate the Glaze Tool delivers custom machinery at one-third the cost with digital prototyping. and then the operator would remove real-world conditions the two joined pairs. This cycle was the bike will eventually repeated for the remaining corners, confront. 3D design software to reduce overall producing about 250 units per shift. The designers create the models development costs by 66%, build The new system built by Glaze Tool with all the components of the frame products that decrease production automatically cuts the strips of rubber built into them. They then deconstruct time by 75%, and bring higher quality and feeds them into the press. In the digital model and generate 2D designs to the marketplace faster. reducing the operator’s steps by more engineering drawings that have all the Often, the machines are one-of-athan two-thirds, each shift can now relevant dimensions and tolerances. To kind. Therefore, it is important that produce a thousand units with 100% try and do this any other way, such as the company gets it right the first time. confidence. physically creating all the 2D drawings Among the many types of specialised by hand would take a drafting team mechanical equipment designed by days or weeks. “By using such software Glaze Tool was a press feed machine Pi Mobility to create digital prototypes, we were for a major automotive supplier, who “I grew more convinced that the able to bring down the development needed to optimise production cycles electric bike would be a singular tool timeline from roughly 18 months to in the fabrication of window seals. in enabling us to move away from 9 months,” explains Faircloth. He Glaze Tool began with a concept our dependency on automobiles,” says also points out that there was no design and finished with a model Marcus Hays, CEO, Pi Mobility, extra money spent on R&D, nor was designed in Inventor. “You can start adding, “I started Pi Mobility in any additional staff hired. “It was with a 100-feet design, and if you are 2000, and I have been working in this made possible simply because such off a fraction of an inch, you can end segment ever since.” Electric bikes use software was available,” he adds. up with a transfer arm off by 15 feet,” less than 1,000 watts of total power Using Inventor, the designers create says Michael Forkert, Manufacturing and can be used on bike paths. When the models with all the components Engineer, Glaze Tool & Engineering Hays first encountered these hybrid of the frame built into them. They Inc, adding, “Such software enables us vehicles, most models were imported then deconstruct the digital model to visualise and simulate our designs from a variety of countries, especially and generate 2D engineering drawings without spending valuable time China. The bikes typically relied on that have all the relevant dimensions and materials on physical and tolerances. prototypes.” “Digital Prototyping (DP) is going “Since the software has set to become more important in the way file extensions and drawing we do our business. We are going to standards already in place, I rely less and less on physical models. have adapted our job number Before that no tool allowed us to do and file system to work hand what we are doing now,” emphasised in hand,” Forkert continues. Faircloth. By creating a bill of materials, the data can be transferred into other file types with no Glaze Tool errors in part numbers. This Glaze Tool & Engineering Inc produces not only lets the purchasing custom equipment, unsurpassed in department know exactly quality and detail for the automotive, what to buy, but also helps appliance, construction and electronics Glaze Tool to use a standard Pi Mobility uses digital prototyping to design electric bikes. industries. The company uses digital

3D Manufacturing an injection moulding manufacturing process that produced parts made using a variety of thermoplastics. The plastic parts raised questions of reliability and tended toward unsightly discolorations & dangerous cracks. All too often, those bikes were simply discarded. “As an advocate for electric bikes, I felt these problems had to be resolved,” explains Hays. To efficiently produce a more reliable and environment-friendly electric bike, Pi Mobility took a decidedly minimalist approach. With the help of Autodesk software, changes to the design can be embedded very quickly; moreover, it reduces the required labour to a fraction of more traditional electric bikes. Thanks to the less labourintensive design of the single tube, Pi Mobility has been able to maintain production in the US and still be profitable. “We can create smaller volumes wherever there are enough Pi riders, and be profitable,” says Hays, adding, “For a small company like ours, that means much better quality control and throughput. We can form a tube in about 30 seconds, and with the help of such software, changes to the design can be embedded very quickly. Our manufacturing method not only offers very competitive prices, but also reduces the required labour to a fraction of more traditional electric bikes. By producing our bikes locally, much of the transportation carbon that often affects even environmentally sustainable goods can be eliminated.” Hays further emphasised, “Software solutions, from Autodesk, for DP were used and our design team took to the software immediately. After only three weeks, the team produced a 3D digital prototype using Autodesk Inventor proving that by increasing the diameter of our tube by a half an inch, we could immediately save $335,000. When you extrapolate that over the next few years, it means easily seven figures saved. That discovery means that Pi Mobility can achieve profitability a full year ahead of schedule.” 98

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Using digital prototyping, ADEPT develops an innovative, highly competitive aviation engine.

Adept Airmotive Using DP software from Autodesk, from conceptual design to manufacturing, ADEPT Airmotive is boosting efficiencies, minimising expensive downstream changes and innovating faster by leveraging a single digital model. They have been able to develop a prototype engine that weighs 60 kg less than comparable engines, complete processes in minutes that once took hours, reduce costs by minimising the need for tooling changes and produce fewer physical prototypes before manufacturing components. “At an early stage, we can bring customers into the decision-making process using a digital model that truly sells a flying experience. Making changes that once resulted in tonnes of rework is now effortless, says Raymond Bakker, Designer, Adept Airmotive. “The company has such confidence in the digital prototypes it creates that it often bypasses physical prototyping. If we do not need a physical prototype for something downstream, we will manufacture components directly from the digital prototype,” further explains Bakker, adding, “Once we create a sketch and define the geometry of a 3D model, we get team input. Then, we tweak the design on the fly and do interference checks & refinement. It is very fast and intuitive—a tool for ‘every man’.” “We are able to do parametric models so that we can change a wall thickness on motor packaging, for example, without having to remodel

everything,” says Bakker. With DP, ADEPT is meeting one of its primary requirements—to design tooling simultaneously with components. DP breaks down barriers, from conceptual design all the way through to the development of tooling and manufacturing, enabling ADEPT to innovate faster & more cost effectively. “We are able to incorporate tooling considerations into the component upfront as we design it,” explains Bakker, adding, “We do not have to do a lot of editing of the component downstream to make it toolable. And because we do not have to subcontract tool design, we are reducing costs significantly.” DP lets the company’s designers and engineers consider tooling upfront and incorporate engineering constraints and requirements from the earliest stages of design. “If we are designing a piece of metal that needs to perform certain functions, there are certain laws of physics we must follow. But we do not want our designs to be merely functional; they need to be beautiful too. DP helps us make engineering changes, see the impacts visually, adjust them aesthetically, and then develop the tooling,” says Richard Schulz, MD, ADEPT Airmotive. Processes that once took hours, such as changing geometry deep within a part, now are completed almost instantaneously. In less than two years, a core team of three people has produced an engine ready for tooling—an incredible accomplishment. “Inventor is such a delight”, adds Geoff Cronje, Design Director, ADEPT, adding, “The user interface is superb; so easy to use outof-the-box.” Not only are ADEPT’s design processes more efficient, they also have a big impact on project costs. “Inventor is saving us money because we do not have to make many changes to tooling. Without Inventor, this project would not have been possible,” concludes Bakker. Courtesy: Autodesk Inc. (India) Compiled by Tarun Tampi

FACILITY VISIT HMT Machine Tools Ltd

Resurging Manufacturing Grandeur The legacy of the Indian machine tool industry started with a dream which was built on the foundations of Hindustan Machine Tools Ltd. However, the journey and the goal to shoulder the country’s manufacturing industry slowed to a sluggish pace. It instead became a saga that narrated the story of the by gone glorious days. However, the company is now gathering its strength to embark on a path of revival and is confident of emerging as the behemoth it once was. Debarati Basu takes a look at this new fascinating journey that has just begun…

ay back in the 1950s, when India was basking in the glory of its independence and aiming to become self-dependent in every aspect, Hindustan Machine Tools (HMT) Ltd began, in a small way, to meet a big commitment: ‘To manufacture mother machines to build modern industrial India’. With the objective of producing a limited range of machine tools required for building an industrial edifice for the country, the Bengaluru unit of the machine tool division of HMT was inaugurated in 1955. Thus, HMT was not just the first machine tool company, it was also the first 100 MODERN MACHINE TOOLS - August 2012

step towards attaining selfsufficiency in meeting the country’s manufacturing needs. Over the next few decades, HMT became the ‘Brand of India’. With numerous global collaborations and joint ventures, HMT machines became a part of every shop floor. However, in due course of time, the manufacturing challenges outshone the achievements. With support from the government declining, the growth charts of HMT, the premier publicsector undertaking (PSU) in India, experienced a significant downfall. Howver, the company has now started taking small, confident steps towards reviving the ‘brand’ image that it once enjoyed.

The Heydays HMT, even today, is known for its pride and zeal to innovate. The company was the first to introduced India to CNC machines in the 1970s. Spread across 83 acres, HMT’s Bengaluru facility has the capability to offer end-to-end manufacturing solutions. Right from a full-fledged foundry, die casting unit and precision machining, the company has the capability of undertaking every aspect of manufacturing under the same roof. Elaborating further, S Rajaram, GM – MBX, HMT, informs, “The Bengaluru unit of HMT was the beginning of the industrial revolution in the country in terms of machine building and machinery.” Over time, the company has kept

HMT Machine Tools Ltd itself updated with the latest designing and manufacturing technologies to produce indigenous products required in a variety of industries. HMT, from the very beginning, has had a strong presence in every division, like machine tool, tractors, bearing, dairy machinery, watches, printing machinery, die casting, plastic processing machinery, etc. Although the volume of production is low, HMT has been consistently supplying to sectors, such as aerospace, defence, railways, shipbuilding & medical applications industry and the company continues to expand its reach. Commenting on the same, Basava Raju Pondhe, Jt GM – Sales, HMT, avers, “For us, value does not matter, technology does! There are various indigenous products that we have manufactured. For instance, we have taken up projects in the fields of aerospace and defence, which no one else in India could do. Most competitors do not take up such risks as they are of the view that volumes define a business’ growth.”

Proud Projects HMT has its units in other regions including Pinjore, Kalamassery, Hyderabad and Ajmer with over 3,000 employees. The Bengaluru unit alone has over 800 employees with 345 machines and is the only engineering complex with more than 100 machine tool product variants. The company has manufactured various indigenous machines like specialised components for aerospace applications & radar assembly, linear transfer machines, three-piece manipulators and rugged duty manipulators for nuclear applications & other precision-class machines like jig boring, jig milling, vertical boring machines, etc. It has also built some unique CNC double column coordinate drilling & tapping machines for heavy and bulk

components & tube sheet drilling suited for heavy engineering, aerospace and defence sectors apart from moulds for reflector antenna of satellite & LCA wing assembly jig. For the nuclear power sector, HMT manufactured rugged duty manipulators to safely handle hazardous substances up to the capacity of 54 kg. The company has also forayed into medical applications and has made a mark in manufacturing small titanium needles of 0.8 mm diameter for radio isotope impregnation. Moreover, at a time when the country heavily depends on importing ball screws, HMT is one of the very few Indian companies that manufacture ball screws for various industrial applications.

Changing Business Strategy Even though the company manufactures some of the most indigenous products and machines, the sales record is not the same. The dire lack of government support has been one of the many issues that have hit the company’s growth in a big way. While last year, the company grew at the rate of 17%, it now aims to achieve a turnover of `340 crore this year. To this, MD Sreekumar, MD, HMT, says, “We are targeting at least a 20% growth YoY and are very close to achieving it. We are aware of our strengths and weaknesses & are starting with a fresh approach and a new business strategy to once again become one of the major players.” He further adds, “Last year, we successfully managed to bring down our losses by half. Now, we are moving forward to significantly lower the losses even further.” Moving forward on a positive note, the company aims to bag `404 croreworth orders in this year. In the first quarter itself, the company has already booked orders worth over `250 crore, making the target a manageable one. “We now have to convert the orders into finished goods as fast as possible. But that is where the problem arises,” says Sreekumar, elaborating, “Due to lack of finances, many orders are

delayed by six months. No client waits for more than three months for delivery. Besides, around 75–80 % of the bagged orders are government projects, which come without any advance payment. This hits us hard as we cannot invest in manufacturing if the money does not flow in. As a result, the entire process is delayed.” However, this has not deterred HMT. Sans the support, HMT is now changing the strategy to generate its own capital to support manufacturing. “We are trying to create finances by capitalising on our unutilised resources like land and infrastructure. We have started to think beyond boundaries. Instead of being just a manufacturer, we are becoming a solution provider,” states Sreekumar. The company is planning to collaborate with a premier defence PSU by providing it with unutilised land and infrastructure for the latter to initiate its project. The income generated from this collaboration will be rolled into financing the initial expenses of manufacturing projects. Additionally, the company is vigorously trying to optimally utilise every opportunity in its hand to generate the capital support manufacturing operations.

Reviving the Past HMT ‘grew up’ as a brand, which the industry associated with ultimate excellence. But the setback has not dampened the zeal to fight back. “We have a working arrangement for a project with World Machinery Works, Romania, for floor-type boring machines. Along with generating foreign collaborations, we are also exploring opportunities for diversification in new avenues like missile manufacturing and missile assembly,” informs Sreekumar. The company is also striving towards offering attractive employment opportunities and subsequently, reviving the awe among young engineers to become a part of the ‘brand’ called HMT. debarati.basu@infomedia18.in

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Latest Happenings

• Rail Coach Factory Coming Up in Britain Hitachi is building a rail coach factory in Britain. It is part of a contract to supply around 600 train carriages for the British high-speed railways. The Japanese machinery leader won a $7-billion deal from the British Government to replace ageing trains with new rail cars and maintain them for the next 27 years. The company plans to operate the factory at full capacity by 2016 and hire about 700 workers, including research and development staff. • Bombardier Signs Technology Licence Agreement to Take State-of-the-art Tram Technology to China Rail technology leader Bombardier Transportation signed a Technology Licence Agreement with CSR Puzhen, a subsidiary of the largest player in the railway manufacturing sector in China – China South Locomotive & Rolling Stock Corporation Ltd (CSR). Under the agreement, Bombardier provides CSR Puzhen with a 10-year licence to manufacture and sell 100% low-floor trams with Bombardier technology. • CAF to Set Up Manufacturing Plant in India Spain’s Construcciones y Auxiliar de Ferrocarriles (CAF) is planning to set up a new manufacturing plant in the country to take advantage of an increasing demand for railway vehicles and equipment. The company is currently scouting for suitable locations. The Spanish firm had set up its Indian arm, CAF India Pvt Ltd, in 2010 to look after its operations in the country. • Indian Railways Demands New-age LHB Coaches To enhance safety features in coaches, the Indian Railways have decided to double the production of new-age Linke Holfmann Bush (LHB) coaches. The production will be scaled up from about 400 LHB coaches to 800 coaches. These coaches passed the safety test in 2010 when the coaches of the Bhubaneswar–New Delhi Rajdhani that derailed on March 22, 2010 did not topple on one another.

Industry Projection

Global demand for passenger and freight rail equipment, infrastructure, and related services is projected to grow to $214 billion by 2016.

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Market Snap Shot

International Coach Builders shows interest in the `15,000-crore project being executed by a special purpose vehicle for for Gujarat Metro Project. Chennai Metro Rail Ltd has signed with Alstom Transport a €243-million contract to supply 168 cars. China’s railway infrastructure investment may double in the second half of this year from the first six months and the full-year spending would be around $70.3 billion. Wärtsilä TMH Diesel Engine Company LLC is ready to start construction of a modern factory at Penza, Russia. China’s Railways Giant Announces $126-million Manufacturing Centre in Malaysia China South Locomotive and Rolling Stock Corporation Ltd (CSR) plans to set up its ASEAN manufacturing centre in Malaysia. CSR Zhuzhou Electric Locomotive Co Ltd (CSR ZELC), a subsidiary under CSR and an active player in Malaysia’s mass transit projects, announced the plan for setting up a 50-acre facility located in Batu Gajah of the Perak State, around 200 km from Kuala Lumpur.

Compiled by Nishant Kashyap

INSIGHTS & OUTLOOK RAILWAY & EQUIPMENT MACHINING 104 History of Railway Manufacturing The Way It Began: Indian Railways Manufacturing

110 Business Dynamics Tugging At Wagons Full Of Growth Opportunities

112 Technology On Tracks Laying Foundation For New-Age Railway

118 Railway Machining Technologies Transforming Industry Dynamics

August 2012 - MODERN MACHINE TOOLS 103

INSIGHTS & OUTLOOK History of Railway Manufacturing

The Way it Began Indian Railways MANUFACTURING India boasts of the third largest railway network in the world. And why not? From tugging the first carriage with just 400 people over a mere 34 km to transporting 23 million passengers every day across 63,900 km, Indian Railways has certainly emerged as the strong base that continues to keep the country’s movement on track. Debarati Basu and Tarun Tampi track down the journey of Indian Railways…

he journey of the Indian Railways (IR), which started 159 years ago, has etched an indelible mark in India’s history. Practically, the first commercial passenger carriage rolled out on the tracks in the year 1853, from Mumbai (then Bombay) to Thane (then Thana), with 400 people. Since then, the railways have been consistently growing to support the massive transport system across the country. The first short experimental line was laid near Chintadripet in 1835 and the construction began on this line in 1836; 104 MODERN MACHINE TOOLS - August 2012

it was intended for carrying granite stones. Although, the rail wagons were primarily intended to be hauled by animals, locomotives were also used on this line. With various other lines being constructed in other parts, the country had already laid 42 rail systems by 1947. By early 1853, steam locomotive was in use for hauling construction material in Roorkee as a part of the Ganges Canal Project. The construction material was transported along about 5 to 10 km-long light rail lines from Piran Kaliyar to Roorkee. Standard gauge wagons, which were built from parts

brought over from England, were hauled by men and horses. In late 1851, the locomotive Thomason was assembled on the spot from parts transported from Calcutta. It hauled two wagons at a time, at a speed of about 6 km/h. However, India’s first steam locomotive died a tragic death nine months later with a boiler explosion. Around this time, most railways were used for conveying construction materials, etc. More locomotives started to be brought into India, and on November 18, 1852, a locomotive hauled some coaches on a trial run

History of Railway Manufacturing from Bori Bunder (Bombay) to Thana (Thane). This accounts as the first real train to run in India. By 1875, about £95 million were invested by British companies in Indian-guaranteed railways. By 1880, the network had a total route mileage of about 14,500 km, mostly radiating inward from the three major port cities of Bombay, Madras and Calcutta. And by 1895, India had started to build its own locomotives. Today, the IR operates 19,000 trains each day transporting 2.65 million tonne freight and 23 million passengers every day. From bullock-hauled locomotives to high-speed railway lines, the IR has travelled a long distance strengthening the transport system of India.

Building the Backbone of IR The IR is the third largest railway network in the world, with over 63,900 kilometres of rail laid out across the country. And the key to this gargantuan transport system has been in the manufacturing of locomotives, axles, wheels, production of rolling stock and setting up of workshops for ancillary services. Here is a look at the current production units of the IR and their history.

Chittaranjan Locomotive Works (CLW) CLW was born on January 26, 1950, in a village called Mihijam, on the border of West Bengal and Bihar. It produced its first steam locomotive, #8401 named ‘Deshbandhu’ in November 1950, and went on to produce over 2,300 steam locomotives by 1972. Its first electric locomotive was named ‘Lokmanya’, made in October 1961, although the first entirely Indian-built electric locomotive was the ‘Bidhan’, made in November 1963. With a history that stretches through nearly a century of railway manufacturing, CLW, a public-sector undertaking has emerged as the premier railway manufacturing unit in India. It currently has the capacity to produce over 200 electric locomotives annually. It also started producing diesel locomotives, 106 MODERN MACHINE TOOLS - August 2012

World’s Oldest Narrow Gauge Track India has one of the oldest twoand-a-half feet gauge railway track in the world, which is still operational. The Dabhoi– Miyagam line in Vadodara district was constructed over 150 years ago during the Gaekwad rule to expedite business and trade in the region. The locomotives were used to be hauled by bullocks. However, this was one of the significant arrangements as farmers used the line to export cotton to Mumbai where the textile industry was booming in that period. This is also one of the few places in India where narrow gauge railway track still exists and is operational. Dabhoi was the first narrow gauge railway junction from where 42 trains were operated in six sections. While some railway tracks connecting Dabhoi railway station have been converted into broad gauge, the tracks to Chandod and Miyagam still operate in narrow gauge.

For manufacturing rolling stock, production units notably include the Integral Coach Factory (ICF) in Perambur.

Integral Coach Factory (ICF) Swiss Car and Elevator Manufacturing Co. from Schlieren, Switzerland collaborated with IR to set up ICF in 1955–56. Initially intended to manufacture coach shells, it gradually developed a reputation in the production of uniquely integrated single tube structures (underframes, sidewalls and roof integrated to form a single tube structure) for anti-telescopic coaches in multiple configurations. The first completely indigenous coach was commissioned in 1956 with fully furnished, air-conditioned units It has produced over 35,000 coaches for the IR and manufactures 170 different kinds of coaches, with current capacity exceeding 1,300 coaches annually. It is also responsible for producing diesel rail cars, track recording vehicles, overhead equipment monitoring vehicles, etc. The facility also exports to Myanmar, South Africa, Taiwan, Vietnam, Sri Lanka, etc., and has already exported more than 425 units since 1971.

ICF: Key Milestones primarily diesel-hydraulic shunters, from 1969. So far, it has produced over 660 BG diesel shunters, over 140 NG diesels and over 40 BG main-line diesels. CLW draws the required raw material and energy for manufacturing railway units from its surrounding areas. Iron and steel come from Asansol and Jamshedpur while it uses hydroelectric power generated at the Maithon Dam. CLW broke the existing annual locomotive production records by surpassing the Railway Board’s target of 230 by manufacturing 257 locomotives in the year 2011-2012. It had produced 246 locomotives in the previous year. Some other major locomotive production units are Diesel Loco Works, Varanasi (1961), Diesel Modernisation Works, Patiala (1981) and Parel Workshops, CR (2006).

February 1955: First machine installed by Lal Bahadur Shastri (then Railway Minister) October 1955: Production commences (in Shell Divison) 1961–62: Started manufacturing first-class coaches June 1967: Enters export market; first export of bogies to Thailand 1971 - Export of coaches to Taiwan 1980–81: Manufacture of AC chair cars March 1999: First AC accidentrelief medical van by ICF 1999–2000: Manufacture of first all stainless steel AC coaches by ICF. Some other production units are the Rail Coach Factory, Kapurthala (1987), Bharat Bhari Udyog Nigam Ltd (formerly Jessop & Co, 1820) and BEWL (1978).

History of Railway Manufacturing Rail Wheel Factory, Bangalore (1984) produces axles and wheels and has an annual capacity of 40,000 wheelsets, over 1,70,000 wheels and over 60,000 axles. There are also several workshops that manufacture components, and provide ancillary services, including maintenance, repair, refit and servicing for the railways.

Jamalpur Workshop Set up in 1862 by the East Indian Railway Co, this was the first fullfledged railway workshop facility in India. Initially, the Jamalpur unit simply repaired and assembled locomotives from parts salvaged from damaged locomotives. By the early 1900s, however, they had begun producing their own locomotives. ‘Lady Curzon’ was the first locomotive to be produced at the Jamalpur unit in 1899. It was also at Jamlapur that India’s first railway foundry was installed. Presently, this unit has been expanded to include foundry and metallurgical labs along with specialised machine tool facilities. Its power usage is also self-contained as it has a captive power plant rated at 5 MVA. Also, beginning in 1961, it has been producing rail cranes and breakdown cranes of 10, 20 and 140 tonne capacities. Additionally, the Jamalpur unit manufactures wheels for coaches & wagons, cast iron sleepers, electric arc furnaces, ticketing machines and accessories. The facility grew famous with the manufacture of its heavy-duty, high-capacity, lifting jacks, which came to be known as ‘Jamalpur Jacks’.

Rail Coach Factory (RCF), Kapurthala RCF was set up in 1987 (although the proposal for it came up in 1985) to augment the supply of passenger coaches to the Indian Railways (IR). The first coaches from RCF were delivered on March 31, 1988. It also undertook the design and development of new lightweight IRY coaches using the high-speed IR20 bogies. These have been used in some of the high-speed trains, such as the Amritsar Swarn Shatabdi, although it appears that more recently their development has been put on hold following the introduction of the new lightweight high-speed coaches from LHB Alstom. Having been set up with a capacity of 1,000 coaches annually, RCF manufactured around 900 or so coaches a year in the 1990s and is now manufacturing around 1,400 coaches annually. 1962, it has started building wagons as well, repaired and manufactured double-decker automobile carriers, boxcovered wagons, multi-axled special purpose heavy wagons, flat wagons, etc. At present, they are India’s foremost workshop for restoration and rebuilding work for the damaged locomotives. This workshop is also noted for the fact that it exports diesel locomotives to Myanmar, Malaysia and Sudan.

Kharagpur Workshops Golden Rock Workshops Initially setup at Nagapattinam, Golden Rock Workshops moved to Tiruchirapalli in 1928. It was under the management of the South Indian Railway Co. The workshops here are equipped to deal with locomotives & carriages, carrying out overhaul, repair and restoration works. They were also known to overhaul the ‘X’-class locomotives of the Nilgiri Mountain Railway, along with the building of rakes for coaches. From 108 MODERN MACHINE TOOLS - August 2012

Sanctioned by the Bengal Nagpur Railway in 1900 and beginning operations in 1904, Kharagpur Workshops began with maintenance work for the railways. It is currently the largest integrated workshop on IR with facilities to service all types of rolling stock and locomotives. Spread over an area of 6,10,000 square meters, 2,60,000 of which are covered, the workshop handles work for dieselelectric and electric locomotives, motor

coaches, freight wagons, coaches and diesel cranes.

Future of the Railways With an illustrious history, the IR now needs to take ambitious steps towards becoming a global leader, able to indigenously develop state-of-theart railway technologies, components and equipment at world-class standards. An institute for research about railways needs to be established along with setting up centres of excellence at various universities promoting research work on issues, such as safety, wagon prototyping, mechatronics, green toilets, etc. Existing R&D facilities need to be upgraded and strengthened locally. Indian standards, protocols and critical vendor systems also need to be developed. This will create a strong base for production for the railways, thereby increasing local output and domestic manufacturing. The total cost of modernising the IR has been put at Rs 5,60,000 crores, which will include the modernisation of over 19,000 km of track, strengthening of over 11,250 bridges, elimination of level crossings, introduction of newgeneration locomotives, high-speed rail corridors, etc. The obstacles on the tracks for IR are evident. The IR is making huge losses, and its infrastructure is also lagging that of the developed world by roughly 20-25 years in terms of adopting new technologies and other means of modernisation. Freight capacities are too low, forcing a massive dependence on road transport that is not efficient. Yet for a transport system with a rich history, the future must inevitably be bright. With an industry built on strong foundations extending over centuries, the IR, as it grows and expands, is bound to leave a golden track, unique in the transportation history of the world. The IR is deeply entwined in the progress of this nation, and making it in-tune with the modern times will reinforce our efforts towards making the transport system of India truly world-class. debarati.basu@infomedia18.in tarun.tampi@infomedia18.in

INSIGHTS & OUTLOOK

f o l l u F s n go a W t a g n i Tugg

Business Dynamics

H T W S O E I T R I N G U T R OPPO

Even today in the twenty-first century, the Indian Railways stands tall as one of the most preferred modes of transport by the Indians. And as the population of India outgrows the ever-expanding city limits, developing the railways at an exponential pace is the need of the hour. With the Indian Railways expanding its network of rail lines, railways promises a huge business opportunities to the machine tool and rail coach makers. Debarati Basu takes a glimpse at what the Indian Railways has to offer.

he Indian Railways is currently in the process of undergoing complete modernisation, and the next decade should see a transfomed Indian Railways. The Railway Budget also 2012â&#x20AC;&#x201C;2013 emphasised on the immediate need for expansions and pointed out major investments that this sector can bring in. With new coach building factories being set up, the Indian Railways will definitely brighten the businessgeneration opportunities for the machine tool industry. The Planning Commission envisages an investment of $1 trillion in the infrastructure sector during the 12th Five Year Plan. And amidst all these developments, railways is fast turning out to be one of the crucial areas for investment. As the country develops, a proper spread of the rail network across every state is the need of the hour. To meet this demand, the Indian Railways has proposed an investment of `7.35 lakh crore in the 12th Five Year Plan.

Lugging Investments The railways has a vast array of 110 MODERN MACHINE TOOLS - August 2012

expansion projects in its hands, with over 487 projects of new lines at various stages of completion. In addition to this, there are over 476 requests for new projects. With almost 80% of the traffic being carried on 40% of the rail network, there is a crying need to upgrade and expand capacity of the railways to reduce congestion with improved safety measures. Over the next five years, the Indian Railways plans to modernise over 19,000 km of tracks through renewals, upgradation, replacement and strengthening 11,250 bridges to run heavy freight trains of 25-tonne axle load and achieve passenger train speeds of 160 km/h and over. Apart from this, upgradation of coaches, locomotives and wagons is also one of the key areas of modernisation. This would include increasing the manufacture of crash-resistant Linke Holfmann Bush (LHB) coaches, which has features that prevent the coaches from turning turtle in accidents. In all, the industry will see the railways investing over `63,212 crore over this period for its various modernisation plans.

Meeting Demand One of the major thrust areas for the Indian Railways is to meet the gap between the dearth of coaches and train lines as against the outstanding and ever-increasing number of passengers and cargo. This gap can be met partially by adding more coaches to the existing trains, which would require new-age, high-strength engines. The railways is expected to quickly procure such new-generation electric and diesel locomotives that can run heavier and longer freight trains at higher speeds. There are also plans to introduce new wagons with capability of 25-tonne axle load and higher payload to meet this gap. The introduction of new age-auto car wagons will significantly increase the carrying capacity of the Indian Railways. The Indian Railways is constantly opening up new units across the country to meet the growing demand for wagons, coaches, etc. As per government records, the Rail Wheel Plant, Chhapra, produced 78 wheels during 2011â&#x20AC;&#x201C;12. The Rae Bareli Coach Factory has also begun rolling out coaches. In addition, new units

Business Dynamics

for manufacturing state-of-the-art aluminium coaches at Kanjikode in Palakkad district, Kerala, and Rail Coach Factory at Kolar, Karnataka, have been sanctioned this year. Kerala’s Palakkad Rail Coach Factory will be the first rail coach factory in India to build aluminium body coaches.

Modern Metro Rail Apart from the Tier I cities, the Tier II and Tier III cities are also growing at a very fast pace. Quick and safe commutation has now become the chief area of concern. And metro rail is increasingly being considered as the solution for these problems. As a result, metro rail projects are being embarked upon by many Indian cities. While Kolkata and Delhi have already incorporated metro rails, cities like Chennai, Hyderabad, Bengaluru, Lucknow, Kanpur, Patna, Jaipur, Ahmedabad, Pune, Surat, Indore, Nagpur, Kochi, Coimbatore and Kozhikode are now following the suit. According to a report, there was a demand of over 300 additional metro coaches by the end of 2011 in Delhi alone. The 11th Five Year Plan had allocated an amount of `3,303 crore for metro rail projects across the country. While major global metro coach manufacturers have entered the domain to grab the opportunity, many Indian players are also foraying into this segment to reap the benefit. The next five years will see a complete transition in the way the

local transport functions. With the rapid expansion of city limits and huge increase in the population, metro rails are becoming a necessity for big and small cities alike. Here is a look at the major metro rail projects that are already in the pipeline and those that are expected to begin shortly: After receiving the Central Government nod, Kochi Metro Rail Project is likely to be completed in three years’ time. The project will cover a distance of 25 km. A major proposal for creating a Twin City Project in Gujarat has brought up the need for metro rail connectivity between Ahmedabad and Gandhinagar. Ludhiana Metro Rail that will span across 29 km will be built in two phases. Of the 29 km, 22 km will be overhead and the remaining 7 km will be underground. Pune Metro Rail Project is expected to begin by 2013. Metro rail in the country’s capital, New Delhi, has seen a huge demand for expansion. An Airport Metro Express Line connecting the Indira Gandhi International Airport has also been constructed. Jaipur Metro Project, covering 35 km, is awaiting budget allocation and is expected to begin shortly. A 63-km long metro project has been planned for the financial capital of the country, Mumbai. The work has already started on this project, and is expected to be

completed by 2021. To reduce the congestion, new coaches will be added to Kolkata metro trains. Diamond city Surat too has pitched in to have its own metro link. The local municipal corporation has sanctioned Rs 1 crore to conduct a feasibility study for its metro rail project. The 36-km long Lucknow Metro Rail Project will have three corridors: North-South, East-West and the Gomti Nagar Link. Patna has a 40-km Metro Rail Project in the pipeline at a total investment of about `8,000 crore. Indore’s metro rail will cover a distance of 180 km. The project will cost `12,000 crore approximately. Kozhikode and Coimbatore have also pitched in for their own metro rail projects. This is a probably the best time for the Indian manufacturers to enter this segment. The metro rails will not only transform local commutation, but will also challenge the traditional modes of coach manufacturing with new technologies that are being used to manufacture the high-end coaches. With large number of new projects lined up, the Indian Railways today forms one of the most lucrative markets for the machine and tool manufacturers. However, the secret lies in how well this opportunity is translated into business.

debarati.basu@infomedia18.in

August 2012 - MODERN MACHINE TOOLS 111

INSIGHTS & OUTLOOK Technology on Tracks

Laying Foundations for NEW-AGE RAILWAYS By the end of this year, the number of train passengers in India is expected to increase to 8.4 billion annually. While the Indian Railways has lined up huge investment to increase the number of trains, the main focus is towards enhancing technology to ensure better speed, less traffic and superior safety for passengers. Debarati Basu takes a look at the technology running on Indian tracks.

lthough the country has the third largest rail network in the world, the Indian Railways has a long way to go in order to match the technology that is rolling on foreign rail tracks. To meet the high passenger density, the Indian railway industry is trying out new options for bringing out high-strength, low-weight coaches with greater carrying capacity than the present coaches. In addition, researches are being carried out about making trains run faster with adequate safety that will also help increase the frequency of trains running. To fulfil these aims, researchers are working full throttle to come up with better material and methods to increase safety & decrease energy consumption, among others, to ensure a profitable and safe ride. In the last decade, aluminium car bodies have replaced steel car bodies to a large extent. This has been a major step towards light yet more energy-efficient rail vehicles. Aluminium is substituting steel in the manufacture of railway car bodies in many areas, especially high-speed, main line and regional passenger transport. Also, various alloys of aluminium and steel are being experimented with for a better option. Safety is the primary focus of any 112 MODERN MACHINE TOOLS - August 2012

development. The Railway Budget 2012–13 has laid additional emphasis on modernisation and safety of the railways. Here is a list of the various endeavours, joint ventures and investments made by the Indian Railways to ensure that the right technology runs on the Indian tracks to ensure a safer mode of transport for the country... Indian Railways Embrace New-age LHB Coaches To enhance safety features in coaches, the Indian Railways has decided to double the production of new-age Linke Holfmann Bush (LHB) coaches. The production will be scaled up from about 400 LHB coaches to 800 coaches. The LHB coaches, which are developed on the basis of German technology, passed the safety test in 2010 when the coaches of the Bhubaneswar– New Delhi Rajdhani that derailed on March 22, 2010, did not topple on one another. There has been a strong recommendation to stop the manufacture of Integral Coach Factory (ICF)-design coaches and completely switchover to LHB coaches in all the coachmanufacturing units in India. The technology has been acquired through a Transfer of Technology

(TOT) agreement with ALSTOM, Germany, for the complete switchover. Railways to Launch Fireproof Coaches The Rail Coach Factory (RCF) at Kapurthala, Punjab, has started manufacturing fireproof coaches to replace all outdated and general coaches. These fireproof coaches are made of superfine stainless steel and have been manufactured on trial basis. Over 40 such coaches have so far been rolled out from the RCF Kapurthala. These coaches are similar in look and design to the LHB German coaches. The indigenous technology with slight modifications is likely to reduce the manufacturing cost by about 40%, compared to the cost of producing one LHB coach made with the German technology. India-made Trains to Run in Pakistan and Bangladesh RCF Kapurthala—the country’s biggest rail coach manufacturing unit, along with diesel locomotives manufacturing units in Patiala and Varanasi, are making coaches and locomotives for the railways of Pakistan and Bangladesh. Railways Infrastructure Technical and

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Technology on Tracks

Economic Services (RITES) has already signed a `413-crore deal with Bangladesh for supplying 16 broad gauge locomotives and is in negotiations with Pakistan Railway Advisory & Consultancy Services Ltd (PRACS) for sending 50 locomotives. A Spanish Wagon Maker to Lay the Tracks for Indian Railways Given the increasing scope for business in the metro railway segment, Spanish rolling stock maker Construcciones y Auxiliar de Ferrocarriles (CAF) is hoping to set up a manufacturing unit in the country. CAF, along with its joint-venture partner MELCO, has been awarded a contract worth `800 crore to supply 84 coaches to the East–West Metro Project in Kolkata. The company had earlier supplied coaches for the Airport Express Link of the Delhi Metro. CAF, currently the fourth largest rolling stock maker in the world, has already bid for orders from upcoming metro rail projects in Hyderabad (L&T Metro Rail, Hyderabad) and Jaipur. International Coach Builders Queue Up for Gujarat Metro Engineering majors from Japan, France, China, Germany and Austria are in the race to build coaches for the proposed Ahmedabad–Gandhinagar Metro Rail Project. Eight global giants like France’s Alstom, CAF, Bombardier India, Austria’s Siemens and Korea’s Hyundai Rotem are among others that have evinced interest in the `15,000-crore project being executed by a special purpose vehicle, Metrolink Express for Gandhinagar and Ahmedabad (MEGA) Co Ltd. ADB to Provide $150 Million Loan to Improve Rail Freight Services Asian Development Bank (ADB) will provide a $150-million loan to the Government of India to improve rail freight services and passenger transport routes in the country. It will help in improving rail services along some of the country’s busiest freight and passenger transport routes, providing double-track for about 840 km of rail routes and electrifying

about 640 km. The programme will help in reducing fuel consumption and enhance energy efficiency, reduce pollution and enhance railway safety. It would also increase the line capacity and incorporate innovating financing modalities. ADB will also provide a programme-linked technical assistance worth $3,00,000 to promote sustainable transport modes by monitoring carbon emission reductions from shifting bulk goods from road to rail. New Energy-efficient Locomotives Introduced for High-speed Trains The Nagpur Division of Central Railway has introduced a new electric locomotive ‘WAP 7’, a highspeed engine indigenously developed by Chittaranjan Locomotive Works, which is capable of hauling trains at speeds ranging from 140 to 160 km/h. The WAP 7 can also haul loads of 24–26 passenger coaches at speeds of 110+ km/h. WAP 7 is the most successful passenger locomotive in the Indian Railways portfolio after WAP-4. As of now, 300 WAG 9, WAP 7 and WAP 5 locomotives save about 100 million units of energy, thereby saving of 105 tonne of CO2 per annum. Stainless Steel and Speed To make trains faster and easier to maintain, ICF Chennai gears up to make stainless steel coaches using German technology in a new plant being set up at Perambur. It is part of the long-term plan to phase out the existing coaches that have been made using 55-year-old designs and replace them with the variants of LHB coaches that can run up to 200 km/h. The conventional coaches made using ICF’s design will soon be outdated, although they are cheaper than LHB coaches. Alstom to Provide 168 Cars to Chennai Metro Chennai Metro Rail Ltd has signed with Alstom Transport a €243-million contract to supply 168 cars. The first deliveries are planned for the end of 2012. In addition to supplying the rolling stock, Alstom will equip the new stainless steel

trains with a signalling system for Automatic Train Protection (ATP) and Automatic Train Operation (ATO). They will be equipped with a regenerative braking system ensuring significant energy savings. The cars will operate on 25 kV AC through an overhead catenary system at speeds of up to 80 km/h. South Korean Experts moot Maglev Tech-based Plan Maglev technology, which uses magnetic force to suspend, levitate and guide vehicles, is being actively considered to resolve the traffic woes of Thiruvananthapuram. Along with the proposals for mono rail and metro rail, a proposal to use Maglev technology for setting up a mass rapid transport system within the city has been put forward. The proposal came from Hyundai Rotem, a South Korean giant manufacturing rolling stock, defence products and plant equipment. Gurgaon’s Rapid Metro Rail Manufactured Using Chinese Technology With trial runs due to begin this October, the Rapid Metro Rail Gurgaon Ltd (RMGL) is all set to start operations by March next year. The trains are being manufactured in China at the CSR Zhuzhou Electric Locomotive Co Ltd. The metro has lightweight aluminium-bodied trains. Boasting state-of-the-art facilities, the lightweight coaches will ensure lesser noise during movement and would require less maintenance. Special sound absorbing cushions in the walls of the coaches and more buffing on doors will ensure that less sound from outside enters the trains to ensure better ambience. The RMGL trains will have a maximum speed of 80 km/h.

The excessively rapid expansion & growth phase of the railways & metro links across the country indicates that the third largest railway network of the world is not far from becoming one of the most technologically advanced in the world. debarati.basu@infomedia18.in

August 2012 - MODERN MACHINE TOOLS 117

INSIGHTS & OUTLOOK Railway Machining Technologies

The liberalisation policy and the railway policies of the Government of India, in recent years, have created a positive impact on the railways component manufacturing industry. The field of railway machining is experiencing unprecedented demand and growth, which, in turn, stimulate innovations and promote the adoption of the latest technologies. Nishant Kashyap finds out some of the technologies that are being used for manufacturing rail coaches.

echnology is increasingly changing the process for manufacturing railway coaches. While coaches are being produced at faster rates, manufacturers must increase productivity & efficiency along with quality & innovation. Some modern technologies that are used to boost the railways manufacturing industry are programmable machines & tools, quality die mould, highspeed data communication & data management, adopting automated solutions, sophisticated sheet-metal cutting methods and advanced forging techniques.

New Product Design and Application The demand for lighter and more efficient coaches has increased ever since the arrival of supersonic and metro trains. This has induced the manufacturers to do away with old production systems and adopt new methods. Traditional Special Purpose Machines (SPMs) and transfer lines have become outdated. Today, the world of rail manufacturing relies heavily on automated system. The automation used presently in rail machine shops currently is reliable, reduces human 118 MODERN MACHINE TOOLS - August 2012

Transforming Industry Dynamics

errors and provides production planning with a committed schedule, eliminating operator dependence to a great degree. Automated or flexible manufacturing technologies affect sheet-metal (a vital component for rail manufacturing) fabricators by radically improving productivity and quality. For OEMs and job shops of all sizes, Flexible Manufacturing System (FMS) offers a strategic opportunity in manufacturing.

Role of Software The makers of rail coaches, dies & tool are hard-pressed to cut down on lead time and optimise material & tooling costs to compete in this demanding market. In addition, using new materials, like High Speed Steel (HSS), is creating challenges as their behaviour changes when stamped. This has increased the usage of sheetmetal formability software solutions to simulate the outcome of the utilisation of new materials and processes, long before the dies were built or even designed. The most used software, CAD/ CAM, provides manufacturers a viable solution; therefore, several coach manufacturers are applying automation, as it provides flexibility and cost

efficiency. Coaches are produced in an assembly line, which requires that the same type of components be produced in large volumes. Different components are pre-fabricated by machining processes and transferred to the assembly line for final production.

Sheet-metal Technology The development of new machines and applications is critical for the growth of any industry. Various advancements are taking place in the sheet-metal working sector, be it in cutting, bending, punching or forming. Sheet-metal is one of the most critical components for railway coach manufacturing. Many new materials are being used to manufacture lightweight coaches, which, in turn, increases the demand for sheet-metal machining technology. With the railway industry increasingly emphasising on both the quality and quantity, companies are bound to shift from conventional systems to automated ones. However, those in the traditional fabrication domain are still using the conventional machines. These days, roll forming has become a key technology. Out of the many sheet-metal cold forming methods, roll forming has been most successful

Railway Machining Technologies in generating significant interest in the Indian sheet-metal industry. Highvolume production, consistent product quality, less material handling and minimum labour utilisation are some of the advantages with cold roll forming process. Longitudinal welded tube made out of cold roll forming process already exists in India. Stainless steel materials up to 12-mm thicknesses are now being roll formed as well. However, as compared to the large variety of products that are being roll formed worldwide, roll forming is still an unexplored opportunity in India. For instance, though the Indian railways has realised the advantages of roll forming process, it has re-designed only a few of the structural members of wagons.

die sinking & wire EDMs, the newgeneration manufacturing extensively utilises hard machining and complex profiling on multi-axis machining centres to completely finish the dies & moulds with little need for manual finishing & correction. Supporting these machining methods are new developments in design analysis, inspection techniques and complex programming systems. Railway is one of the biggest caterer to the die and mould industry. Besides, demand is rapidly increasing from aerospace, computer hardware and telecom industries. This is a challenge as well as an opportunity for dies & mould manufacturers to deliver high-quality product at low cost in future.

Forging Die & Mould To meet the challenges of railway industry, a host of new technologies have evolved over the years. Apart from the conventional technologies, like

The characteristics of forged parts, such as strength, reliability and economy, make forging ideal for railway coach manufacturing. Forged components are commonly found at points of shock

and stress such as wheel spindles, kingpins, axle beams & shafts, torsion bars, ball studs, idler arms, pitman arms and steering arms. Another common application is in the powertrain, where connecting rods, transmission shafts & gears, differential gears, drive shafts, clutch hubs and universal joints are often forged. Although typically forged from carbon or alloy steel, other materials such as aluminum and microalloyed steels are also seeing great advances in forged rail applications. To improve product quality and efficiency in production, coach makers invest a large amount of time & money into developing and improving the manufacturing process, especially on materials & the cutting methods. Over the last decade, significant technological developments have taken place, changing and reinventing how coaches are produced, which should continue in the future as well. nishant.kashyap@infomedia18.in

August 2012 - MODERN MACHINE TOOLS 119

STRATEGY Top Shops Management

What’s the SECRET to SUCCESS?

If the answer to this question lies in the answers to our open-ended survey question, it is these four factors: 1. Focus on the customer; 2. Keep up with new technology; 3. Engage in continuous improvement; 4. Train your workforce.

lmost half of the respondents to our Top Shops benchmarking survey gave an answer to the openended question, ‘Briefly explain the machining technology or strategy that contributed the most to 120 MODERN MACHINE TOOLS - August 2012

the overall success of your business in recent years.’ Although the answers were diverse and far-ranging, several themes emerge clearly. The methodology to this analysis was very simple. The words or sets of related terms that appeared most often provided

clues to what respondents consider important. About 165 survey takers provided input to this question, but about three quarters of them listed more than one strategy or technology as having the biggest influence. This gave us a rich sample to investigate and interpret.

Top Shops Management Management strategies or principles were mentioned far more often than specific technologies. Only about a dozen answers pinpointed a single machining process or technology, such as ‘hard milling’, ‘modular fixturing’ or ‘high-speed machining’. One inference here is that shop management is more about sound strategic thinking than tactical applications.

Focus On the Customer One striking characteristic of the body of responses was the conspicuous recurrence of a single word: customer. ‘Keep the customer happy’, ‘meet customer needs’, ‘respond to customer requests’ and ‘guarantee customer satisfaction’ were the typical contexts for this usage. It occurred 24 times among the answers—no other single word approached this frequency. This does not count several answers that mentioned ‘service’ where the meaning was clearly ‘customer service’. Several answers implied a more nuanced emphasis on customer relationships. For example, one respondent mentioned ‘advising customers on more economical solutions’. Another spoke of ‘consulting with customers to add value’. ‘Providing personal service to the customer’ and ‘building customer confidence’ were also suggested as success factors. Although a focus on the customer is a part of basic business sense, shops that develop and expand this advisory role to customers have an advantage. For one thing, this approach shifts attention away from a ‘choose the lowest bidder’ mentality to one of ‘find the shop that gives the most value’. For another, greater responsiveness and interaction are cited by proponents of ‘re-shoring’ initiatives as a key reason for large manufacturers and OEMs to return to domestic suppliers, job shops and contract manufacturers. Strong customer relationships are part of the appeal of re-shoring.

Invest in Technology The machining technologies that are

Many shops are investing in technology that enables one operator to tend multiple machines during the day and then run those machines without the operator for at least one extra shift. Photo courtesy of Jet Machine.

prevalent among Top Shops were examined in detail by the survey. The importance of continual investment in technology as a management priority was amply reinforced in answers to the open question. At least 25 answers cite ‘new technology’, ‘upgraded machines’, ‘replacements’, ‘modernisation’, ‘advances’, ‘the latest’ or similar terms as a reason for overall success. Most of these answers did not indicate specific targets for this investment, but rather a general principle

of keeping up with new technology. As a matter of fact, survey questions that asked about spending on capital equipment and tooling showed that Top Shops outspend other shops in every category. The following answers to the open-ended question were typical: “Latest tooling and machining centers, CAD/CAM technology and good, smart and talented employees.” “Modernising to new equipment along with making employees

TABLE 1—IMPROVEMENT METHODOLOGIES USED TOP SHOPS OTHER SHOPS Continuous-improvement programme 80% 45.4% Quality certifications (e.g., ISO, NADCAP, etc.) 55% 34.1% 5S workplace organisation 42.5% 38.5% Cellular manufacturing 40% 20.8% Just-in-Time (JIT) movement of material 37.5% 24.9% Total quality management 35% 19.2% Value-stream mapping 35% 20.5% Kanban and pull systems 32.5% 23.7% Benchmarking 25% 17.4% Kaizen events/blitzes 25% 18.3% Six sigma 25% 14.8% Total productive maintenance 25% 12.3% Poka yoke (error prevention) 20% 18.9% Overall Equipment Effectiveness (OEE) 15% 11% monitoring and analysis Theory of constraints 15% 6% Single-minute Exchange of Dies (SMED) 10% 6% Agile manufacturing 7.5% 4.4% Other 0.0% 2.5% No formal methodology 12.5% 20.5%

August 2012 - MODERN MACHINE TOOLS 121

Top Shops Management TABLE 2—AVERAGE HOURS OF FORMAL TRAINING FOR EACH FULL-TIME EMPLOYEE IN 2011 TOP SHOPS

OTHER SHOPS

Less than 8 hours

35%

44.9%

8–20 hours

45%

33.3%

21–40 hours

20%

13%

More than 40 hours

0.0%

8.8%

understand spindle utilisation.” “Continued development and incorporation of new technologies supported by a commitment to continuous improvement has been key to our success in new business development.” Of course, the respondents that did give information about specific technologies or processes as key success factors deserve a mention here. ‘Cells’, ‘automation’ and ‘unattended machining’ were the most frequent short answers indicating these shops’ investment priorities. Another favoured tactic is indicated in these responses: “We plan to work so all personnel can run multiple machines.” “More machines than people.” “Add ops together to allow fewer operators to run more machines.” “Our strategy is to move to modern multi-tasking equipment, taking the labour out of the process.” These results confirm other industry reports that note the uptick in the manufacturing sector without the expected growth of new jobs. Companies are clearly more interested in adding new technology than increasing the headcount.

Continuous Improvement & Lean ‘Continuous improvement’ was the exact phrase respondents used most often to single out a shop floor practice that contributes the most to success. Twice as many respondents cited lean manufacturing or a specific lean technique, such as kaizen, kanban or 5S. Altogether, about 30 total responses mentioned a form of continuous improvement. 122 MODERN MACHINE TOOLS - August 2012

For many shops, set-up time reduction is one of the most rewarding results when lean manufacturing is first implemented, because so much waste and inefficiency are hidden by poorly managed set-up procedures. Reduced set-up time was a prominent theme in several responses. This sample is representative: “We do a lot of short runs, so improvements in set-up time count.” “Standardising tooling and optimising set ups and run times.” “Both 5S and kaizen events focussed on reducing machine set-up times.” Also mentioned numerous times as success factors were ‘quick turnaround’, ‘short lead times’ and ‘quick response manufacturing’. Adopting lean manufacturing practices is often described as a journey. Lean manufacturing always seeks to move to a ‘future state’ with less waste, but the journey has no final destination. This sense of ‘lean as journey’ came through in several responses, but most clearly in this: “(We) began using basic tools for lean manufacturing in 2007, with a stronger push beginning in 2010. We began seeing big rewards in late 2010 with better on-time delivery, uptime and efficiency.” That continuous improvement and lean were frequently credited as significant contributors to success is not a surprise. Table 1 details the prevalence of these practices. Most notable is the finding that 80% of Top Shops are pursuing some sort of continuous improvement programme.

Training Next to ‘customer’, the most frequently used single word among all of the

responses was ‘training’. A half-dozen responses mentioned training as the one factor contributing the most to their shops’ success. Just as common, however, were responses that listed training and skills development alongside technology or some other shop floor practice as a ‘strategic package’. Consider these responses: “Automated processes, machinery upgrades, employee cross-training.” “Invested heavily in new equipment, software and training of young machinists.” “Technology of the machines and training.” “Emphasis on investing in technology and training to reduce number of operations needed to produce parts.” What kind of training shops are pursuing is a good question. The survey responses did not give any strong clue. However, formal training does not appear to be a top consideration. Table 2 shows findings from this year’s survey. It is more likely that Top Shops and shops in general make training an integral part of the regular shop routine, with classroom or off-site training being the exception rather than the rule. This is strictly an interpretation, as the responses do not provide solid evidence.

Blend and Balance Success in manufacturing seems to be an effective blend of technology and people. You might call this blend ‘know-how’. Know-how is not possessed equally among manufacturing companies. Some apply processes and equipment more productively and profitably than others, for example. Keeping the importance of this know-how in mind is a good way to balance the value of what machines and equipment can do and the value of what a shop floor workforce can do. It is no secret that Top Shops maintain a balance of these capabilities at a very high level. Courtesy: MMS Magazine

ENERGY MANAGEMENT Reducing Leaks

Energy Miser

Plug Costly Compressed-Air

Leaks In a manufacturing set-up, compressedair usage is one of the first places any manufacturer should look to reduce energy cost. This is because compressed air is expensive; unfortunately, it is often wasted. Curtailing this waste should be accomplished quickly, as the gains are easy to quantify. Here is a look at how to avoid money from disappearing into thin air.

educing leakage is the first step in minimising compressed-air demand. In plastics processing, typical leakage rates are of the order of 30% to 50%, with an approximate average of 40%. That is, 40% of the compressed-air generating power (forty percent!) is wasted through leaks in the distribution system. Every system will have leaks, and target ‘acceptable’ leakage rates vary with the plant size: For small plants, the leakage should be from 5% to 7%. For medium plants, it should be within the range of 7% to 10%. For large plants, it should be from 10% to 12%. Most plastics processing plants fall into ‘medium’ category and should aim for a leakage rate of 7% to 10%. This means that the average site could save approximately 30% of the cost of compressed air by achieving the target leakage rate. Leakage is not only a direct source of waste; it is also an indirect contributor 124 MODERN MACHINE TOOLS - August 2012

to operating costs. As leaks increase, the system pressure drops and the most common solution is to increase the pressure to compensate for the losses. And generating extra pressure costs more money. The first step in leakage reduction is to recognise the costs involved and make a commitment to a plant awareness programme. Regular, continuous attention to the compressed-air system, coupled with proper maintenance, will lead to progress in minimising leaks.

‘Sssss’: Sound of Money Escaping The cost of a given leak (in terms of equivalent mm diameter) at a pressure of 100 psi operating for 8000 h/yr is shown in the accompanying graph. A 3-mm

hole in a system at 100 psi will cost around $1,300 per year in generation costs. In a system with numerous leaks, this cost will multiply rapidly. The lower limit for an audible leak is in the region of $130/yr. This means that if the plant is not operating and is quiet, then any leak you can hear will be costing you a minimum of $130 per year. That ‘ssssss’ noise you hear is not a normal operating condition; it is energy and money being wasted. The cost of a given leak will be even greater if the system is running at a

Reducing Leaks pressure of more than 7 bar (100 psi) or for longer than 8,000 operating hours.

Conduct a Leakage Survey Simple leakage surveys and maintenance can produce dramatic cost reductions. In some cases, leak reporting and repair has enabled companies to shut down some compressors for all or most of their operating time. A leak detection programme should be established to survey the plant regularly to detect leaks and fix them. Surveys can be made by finding audible leaks during a shutdown period, using a solution of soap and water to find leaks during normal operation, or by using an ultrasonic detector at any time. Compressed-air leakage control is not a single task that can ever be completed; it is a continuous rolling programme of leak detection and sealing that never ends. We advise using an ultrasonic detector and a programme of 2 hour per week for detection and rectification of leaks in specific areas. Find a leak, tag it and seal it.

Mechanical fitters use adhesive tape.

Operators use anything.

Leakage Measurement It is possible to carry out actual measurement of system leakage only when all of the equipment that normally uses compressed air is completely shut down. This means that the measurement must be outside normal operating hours, a difficult thing to do when running 24/7. Here are two methods: Cycle timing method: Shut down all air-operated equipment. Start the compressor. After the mains and receivers have reached the setpoint, the compressor will switch off. As air leaks cause the pressure to fall below the setpoint, it will switch on again. Record the average on-load time (T) and average off-load time (t) over a minimum of at least five cycles. Establish the compressor delivery capacity Q (in cubic ft/min) from the nameplate or 126 MODERN MACHINE TOOLS - August 2012

other documentation. Calculate total leakage from T, t, and Q: Leakage = Q x T/(T+t).

If the compressor capacity is not known, then this method can provide an estimate of the leakage as a percentage of the total compressor capacity. Pressure decay method: This method can be used if the compressor delivery capacity (Q) is not known or if it is a modulating compressor. This is not as accurate as the cycle timing method at low pressures, such as 100 psi, but is sometimes the only method available: Calculate the volume of the compressed-air distribution system (V) in cubic ft. This should include the volume of all piping over one inch diameter and all receivers.

Pump up the system to the setpoint (P1) as recorded on the receiver pressure gauge. Isolate the receiver and the system from the compressor. Using an accurate pressure gauge, record the time (T) for the pressure to drop to P2 (at least 30 psi below P1) over a minimum of at least five tests. Calculate the total leakage: Leakage = V x (P1 - P2)/T.

Where to Look for Leaks Use a Compressed Air Map to plan your leakage survey. Keep a record of where you fixed leaks last timeâ&#x20AC;&#x201D;leaks often occur in the same places. Here are some typical culprits: Redundant spurs in the system. Condensate traps. Ageing pipework. Fittings and flanges. Leaks are caused by pipe strain due to inadequate supports, inadequate joints, or twisting. Flexible hoses. Leaks can be caused by abrasion, deterioration (e.g., from heat sources), or mechanical impact. Use permanent fixings rather than worm-drive fixings. Regulators. These are often a source of leakage and abuse by operators. Check all regulators for correct setting and operation, and replace as required. Isolate machinery, supply lines, even whole buildings, from the compressedair mains when not in production. This can be done automatically using electronic controllers.

Feeding Itself During an energy survey, it was once discovered that the plantâ&#x20AC;&#x2122;s substantial compressor system was doing nothing but feeding the leaks. The system was maintained and was being paid for, but the compressed air was not actually being used for anything. The only consumer of compressed air was the leakage of the system itself! We turned it off. Courtesy: MMS Magazine

EVENT REPORT AMTEX 2012

Prospects Rise Northwards The 8th Indiamart AMTEX 2012, hosted by New Delhi, was a confluence of exciting business opportunities, world-class technologies and enthusiastic participants from across the globe. The four-day exhibition, held between July 27 and 30, 2012, undoubtedly proved to be a gateway to the world of opportunities. Adding edge to the advantage, the potential that the National Capital Region presents can take the prospects of the region northwards. A report…

ince its inception 12 years ago, the Asian Machine Tools Exhibition (AMTEX) has grown by 300% to become one of the largest shows of machine tools, machineries and manufacturing technologies in Asia. AMTEX is an attempt towards creating a platform where all the relevant sectors and technologies can interact. It offers the exhibitors an opportunity to present a brand new approach to enhance productivity by optimising the production process. At AMTEX, the key industrial sectors not only display their individual strengths, but also engage in interdisciplinary knowledge transfer. Cyril Pereira, MD, Triune Exhibitors Pvt Ltd, says, “AMTEX is an exhibition to exchange latest technological trends. 128 MODERN MACHINE TOOLS - August 2012

It helps generate demand and intensify sales. The exhibition offers a chance to meet and network with leading players. It is a venue to look for enhancing capabilities and expand business horizons.” AMTEX 2012 was inaugurated in the august presence of Hon’ble Minister for Corporate Affairs, Dr M Veerappa Moily. Also present on the occasion were Abhishek Bhartia, Senior Manager, IndiaMART InterMESH Ltd; Maulik Patel, Executive Director, Sahajanand Laser Technology Ltd; Satish Godbole, VP – Motion Control Systems, Siemens Ltd; Satish Ranade, VP, Electronica Machine Tools Ltd and Deelip Godbole, Manager – Sales & Marketing, Electronica Machine Tools Ltd, among other industry experts. “Events of such caliber will help the

industry. Exhibitors can project their products in such a way that it shows their potential in the market. Talking about potential, events like AMTEX will help them gauge the competition around and find a suitable market,” said Moily. The theme of exhibition ‘Create Awareness about the Technological Advancements in the Machine Tool and Engineering Segment in the Country Today’ would not have been more apt as machine tool manufacturers are exploring options to do better to be in sync with the growth of its end user, automobile industry. It showcased of technologies in all manufacturing areas, including metal cutting & forming technologies, precision tools, industrial automation and allied technologies. AMTEX 2012 expects to generate

AMTEX 2012

Exhibitors’ Views

Visitors’ Views

Shiddhalingesh Jolad, Managing Partner, RadCAM Software Solution

Rohit Pandey, Business Development Executive, FSL Software Technologies Ltd

With the industrial growth that we are experiencing since the last two quarters, I am expecting a lot because Delhi–NCR contributes to over 30% of our business. The region has many sheet-metal manufacturers who are using our CAD/CAM software extensively. While IMTEX is the gateway to the South Indian market, AMTEX is the place to be if you want to tap the North Indian market.

We are into Customer Relation Management (CRM) software. We have been getting many customers from machine shop since last few years. This is why AMTEX has become an ideal place to visit. It is a platform where all machine tool builders meet, which gives us a great opportunity to meet potential customers and their requirement. Lakhbir Singh, Senior Manager, Pritika Industries Pvt Ltd

AV Srinivasan, CEO, Meiban Engineering Technologies Pvt Ltd AMTEX provides us a good opportunity to get more enquires and customers from North India. The Northern region has a well-established auto component and infrastructure industry, mainly in the field of sheet-metal manufacturing. This becomes a very good reason for us to focus on North India and participate in the event. SK Manchanda, Senior Product Manager, Marposs India Pvt Ltd AMTEX has always been an excellent experience for us. It is an important exhibition in North India. This provides us an opportunity to showcase our company & products and also gives us an opportunity to meet our customers & OEMs at the same platform. We expect that AMTEX will attract more and more participants & become a benchmark for technology exhibitions in India. Sunil Kumar Rao YK, Director – Marketing, Farmax Machines Pvt Ltd This is the third time that we took part in this event and we can see huge improvement over the years. A good number of crowd visited the event on the very first day, which was very motivating.

business enquiries worth `850 crore. The estimates were based on the visits likely to be made by around 40,000 business visitors during the four days of the exhibition—almost 40% more than what was witnessed in the 2010 edition. “It was a grand spectacle of the latest advances in machine tools & manufacturing solutions and provided a superlative stage for interaction between manufacturers, suppliers & users of the growing Indian market,” said Pereira.

The Route To Success AMTEX has grown exponentially through each of its eight editions so far, and has grown by 300% during this period. This year too, the mega trade fair had over 1,400 exhibitors participating – both domestic and international. There were special country pavilions for companies from China, Taiwan and Korea. Other countries participating in the exhibition were Germany, Italy, Malaysia, Spain, Switzerland, Sweden, Belgium, Spain, Israel, Turkey, the USA and Sri Lanka. The event proved to be an excellent platform to attract major investments creating more business opportunities for the region.

We are into casting, forging & machining, and majorly cater to the auto component industry. AMTEX provides us an excellent platform to exchange ideas and understand the latest technological advancements happening in the industry. The biggest advantage of visiting such event is that one can compare the cost and the technology at the same platform. Vikram Kumar, Partner, JKT Technologies I have been visiting AMTEX since the last three editions. This is the only machine tool event in North India. I get not only some good technologies, but also meet a large number of potential customers at AMTEX. North India has many good heavy engineering and sheet-metal companies, which is why AMTEX has become an essential event to visit. RP Singh, Director, Alfa Therm Ltd

We have come to AMTEX 2012 with an aim to find new technologies & systems to further improve our manufacturing capabilities. We produce medical, industrial and general waste incinerators. It gives us a huge scope to choose from a wide range of available solutions & equipment at competitive prices. August 2012 - MODERN MACHINE TOOLS 129

TECH TALK CNC Machines

Different Company Types

Have Different

CNC Needs

There is a vast difference in the needs of product and workpiece-producing companies that heavily use CNC machines. Product-producing companies ought to be efficient, while workpiece-producing companies, using specialised processes, need to perform exceptionally well. This will enable them to outperform product-producing companies and profit from producing reliable workpieces quickly.

epending on how a company earns its revenue, it can be categorised into one of the following four types: Product-producing companies: These companies get their revenue from the sale of one or more products. Workpiece-producing companies: These companies, also called job shops or contract shops, get their revenue from the sale of workpieces to product-producing companies. Tooling-producing companies: They get their revenue from the sale of tooling—cutting tools, fixtures, dies, moulds, gauges and more—to product and workpiece-producing companies. Prototype-producing companies: They get their revenue from the sale of prototypes to product-producing companies. Most companies that use CNC machines fall into product and workpiece-producing companies.

Engineering, Planning and Resources Product-producing companies engineer all aspects of the manufacturing processes they perform. Therefore, a great deal of work must be done well before a new product is produced. Every production step/operation must be well documented so that employees know what to do. Also, profitability must be determined long before the first component workpiece is machined. On the other hand, workpiece-producing companies machine the same workpieces as product130 MODERN MACHINE TOOLS - August 2012

producing companies, but often for an equal or lower cost. One of the most important reasons a product-producing company will farm out work is to save money. This means the workpieceproducing company must be able to produce workpieces using a fraction of the resources available to the productproducing company that has contracted it. It also must be able to produce the workpiece on a tighter schedule. With limited time to plan and engineer the jobs, ingenuity is more important to a workpiece-producing company. A unique method of production must often be found to bridge the gap.

Personnel vs Machine Utilisation Product-producing companies need their CNC machines to be in cycle at a pace that matches their production volumes. To run at capacity, the machines must always be busy. That is why product-producing companies emphasise machine utilisation over personnel utilisation. By comparison, workpiece-producing companies need to use the available personnel to ship jobs on a timely basis. These companies emphasise on personnel utilisation over machine utilisation. While it is important to keep machines running for as much time as possible, workpiece-producing companies often need to compromise in this regard. It is common for one person to take up the responsibility of getting a job out. This person will perform all tasks required to set up the machine, complete the production run and, possibly, even create the programme for it. In these instances, machines often sit idle, waiting for someone to run them.

Processes Diversity It is not unusual for a new product to require additional equipment. Even simple products can require a diverse group of machine tools, including conventional and CNC machines as well as machines for processes that are not related to metal removal (such as plating, heat treating, cleaning and painting). The more CNC diversity, the more difficult it will be to make wise decisions that impact all of the machines. So, product-producing companies need to be ‘Jacks-of-all-trades’, able to deal with any process that occurs in the manufacture of their products. They may not fully master all aspects of a given process, but should be proficient enough to produce workpieces at a rate that matches their production schedules. Conversely, workpiece-producing companies tend to specialise in their machine tools. Many companies have only one kind of CNC machine tool, and they specialise in the processes that this type of machine can perform. For example, the company might specialise in turning processes performed by sliding-headstock CNC lathes. They also tend to specialise in running small lots—giving them much in common with prototype-producing companies. For these reasons, workpiece-producing companies need to be very good at the processes in which they specialise. This narrow focus is often the very factor that enables them to outperform productproducing companies and make a profit producing workpieces those companies farm out. Courtesy: MMS Magazine

GEOGRAPHY WATCH Delhi-NCR

Constructing a Corridor for Global Investments

orth India has traditionally and historically been a centre of the manufacturing industry. And as the demands are pouring in, production is expanding. Amidst all these rigorous expansions happening in the region, the National Capital Region (NCR) rose to become the focal point that held together the diverse manufacturing excellences emerging in small pockets of Delhi, UP, Haryana and Rajasthan. The Northern states are undoubtedly an integral part of India’s growth story as this consists of 7% of the world’s population. The region contributes 25% to the country’s GDP and accounts for 31% share in the agriculture output. Hence, the NCR indisputably presents a huge market.

Why Invest in NCR? This region has shown a consistent growth. According to a Confederation of Indian Industry (CII) report, the FDI inflows in the Northern region have grown steadily in the last decade. Ajay S Shriram, VP – CII and Chairman & Senior MD, DCM Shriram Consolidated Ltd (DSCL), says, “North is a very important part of India. It has a huge base of educated people. The state governments are very proactive in terms of inviting investment. The average GDP growth of Northern India is at par with the rest of India and the market too is very strong here, which is a very attractive proposition for investors.”

The National Capital Region (NCR), situated at the heart of the sub-continent, has seen an unparalleled industrial growth. The NCR has now grown to become the key attractant of investments for the manufacturing sector. Even amidst growing competition from other quarters of the country, there are many reasons for the investors to pour their investments in the NCR. Debarati Basu and Nishant Kashyap find out...

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MMT Aug-2012 Ad Name: Samkrish Pg No. 133

MMT Aug-2012

Ad Name:Expo Pg No. 134

MMT Aug-2012 Ad Name: Austin Pg No.135

MMT Aug-2012 Ad Name: IMTMA Pg No. 136

Indian Machine Tool Manufacturing Association

Delhi-NCR The region is fast developing itself to have a better reach and infrastructure. Under Delhi–Mumbai Industrial Corridor (DMIC), a number of investment regions and industrial areas are proposed to be built across Delhi, Uttar Pradesh, Haryana and Rajasthan, changing the way industry operates in this region. Western and Eastern Dedicated Freight Corridors will pass through 37% territory of Rajasthan and 57% territory of UP, respectively. This will also ease the logistic pressures off the industries of the NCR and provide speedy links to the various ports. This will also make for capacity expansion and better & improved availability of power, water & infrastructure in this region. Unlike other regions that are facing concerns regarding skilled workforce, about 33.4 million students from North India are expected to enter higher and vocational educational space by 2016. This will build a huge resource of workforce. The NCR is a seat for a diverse group of industries. Beginning from auto industry where the initial development began, the region is now expanding its reach towards medical and agrobased industries, among others. This has brought in added advantage for the machine tool builders to expand their capabilities as well. “The Northern India was where everything started. Even the auto industry had its base here. The region accounts for a huge amount of consumption, and therefore, the manufacturers need to be close to their consumers. Hence, NCR has created the advantage for itself,” says Richard Rekhy, Country Head – Advisory, KPMG.

What NCR Needs… Although a large market, significant resources and conductive investment policies make Northern states a preferred investment location, NCR needs to do more. It needs to be proactive in showcasing its capabilities. Places like Gurgaon and Noida have been successful in attracting MNCs that, in turn, have

made investments in the R&D activities in the region. The region now only needs a proactive effort from the industry and government to build a stronger base to attract more investments and make way for development.

Obstacles to Growth The economy of the NCR has increased tremendously over the past few years. However, to become a manufacturing hub and an investment destination, the government needs to address some major concerns of the industry. Manufacturers based in this region are facing many challenges that affect their production. Some of the major areas that need immediate attention are: Infrastructure: Investing in modern infrastructure is vital for economic development and growth. Infrastructure plays an important role in stimulating the growth of

The region now only needs a proactive effort from the industry and government to build a stronger base to attract more investments and make way for development.

commerce. Though the Northern (especially NCR) region is growing and witnessing a good number of investment from national as well as international companies, it still lacks good infrastructure. And it is the biggest concern for investors while setting up facilities in the NCR. Power & Water Shortage: Before setting up a manufacturing facility, the key areas that companies look for is availability for power, water, land, labour and logistics solutions. Power cuts in Delhi and its industrydriven satellite cities like Ghaziabad, Gurgaon, Noida, Greater Noida, Faridabad, Bhadurgarh, Sonepat, etc., have already been losing on their planned production. According

to the Associated Chambers of Commerce and Industry of India (ASSOCHAM), factories in NCR are losing almost 60% of their production due to erratic power cuts. Some of the small industrial units have even slipped to the edge of closing down. Another hurdle is water shortage. Almost every industrial process requires huge amount of water and the demand for water grows in sync with the increase in the global industrial base. The NCR has been facing water crisis for a long time. If the situation for power & water remains unchanged, it could seriously affect the industrial growth. This issue needs special attention from the government. Logistics: The connectivity of some of the industrial areas in Uttar Pradesh and Rajasthan is poor. This poor connectivity increases the logistics cost, which affect the overall cost of product. For the five Northern states to grow more rapidly than the national average, it is important to have policies that ease the connectivity and help increase the growth opportunities. Government Initiatives: The Government of Delhi should take proactive roles to help companies attract more investors, which will help them grow mutually. The government also needs to carry out proper branding exercise for the NCR to create an investment-friendly environment.

Though the Government of Delhi and that of other NCR areas are initiating many industrial policies to grow the business & economy of the NCR and promote industrial growth in the region, they need to address the above-mentioned areas at the earliest. Only then can NCR achieve optimum level of production using less power and space, which, in turn, will generate more employment opportunities for the skilled as well as unskilled workforce of the region. debarati.basu@infomedia18.in nishant.kashyap@infomedia18.in

August 2012 - MODERN MACHINE TOOLS 137

Event List - National

AHMEDABAD Gujarat Oct 5-8, 2012

PUNE

CHENNAI LUDHIANA INDORE

Maharastra Tamil Nadu Punjab Madhya Pradesh Nov 2-5, 2012 Nov 22-25, 2012 Dec 21-24, 2012 Jan 11-14, 2013

AURANGABAD

RUDRAPUR

Maharastra Feb 1-4, 2013

Uttarakhand Feb 23-26, 2013

India’s premier industrial trade fair on products and technologies related to Machine Tools, Hydraulics & Pneumactics, Process Machinery & Equipment, Automation Instrumentation, Packaging & Auxiliaries, IT Products, Electrical & Electronics, Material Handling and Safety Equipment. For details Infomedia18 Ltd, Ruby House, 1st Floor, JK Sawant Marg, Dadar (W), Mumbai 400 028. Mob: 09819552270 • Fax: 022 3003 4499 • Email: engexpo@infomedia18.in • Web: www.engg-expo.com

Automation 2012

India Manufacturing Show 2012

The event will showcase the power of collaboration between solution providers, i.e., vendors, engineering companies and actual users of the technology. The conference held during the course of the event also provides an excellent insight in the latest practices; September 7–10, 2012; Bombay Exhibition Centre, Mumbai

The exhibition is an ideal platform of all Indian and global manufacturing, engineering and other ancillary industries including Public Sector Undertakings (PSUs), especially for the micro, small and medium enterprises; September 27-30, 2012; Bangalore International Centre, Bengaluru

Industrial Automation India 2012 International trade fair for process & production, automation and industrial building automation; November 21-24, 2012; India Expo Center, Delhi For details, contact: Hannover Milano Fairs India Pvt Ltd No 13/16, Vatika Business Centre Wing B, 7th Floor, Supreme Business Park, Hiranandani Gardens, Powai, Mumbai 400076 Tel: 91 22 40050681/82 Fax: 91 22 40050683 Email: info@hmf-india.com Web: www.ia-india.com

IMTEX 2013

For details, contact: IED Communications Ltd 243, Shiv Shakti Industrial Estate Marol, Andheri Kurla Road Opp Mittal Estate, Andheri (E) Mumbai 400059 Tel: 28505138/28514673

For details, contact: IMS Foundation #15/47, 47th A Cross, 8th Block, Jayanagar Near Gelli Apartments, Bengaluru Tel: 80 2665 1234/4171 6085 Email: info@ims2012.in Web: www.indiamanufacturingshow.com

Bengaluru Space Expo 2012

CeMAT India 2012

The premier event will provide a platform for space agencies, specialists, entrepreneurs and space industry heavyweights to display their visions to the decision makers; September 12-15, 2012; BIEC, Bengaluru

One-stop shop for the automotive and transport, infrastructure, manufacturing, pharmaceuticals, dry ports, steel and food processing sectors; November 21-24, 2012; India Expo Centre, Delhi

The 16th Indian Metal-cutting Machine Tool Exhibition, with international participation, will showcase the exhaustive range of innovations and technological refinements in the complete product segment of metalcutting machine tools and manufacturing solutions. The concurrent event—Tooltech 2011— the international exhibition of cutting tools, tooling systems, machine tool accessories, metrology and CAD/CAM will feature the latest trends in cutting tools and tooling systems from across the globe; January 24-30, 2013; at Bangalore International Exhibition Centre (BIEC), Bengaluru

For details, contact: Confederation of Indian Industry Trade Fairs Division Plot No 249-F Udyog Vihar Phase 4, Sector 18 Gurgaon 122015 Tel: +91 124 4013871 (D) Email: rachna.jindal@cii.in Web: www.bsxindia.com, www.cii.in

For details, contact: Hannover Milano Fairs India Pvt Ltd No 13/16, Vatika Business Centre Wing B, 7th Floor, Supreme Business Park, Hiranandani Gardens, Powai, Mumbai 400076 Tel: 91 22 40050681/82 Fax: 91 22 40050683 Email: info@hmf-india.com Web: www.cemat-india.com

For details, contact: Indian Machine Tool Manufacturers’ Association Bangalore International Exhibition Centre, 10th Mile, Tumkur Road Madavara Post, Bengaluru Tel: 080 6624 6600 Fax: 080 6624 6661 Email: info@imtex.in Web: www.imtex.in

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Event List - International

AfriMold 2012 The international event will focus on tooling, mould-making, design & application development and will provide an ideal platform for die and mould manufacturer; October 10-12, 2012; Gallagher Convention Centre, Johannesburg For details, contact: DEMAT GMBH Postfach/PO Box 11 06 11 D-60041 Frankfurt / Main Tel.: + 49 (0) 69 - 27 40 03 - 0 Fax: + 49 (0) 69 - 27 40 03 – 40 Web: www.afrimold.de

IMTS 2012 America’s largest manufacturing show—the International Manufacturing Technology Show (IMTS) 2012—is one of the largest global industrial trade shows, with over 1,100 exhibitors & 82,000 visitors; September 10–15, 2012, McCormick Place, Chicago, USA

140

Tel: +49/69/27 40 03-0 Email: asiamold@demat.com Web: www.asiamold.de

BI-MU The 28th international event will showcase latest in metal-forming & metal-cutting machines, robots, automation and auxiliary technologies; October 2-6, 2012; Fiera Milano, Italy For details, contact: BI-MU c/o CEU-CENTRO ESPOSIZIONI UCIMU SPA viale Fulvio Testi 128 20092 Cinisello Balsamo MI, Italy Tel: +39 0226 255 234/860 Fax: +39 0226 255 897 Email: bimu.esp@ucimu.it Web: www.bimu-sfortec.com

METALEX Vietnam 2012 The international exhibition will be the all-under-one-roof meeting centre for new machine tools, metalworking technologies; October 4-6, 2012; Saigon Exhibition & Convention Center (SECC), Vietnam

For details, contact: The Association for Manufacturing Technology John Krisko, AMT Director – Exhibitions 7901 Westpark Drive, McLean VA 22102-4206, USA Tel: 703-827-5252 Fax: 703-827-5250 Email: jkrisko@amtonline.org Web: www.imts.com

For details, contact: 32nd floor, Sathorn Nakorn Tower North Sathon Road, Silom, Bangrak Bangkok, Thailand Tel: +66 2686 7299, Fax: +66 2686 7288 Email: rtdx@reedtradex.co.th Web: www.reedtradex.com

AsiaMold 2012

EuroBLECH 2012

Innovative technologies, informative events and increasing business opportunities make the exhibition the most distinguished mould-making and tooling design exhibition; September 19-21, 2012; Poly World Trade Center, Guangzhou, China

The world’s largest International Sheet Metal Working Technology Exhibition will emphasise on energy-efficient technology, environment-friendly manufacturing processes and intelligent use of material; October 23 -27, 2012; Hanover, Germany

For details, contact: DEMAT GmbH Carl-von-Noorden-Platz 5 60596 Frankfurt/Main

For details, contact: Mack Brooks Exhibitions Romeland House, Romeland Hill St Albans, Herts AL3 4ET, UK

MODERN MACHINE TOOLS - August 2012

Tel: +44 0 1727 814400 Fax: +44 0 1727 814401 Email: press@mackbrooks.co.uk Web: www.euroblech.com

JIMTOF 2012 The 26th Japan International Machine Tool Fair will contribute to the promotion of industry and trade through increased international transactions and technical exchanges of machine tools and their related equipment; November 1-6, 2012; Tokyo Big Sight (Tokyo International Exhibition Center), Japan For details, contact: JIMTOF Fair Management (Tokyo Big Sight Inc.) 3-11-1 Ariake Koto Tokyo JAPAN 135-0063 Tel: 03 5530 1333 (Direct dialing) Fax: 03 5530 1222 Web: www.jimtof.org

EuroMold 2012 International trade fair for Moldmaking and Tooling, Design and Application Development; November 27-30, 2012; Frankfurt, Germany For details, contact: DEMAT GmbH Carl-von-Noorden-Platz 5 60596 Frankfurt am Main Germany Tel: +49 69 27 40 03 - 0 Fax: +49 69 27 40 03 - 40 Email: info@demat.com Web: www.euromold.com

The information published in this section is as per the details furnished by the respective organisers. In any case, it does not represent the views of

Tenders

Latest Popular Tenders brought to you by www.tendersinfo.com LATHE, CENTRAL VERTICAL TURRET AND HORIZONTAL BORING MACHINE Org : ORDNANCE FACTORY BOARD TRN : 11814848 Desc : Tenders are invited for fully automatic machining system comprising CNC M/Cs, OH gantry conveyors, electric hoist storage pallet BOD : September 17, 2012 LOC : India BT : Tender VERTICAL MILLING MACHINE Org : HEAVY VEHICLE FACTORY (HVF) TRN : 11803458 Desc : Tenders are invited for supply of vertical milling machine (1500 X 300 MM) BOD : September 3, 2012 LOC : India BT : Tender VERTICAL MILLING MACHINE Org : ORDNANCE FACTORY AMBAJHARI TRN : 11778596 Desc : Tenders are invited for supply of vertical milling machine - 2 Nos BOD : September 10, 2012 LOC : India BT : Tender CNC PLASMA CUTTING MACHINE Org : VEHICLE RESEARCH AND DEVELOPMENT ESTABLISHMENT TRN : 11571442 Desc : Tenders are invited for supply of CNC plasma cutting machine BOD : August 21, 2012 LOC : India BT : Tender UNIVERSAL TOOL GRINDER Org : DEFENCE RESEARCH & DEVELOPMENT LABORATORY (DRDL) TRN : 11743224 Desc : Tenders are invited for supply of universal tool grinder for single LIP cutters BOD : August 31, 2012

LOC BT

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SCADA/EMS SYSTEM Org : POWER GRID CORPORATION OF INDIA LIMITED TRN : 11734074 Desc : Tenders are invited for replacement/up-gradation of existing SCADA/EMS System at ERLDC and SLDCs of Easter Region BOD : August 28, 2012 LOC : India BT : Tender NATIONAL SYSTEM CONTROL CENTRE, SCADA/EMS Org : CEYLON ELECTRICITY BOARD SRI LANKA TRN : 11727574 Desc : Tenders are invited for construction of national system control centre and installation of SCADA/ EMS System, installation of communications system BOD : September 5, 2012 LOC : India BT : Tender CNC VERTICAL TURNING AND BORING MACHINE Org : CENTRAL ORGANISATION FOR MODERNSATION OF WORKS TRN : 11619383 Desc : Tenders are invited for CNC vertical turning and boring machine BOD : August 31, 2012 LOC : India BT : Tender LATHE, CENTRAL VERTICAL TURRET AND HORIZONTAL BORING MACHINE Org : DIRECTOR GENERAL NAVAL PROJECT, VISAKHAPATNAM TRN : 11464042 Desc : Tenders are invited for Fitment of DROs on lathe, central vertical turret and horizontal boring machine under augmentation of pipe fitting and valve repair shop of SAX Dept. at ND, Visakhapatnam. BOD : September 13, 2012 LOC : India BT : Tender

Org: Organisation’s name, TRN: Tendersinfo Ref No, Desc: Description, DSLD: Doc Sale Last Date, BOD: Bid Opening Date, Loc: Location, BT: Bidding Type.

INFORMATION COURTESY: TENDERSINFO.COM 1, Arch Gold, Next to MTNL Exchange, Poisar, S.V. Road, Kandivali (W), Mumbai - 400067, Maharashtra, India Tel: +91-22-28666134 • Fax: +91-22-28013817 • Email: mktg@euclid-infotech.com

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Back artwork

Front artwork

National - Products This section gives information about the national and international products available in the market

Pad printing machine This high-quality sealed ink cup 60 pad printing machine - SIC 60 is suitable for automation because of its interface with PLC. It has ink/doctoring cup Ă&#x2DC; of 60 mm, cycles/hour up to 1500; print image size Ă&#x2DC; is max. 55 mm, drive is electro-pneumatic & printing pressure is 450 N. Other available features are different sequence cycles adjustable & ink residue pick up system. Spinks India Gurgaon - Haryana Tel: 0124-4770500 Email: info@spinksindia.com Website: www.spinksindia.com

CNC Lathe The CY-K510n model lathe has specially designed independent spindle structure ensures the maximum heat dissipation and brings down the heat distortion. Unique design brings high precision, high rigidity and low noise performance in turning. Automatic 3-step gear box with inverter is standard spindle drive, while servo motor drives as optional. The important technical specifications are: distance between centers is 1500 mm; swing over bed is 500 mm & spindle speed is 480-2500 rpm. Emtex Machinery Pvt Ltd New Delhi Tel: +91-011-49491666, Mob: 09899008130 Email: marketing@emtex.in Website: www.emtexmachinerylimited.com

CNC Lathe The Yunnan CY series model CY-L1640G is a high speed gap-bed lathe. Important technical specifications are: distance between centers is 1000mm, swing over bed is 410mm, width of the bed is 274 mm, spindle speed ranges between 33-32000 rpm(16 steps) & spindle bore is 52 mm. Dimensions (cm) are 228x112x170. The bed-ways are induction hardened & its hardness is around HRC 55. Foot brake, overload protection, chip guard, longitudinal automatic stop device, pointto-point control in spindle, manual lubrication pump ensures easy operation and good performance of the machine. Emtex Machinery Pvt Ltd New Delhi Tel: +91-011-49491666, Mob: 09899008130 Email: marketing@emtex.in Website: www.emtexmachinerylimited.com August 2012 - MODERN MACHINE TOOLS 149

Products - National Tool setters

Drill & Tap center

These tool setters for CNC lathes are used to detect the position of the tool (inserts) for compensation. When the tool is pressed against the H4A contact surface, high-accuracy signal is transmitted to the CNC controller indicating the position of the tool and the same is updated automatically. As a result, it is no longer necessary to repeat the process of trial grinding, measurement calculation, and inputting the data to CNC controller, thereby eliminating the need for expertise in tool setting. Moreover, tool wear and breakage can also be detected. The tool length can be automatically compensated in CNC controller by contacting the tool in single operation, hence avoiding the rejection of work piece.

The DT-1 is a compact, high-speed drill and tap machine with full milling capabilities. The machine has a 20” x 16” x 15.5” (xyz) work cube and a 26” x 15” T-slot table. A powerful BT30 taper inline direct-drive spindle provides 12,000 rpm, and allows rigid tapping at speeds to 5000 rpm. A high-speed, 20-pocket tool changer swaps tools quickly, while 2400 ipm rapids and high accelerations combine to shorten cycle times and reduce noncutting time. Other features include 15 hp vector drive, 15” color LCD monitor, built-in USB port.

Metrol Corporation India Bangalore - Karnataka Tel: +91-080-42105031 Email: sales@metrolindia.com Website: http://www.metrol.co.jp/en/

Turning centers The Haas ST-20 Series high-performance turning centers were designed from the ground up to provide set-up flexibility, extreme rigidity, and high thermal stability. Available in standard and Super Speed models, these 8” chuck machines offer the most performance for the money in their class. With available high-torque live tooling and C axis, it’s possible to machine multiple features and perform secondary operations in a single setup. Other features included A2-6 spindle nose, 2” Bar capacity, 15” color LCD monitor, built-in USB port and 1 MB program memory. Haas Automation India Pvt Ltd Navi Mumbai - Maharashtra Tel: +91-22-66098830 Email: indiasales@haascnc.com Website: www.haascnc.com

Looking For A Specific Product? Searching and sourcing products were never so easy. Just type MMT (space) Product Name and send it to 51818

eg. MMT EDM and send it to 51818

150 MODERN MACHINE TOOLS - August 2012

Haas Automation India Pvt Ltd Navi Mumbai - Maharashtra Tel: +91-22-66098830 Email: indiasales@haascnc.com Website: www.haascnc.com

Visual optical system VOS consists of a probe with VOP optical transmission, and a receiver with an integrated VOI interface. The proprietary optical system guarantees the best measurement performance and immunity from local interference, together with the convenience of in-process measurement, a wide transmission range, extended battery autonomy and ruggedness, which is capable of withstanding the most challenging machining environments. It features high immunity to interference, a large operating range and a wide transmission angle. It is also capable of handling multiple probes and can be used in conjunction with another VOS system in the case of dual spindle applications. Marposs India Pvt Ltd Gurgaon - Haryana Tel: +91-124-4735700 Email: sales@in.marposs.com Website: www.marposs.in

World radio system WRS system is a high precision gauge composed by a probe/ transmitter module (WRP) and a receiver/interface one (WRI). The applied transmission frequency band is 2.4 GHz, allowing that this single system is suitable for use in any application in most parts of the world. The spherical transmission characteristics and 15 m operating range make the WRS both flexible and powerful. The system automatically searches for the best signal among the 74 available radio channels in order to guarantee optimum

National - Products communication conditions between the probe and the receiver at all times. Additional 4 sub-channels permit to use multiple probes on the same machine by means of a simple NC selection code and extend the working channels up to 316. The WRI receiver interface features a unique remote programming and a four digit display, ensuring that important user messages are clear, immediate and precise, enabling the user to easy program and check the system. Marposs India Pvt Ltd Gurgaon - Haryana Tel: +91-124-4735700 Email: sales@in.marposs.com Website: www.marposs.in

Grinding machine This high precision doublesided fine grinding machine model DSG 720 is capable of fine grind less than 100 micron parts. It provides flatness less than 1 micron, parallelism less than 1 micron, surface finish of 0.25Ra to 0.15Ra. It has Siemens PLC interface & has auto thickness control (with non-contact measuring 0.08 Mic.). It incorporates easy wheel change-over from diamond / CBN / conventional.

Lapmaster India Pvt Ltd Chennai - Tamil Nadu Tel: 044-2834 4041 Email: sales@lapmasterindia.com Website: www.lapmaster.co.in

Laser cutting machine A mid-range high precision sheet metal cutting Brahmastra Prime uses latest laser technology in synchronization with hi-end CNC controller. It is equipped with 400 Watt / 500 Watt of laser having ASHS (Auto Sheet Height Sensing) mechanism. Other features include rapid pierce, low booting time (less than 2 min), optimized nesting software, bend and part number marking. It also has 2-phase rack design for smooth operation. Sahajanand Laser Technology Ltd Gandhinagar - Gujarat Tel: +91-79-23287461 Email: marketing@sahajanandlaser.com Website: www.sahajanandlaser.com

August 2012 - MODERN MACHINE TOOLS 151

Products - National Engineering slide charts It is a hand-held device in the form of a ready recknor. Engineering slide charts on various engineering related subjects like material chemical compositions, machine shop, fabrication shop, raw material sectional weights, gear designing; electrical, plastics, rubbers, ball bearings, o-rings & oil seals etc are available. While designing them, special efforts are taken to solve frequently asked questions (FAQ) and ancillary information related to the particular subject. Thus these charts are made handy, time saving and users friendly.

temperature. The guideways for the longitudinal and cross slides are moulded directly into the machine base and are provided with a non-abrasive slideway coating which guarantees highest possible accuracy. The machine has an open enclosure with sliding door. The B-axis with 2.5 deg Hirth can be manually swivelled in a range of -15 deg/+195 deg. So a 0° plunge machine can be changed to a 30° angular plunge configuration within seconds. Some technical specifications are: center distance is 650 mm, centre height is 175 mm & driving power is 9 kW (12 hp). Korber Schleifring Gmbh Bangalore - Karnataka Tel: +91-80-41554601 Email: sreekanteswar@schleifring.in Website: www.schleifring.in

Mangalmurty Techno Slides Ahmedabad - Gujarat Tel: 079-2573 0222, Mob: 91-942913228 Email: mangaltechno@rediffmail.com

Vortex Vortex has been developed to gain the maximum benefit from solid carbide tooling that can give deeper cuts by using the full flute length as the cutting surface. It can be used for two- and threeaxis roughing, positional five-axis area clearance and for rest machining. Vortex toolpaths are calculated to give more efficient machining by following the shape of the part and by keeping air moves to a minimum. They have a controlled engagement angle, so tools will never be overloaded, achieving maximum tool life. Shock loading due to changes in contact angle is eliminated, preventing chipping of the flutes. The stability of the cutting conditions gives constant edge temperatures & the ability to use step-downs of upto 2-3 times the tool diameter spreads the tool wear evenly over the cutting surface of the tool. Also, it has support for 64-bit computing and multi-processor operation to minimise calculation times. Delcam Software India Pvt Ltd Pune - Maharashtra Tel: 020-3061 3900 Email: india.marketing@delcam.com Website: www.delcam.com

Grinding machine The CNC universal cylindrical grinding machine StuderecoGrinder is based on the proven and high-quality STUDER components and the GRANITAN® machine base (mineral casting) which absorbs vibrations and maintains stable

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Multi spindle heads Suhner offers multi spindle heads for drilling and tapping applications. The multi spindle heads are available in both adjustable and fixed type center distances.They can be fitted on all types of machines like conventional drilling and tapping machines, machining centers or any other type of automatic drilling and tapping machines. Multi spindle are offered with high spindle accuracies,special multi spindles heads for carbide tools,compact, rigid and sturdy design. Suhner India Pvt Ltd Bangalore - Karnataka Tel: +91 -80-27831108 Email: blroffice.in@suhner.com Website: www.suhner.com

Magnetic chucks These pole chucks are equipped with a permanent display which informs the operator on the clamping status of the magnetic chuck.The magnetic chuck is fixed to the machine table, and then connected via a sealed quick release connector to the control unit. On activation, the light of the permanent status display turns to green. The display works independently from the power supply, and will also be visible, if the power cable has been disconnected after activation of the permanent magnet. With the MAGNOS square pole plates, work-pieces can be quickly clamped and are machined in one set-up from five sides. Schunk Intec India Pvt Ltd Bangalore - Karnataka Tel: +91-080-40538999,Mob: 09741211766 Email: info@in.schunk.com Website: www.schunk.com

National - Products Powerhouse for 5-axis machining The KONTEC KSX NC vise is a powerful clamping system for simultaneous 5-axis machining. This system disposes of toolfree adjustable clamping forces between 4 and 40 KN, which are measured directly at the work-piece. The support surfaces at a height of 211 mm ensure that the workpieces are easily accessible from all sides. The clamping mechanism avoids a chuck jaw flexing. These are ideal preconditions for precise machining of the second side. The drive and the adjustment mechanism of the 5-axis clamping vise are completely encapsulated and the easy-to-clean design avoids buildup of chip clusters. It fits smoothly into the SCHUNK modular system for highly efficient work-piece clamping. So the clamping pins of the VERO-S quick-change pallet system can be directly integrated into its base body. The clamping range lies between 0 250 mm, can be enlarged to 749 mm. Schunk Intec India Pvt Ltd Bangalore - Karnataka Tel: +91-080-40538999, Mob: 09741211766 Email: info@in.schunk.com Website: www.schunk.com

Parallel & woodruff keys Parallel keys are manufactured as per IS:2048/83 and woodruff keys as per IS:2294. These are made from EN-8/9 material in soft condition. They can also be made from SS-410 and SS-316. These keys are used in automobile industries, textile industries, machine tool industries, motor and pump industries & cement industries. R K Engineering Company Mumbai - Maharashtra Tel: +91-022-22671141 Email: rkeng@vsnl.net Website: www.rkengineeringco.com

Vertical bodymaker machines The ICON V-Drive is a vertical machine for the forming of can bodies (bodymaker) which boasts compact dimensions, extremely low material consumption and the possibility to process recycled materials. This generates up to 50 per cent more material savings than the extruded cans. Schuler India Pvt Ltd Mumbai - Maharashtra Tel: +91-022-66800330 Email: ninad.sant@schulerindia.com Website: www.schulerindia.com

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Products - National Plasma cutter

CAM software

Powermax105 is a new 105-amp air plasma system used for handheld and automated cutting and gouging. The system is designed to comfortably cut 32mm-thick metals, and sever metals up to 50mm-thick. It has faster cut speed, improved cut quality, and industry-leading consumable life. It has seven different torch options & ease of use with simple controls and patented SmartSenseâ&#x201E;˘ technology. These automatically adjust gas pressure for better, more efficient cutting, and also detect when consumables have reached the end of their lives

PowerMILL will be the first CAM program that calculates the route of a toolpath with reference to the characteristics of the machine on which it will be run. The new release of PowerMILL will incorporate Machine DNA Profiler, which performs automated tests on the machine tool to profile its performance. The results are fed back into the software and used to calculate the optimum toolpath for that machine. Other parameters, such as corner radius and point spacing, are automatically set by PowerMILL, based on the results from the Profiler. It replaces the trial-and error approach to programming by allowing right-first-time toolpaths to be generated on a consistent basis.

Hypertherm (India) Thermal Cutting Pvt Ltd Chennai - Tamil Nadu Tel: +91-044-28345361 Email: htIndia.info@hypertherm.com Website: www.hypertherm.com

Portable measurement arm This six-axis portable measurement arm (prime) is available in four lengths from six to twelve feet (1.8m to 3.7m).The arm is also bluetooth equipped, eliminating the need to connect the device to a laptop.An extended-use battery and composite material construction ensure shop floor durability, day after day. Together, these features make the Prime the ideal solution for basic measurements in inspection, reverse engineering & CAD-to-part analysis. FARO Business Technologies India Pvt Ltd New Delhi Tel: +91-011-46465656 Email: enquiry.india@faro.com Website: www.faro.com

Delcam Software India Pvt Ltd Pune - Maharashtra Tel: 020-3061 3900 Email: india.marketing@delcam.com Website: www.delcam.com

Electronic level This high precision electronic level has a magnetic base that securely attaches the gauge to any metal surface. It has a large LCD display reads upright at any angle. It has the provision of absolute measurement and reference measurement conversion, degree/slope conversion & measure data holding. Other features include back-light, buzzer & auto power off. The battery type is 3V CR2032X3. India Tools & Instruments Co

Digital laser scanner Nikonâ&#x20AC;&#x2122;s superior optics is combined with innovative 3D laser scanning technology as digital laser scanner LC15Dx, and brings laser scanning in the accuracy range of tactile inspection. It is a viable alternative to a tactile probe for an increasing number of high precision CMM applications; including moulds, small turbine blades, medical devices and other complex geometry. A wider variety of parts, geometry and materials can be measured more effectively, including many parts too small or fragile for a touch probe. The application extends to pilot plant metrology, automotive components inspection, aircraft component inspection, surface analysis, sheet metal inspection etc.

Mumbai - Maharashtra Tel: 022-2342 8862,09819345050 Email: itico@vsnl.com Website: www.indiatools.net

Rail systems Low friction rail systems are designed for smooth and low friction movement of material. The rolling surfaces, trolley guidance and articulation suspension systems enable the operator to move loads with rolling effort of less than 1 per cent. The rails are available in different sizes depending on the load capacity. ARM Welders Pvt Ltd

Nikon India Pvt Ltd Gurgaon - Haryana Tel: 0124-468 8500 Email: ateet.kaushik@nikonoa.net Website: www.nikonmetrology.com

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Pune - Maharashtra Tel: +91-020-27120063

Mob: 09822039805 Email: brijesh.khanderia@armwelders.com Website: www.armwelders.com

National - Products Line shafts These line shafts are with split hubs and metal bellows or servo inserts. They have features like backlash-free, high torsional stiffness, precise transmission of rotational angle, maintenance free, low inertia, compensation of radial, axial and angular misalignment etc. They are available upto torques of 525 Nm in case of servo insert type and 500Nm in case of metal bellow type. Normally, it is available with split hub type. The maximum length of the line shafts with servo inserts/metal bellows are 4000mm. Rotolinear Systems Bengaluru - Karnataka Tel: +91-080-23572855,9845196751 Email: rotolinearindia@vsnl.net Website: www.rotolinearindia.com

Fibre discs The COMBICLICK fibre discs comes with differing grit sizes to suit a multitude of applications, from coarse grinding to fine finishing. They are used with matching backing pads and conform to ISO 15636 on standard commercial angle grinders. Other

features are provisions up to 25% increased stock removal, up to 30% lower work piece temperature & up to 30% longer service life; saves time by up to 75% through fast disc change, greater user comfort, reduced stress on power tool, lower noise generation & less vibration. PFERD-SWIT Bengaluru - Karnataka Tel: 080-4218 7117,097414 81117 Email: mathew.jacob@pferd.com

CNC Punching software The Radpunch is a CNC punching software having several enhanced features wherein the sheets can be automatically cut off on punching and combination machines, to create offcuts. It has the provision of sophisticated tagging, securing the remnant in place while unloading the sheet skeleton. The rectangular nesting algorithm for single parts has been enhanced to show increase in material utilisation. Visual feedback in the order mode list shows the stages of processing i.e. whether the tool is not processed/partially processed/all processed. RadCAM Software solutions Bangalore - Karnataka Tel: +91-080-42007936 Email: siddhu@radcamsoftware.com Website: www.radcamsoftware.com

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Products - National CNC milling machine

Boring tool system

This machine has a rigid body structure which makes it stable; wide linear guideways support axis weight proportionally. Cast iron bed is mounted on wide gap to absorb workpiece weight & vibration. Bigger diameter high precision ball screw ensures accuracy and repeatability for faster & smooth operation. High frequency spindle is most suitable for polish finish and small diameter cutter at high RPM. Fully enclosed body prevents chip evacuation from harming operator. Other features include low power consumption, single/3-phase option, and automatic lubrication to ensure all axis lubrication properly.

The new large diameter boring tool system by KAISER combines various technical highlights like super light execution, which ensures minor stress for operators and presetter spindles & offers operating safety up to Vc 2’000 m/min and therefore full HSC capability. The boring range is Ø 200 – 340 mm for ISO 40 and HSK-A63 spindles; Ø 200 – 620 mm, extendable up to 3’000 mm for ISO 50 /HSK-A100 and larger spindles. The simple handling of the components virtually eliminates operator error during assembly and leads to almost 100% safety during operation. High strength and hard coated aluminium and nickel coated steel components provide scratch resistant and rust protected surfaces and ensure a long tool life.

Multi Axis CNC Robotics Gurgaon-Haryana Tel: 98104-55354 Email:-raj.kush@hotmail.com,info@multiaxisrobotics.com Website: www.multiaxisrobotics.com

Formdrill This machine is used for thermal drilling and forming bushings. All malleable materials can be thermal drilled. There is absolutely no cutting involved during the creation of the hole. A standard drill press, milling machine or CNC machining center is suitable. Thermal Drilling is ideal for automation because it is a chipless process, produces accurate holes, and has a long tool life. No secondary equipment is required here. Unimex Formdrill India Pvt Ltd. Bangalore - Karnataka. Ph: 080-41229402, Mob: 09036291674 Email: roopesh.amin@formdrill-india.com Website: www.formdrill-india.com

Production grinder The ANCA MX5 is the latest machine tailored to meet the needs of volume tool production customers. It is a powerful, versatile, next- generation grinding machine. The MX5 is a hard-working, high-productivity system with unique features that make it capable of handling varied batch sizes with minimum set-up time. It is optimized to grind tools up to 16 mm (5/8”) diameter. It has the option to be fitted with the RoboMate loader, which provides high-capacity loading with a small footprint. Other features include diameter range between 3 mm to 32 mm, tool length up to 250 mm, tool head diameter up to 32 mm & 15-second tool change time.

Quattro Engineering India Ltd Bangalore - Karnataka Tel: +91-80-25585439 Email: toolings-info@quattroengg.com Website: www.quattroengg.com

Cylindrical grinding machines CNC cylindrical grinding machines (model SWIFT-500) are designed to cater to customers’ requirements of high accuracy, productivity and reliability of performance. These machines are suitable for production as well as toolroom applications. The machines come with Siemens 802D CNC system and are 2-axis and single spindle controlled. Hi-Life Machine Tools (P) Ltd Ahmedabad - Gujarat Tel: 079-22821615, Mob: 09898083890 Email: info@hilifegroup.com Website: www.hilifegroup.com

Portable radial drills These portable radial drills are available with universal drill heads designed to offer rigidity, precision and flexibility to drill at any angular direction. The drill head swivels on 2 planes, 90-degree up and down, and the 360-degree rotational movement makes possible the drilling operation at any angular direction. Model UR30 has a 30-mm drilling capacity in steel.

ANCA Machine Tools Pvt Ltd

Arsun Engineers

Bangalore - Karnataka Tel: +91-80-42198107 Email: prashanth@anca.com Website: www.anca.com

Bhavnagar - Gujarat Tel: 0278-2514076, Mob: 9426816961 Email: info@arsun.com Website: www.arsun.com

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MMT Aug-2012 Ad Name: Samkrish Pg No. 157

MMT Aug-2012 Ad Name: HIMTEX 2012 Pg No. 158

HIMTEX 2012

MMT Aug-2012

Ad Name: Hyundai Pg No. 159

MMT Aug-2012

Ad Name: EngExpo Pg No. 160

National - Products Hydraulic shearing machines Trimans variable rake angle NC hydraulic shearing machines are built as per International Standards in a range of 4 mm to 16 mm sheet thickness and length of 1500 mm to 5000 mm. Two hydraulic cylinders mounted on the cutting beam provide the shearing force. Synchronising of the two cylinders by differential area principle simplifies the hydraulic circuit. NuGen Machineries Ltd Ahmedabad - Gujarat Tel: 02717-250380 Mob: 09374698657 Email: info@nugenindia.com Website: www.nugenindia.com

Swiss rotary table Series 500 with gear drive is a new generation of 4th & 5th axis rotary tables with 170 different end combinations from its basic four models, viz, 507, 510, 520 and 530. The highly flexible combiflex system allows modular conversion at any time to adapt changed production & process requirements. All rotary table models are compact and fully sealed in compliance with IP67. Stitch Overseas Pvt Ltd Gurgaon - Haryana Tel: 0124-4755400 Email: stitch@vsnl.com Website: www.stitchtools.com

Lathe machines Balaji series VGL geared head light-duty lathe machines have height of centre 165 mm, length of bed ranging up to 1820 mm, admit between centres up to 1135 mm, main spindle hollow 38 mm, and main spindle nose A2-4 or threaded type. Dynamically balanced spindles enable the spindles to run at vibration-free motion at 1200 RPM. Vinit Engimech Pvt Ltd Rajkot - Gujarat Tel: 0281-2312091 Email: vinit@blalajilathe.com Website: www.balajilathe.com August 2012 - MODERN MACHINE TOOLS 161

Products - National Servo controlled voltage stabilisers Servo controlled voltage stabilisers are designed to ensure that their output voltage remain constant irrespective of voltage swings in the incoming power supply. The standard input:340-480V; standard output: 415Âą1 per cent; response time: less than10 msec; rate of correction: 105V/sec etc. Neelkanth Power Solutions Mumbai - Maharashtra Tel: +91-022-25922511

Mob: 9867382364 Email: hm@neelpower.com Website: www.neelpower.com

Servo mechanical presses These servo mechanical presses have the slide driven by high torque AC servomotors with eccentric link mechanism through a gear train. Features of these presses are programmable slide stroke, tonnage, speed and slide reversal at any position. Stepless programming of the slide for speed, acceleration & deceleration allows different slide motion profiles. Electropneumatics & Hydraulics (India) Pvt Ltd Pune - Maharashtra Tel: +91-2135-667500 Email: epchakan@electropneumaics.com Website: www.electropneumatics.com

Intensifier pump systems These pump systems deliver 3.1 litre / min of high pressure water at a pressure of 3,800 bar (55,000 psi). The pumpâ&#x20AC;&#x2122;s power positions are in the medium range, allowing it to supply one waterjet nozzle of up to 0.30 mm diameter or two 0.23 mm nozzles. Karolin Machine Tool (KMT) Pvt Ltd Mumbai - Maharashtra Tel: +91-022-28572494 Email: bhavin.mavani@kmt-waterjet.com, Website: www.kmt-waterjet.com

Hydraulic press brakes The hydraulic press brakes advanced proportional valve synchronises its hydraulic cylinders for better parallelism. This provides automatic tonnage adjustment and stroke adjustment for bending angles. The press brakes have 4 axis CNC standard with 2D colour 15 inch touch screen panel. It adds more RAM and back gauge speed for production efficiency. MC Craftsman Machinery Pvt Ltd Coimbatore - Tamil Nadu Tel: +91-422-6615200 Email: mccm@mccm.in, Website: www.mccm.in 162 MODERN MACHINE TOOLS - August 2012

National - Products Universal grinding machines

Devco Industries

These are light- and heavy-duty machines (model HEW 450) for high-precision grinding of gauges dies and punches for toolroom application with accuracy on diameter 0.002 micron. The one-piece machine body is made from closed grain casting maximum grinding length of 450 mm and height centre 130 mm. Tables are flat on one side and V-shaped on the other side.

Wadhwan - Gujarat Tel: 02752-243997 Mob: 09825343097 Email: devco1980@yahoo.com Website: www.devcogrinders.com

Hydraulic press brakes The NC synchro hydraulic press brakes are available in the capacity of 20 MT x 1500 to 500 MT x 6000 mm. The tough, well dimensioned all-welded structure is made out of IS2062 gr B silicon killed and ultrasonically tested steel plates to withstand continuous & minimum deflection

Hitesh Engineering Works Wadhwan - Gujarat Tel: 02752-241926, Mob: 09879877780 Email: info@precisiongrinders.com Website: www.precisiongrinders.com

Cylindrical grinding machines Universal cylindrical grinding machines (model UC-150) are available in eight different models. Castings are close grained and well ribbed to minimise vibration and distortion. Wheel head spindle runs on bush bearings. Regulating wheel spindle runs on taper roller bearing. Tailstock, wheelhead and workhead spindle are heat-treated to achieve dimensional stability and performance roundness of <0.005 mm.

under full load. NuGen Machineries Ltd Ahmedabad - Gujarat Tel: 02717-250380 Mob: 09374698657 Email: info@nugenindia.com Website: www.nugenindia.com

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Products - National Surface grinding machines The design of these machines makes easy movement of reciprocation table that provide V & flat guideways lining with Turcite–B for easy movement. These are hand-scraped to fine tolerance. The manual surface grinding machines have working surface with manual oil dip of 225 mm x 450 mm & 300 mm x 600 mm and are also hydraulic.

include date/time setup controls; max, min, DIF, AVG record & dew-point & wet bulb temperature. Specifications include response time: less than 300ms, optical resolution is 50:1 Distance to spot size etc. India Tools & Instruments Co Mumbai - Maharashtra Tel: 022-2342 8862,09819345050 Email: itico@vsnl.com Website: www.indiaitools.net

Atul Machine Tools

Anti-vibration mounts & pads

Rajkot - Gujarat Tel: 0281-6542034 Mob: 09825343097 Email: info@atulmachine.com Website: www.atulmachine.com

These machinery mounts are designed to support heavy equipment and isolate intermittent or continuous vibration. This results in greater machine accuracy, longer service life, smoother operation and reduced maintenance. Varied mounts are available to suit different needs. Screw support mounts (series DL) for machines having tapped holes in the base.

Thermometer This infrared thermometer has an IR range between 50 to 2200 deg C 2.2’’ TFT 320 x 240 pixels color LCD display & camera resolution of 640 x 480 pixels. It supports images in JPEG & video in 3GP format. It has provision for micro SD memory card (upto 8 GB), dual laser targeting & USB interface, language selection (English/ French/ German/Spanish). Other features

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Dynemech Systems Pvt Ltd Delhi Tel: 011-27347982 Mob: 09810760131 Email: sales@dynemech.com Website: www.dynemech.com

National - Products CNC lathes Smarturn CNC lathes have high-precision spindle and large diameter high-speed bearings. These machines incorporate vibrationfree fed mechanism using anti-friction LM guides, hydraulically clamped massive turret & minimal thermal displacements that ensure closer pat tolerances and excellent repeat accuracies. As standard, all machines are laser calibrated for compensation of pitch error and backlash. Lakshmi Machine Works Ltd Coimbatore - Tamil Nadu Tel: 0422-2360512 Email: mtdsales@lmw.co.in Website: www.lmwcnc.com

Mini machining centres These machining centres (model MCV-2412) feature Fagor 8040MC 11â&#x20AC;? LCD monochrome, large fully ground work table with 4 T-slot, precision ground ball screw, fully ground way mating surface with Turcite-B, heavily ribbed cast iron components, ISO40 spindle, etc. Large outlet for chips and coolant water enable the recycle run smoothly. Machine Tools Traders (Madras) Chennai - Tamil Nadu Tel: 044-2522 0485 Mob: 09940063403 Email: nehal@mtt1970.com Website: www.mttmadras.com

Mechanical presses The mechanical presses have symmetrical front - rear column structure design which minimises deflection and is suitable for precision progressive die applications. The zero angle deflection of frame and cost effective tooling maintenance work are the some of its features. The clutch brake provides long life operations and minimum maintenance. Goodwill Imex Bangalore - Karnataka Tel: +91-080-26278815 Email: gwimex@gmail.com August 2012 - MODERN MACHINE TOOLS 165

Products - National Graphic user interface

Schuler India Pvt Ltd

Uticor Tough series Graphic User Interface (GUI) has either stainless steel or aluminum bezel and is robust, NEMA 4X, IP66, Class I, Div II, and conformal coated. This can connect to more than 90 per cent of the PLC. This has universal communication capability to Profibus, DeviceNet, DH485,Ethernet IP etc.

Mumbai - Maharashtra Tel: +91-022-66800330 Email: ninad.sant@schulerindia.com Website: www.schulerindia.com

AVG Electronics Pvt Ltd Bangalore - Karnataka Tel: +91-80-23193305/444111 Email: info-india@avg.net Website: www.avg.net

Bending machines The bending machines (Xpert) have perfect integration of cutting and bending processes. The minimised scrap yields higher productivity. All major tool styles can be used on this machine and are supported by the controlâ&#x20AC;&#x2122;s comprehensive database. Simple and convenient operation of the whole machine is possible including its control.

Boring bars Kaiser CKN tool connection is based on a three screw assembly with steel double pin connectors and solid aluminium extension tubes. This is compatible with CKB components. SK and HSK shanks for boring bars with outer diameter 63.5 mm and 90 mm are produced to fit with double pin connectors.

Bystronic Laser India (Pvt) Ltd

Quattro Engineering India Ltd

Robotic bending machines

Pune - Maharashtra Tel: +91-020-67294800 Email: kavita.hatwalne@bystronic.com Website: www.bystronic.com

This robotic bending machine is equipped with a specially designed bending head mounted on a 6-axes robot integrated with a tube magazine. The machine performs unmanned operations such as tube loading, bending and unloading with minimum cycle time. The centre line radius maximum is 30 mm and minimum

Bangalore - Karnataka Tel: +91-80-25585439 Email: bangalore@quattroengg.com Website: www.quattroengg.com

Industrial cleaning system Industrial cleaning system-Universal 81W provides access for maintenance. In this cleaning and drying process is in enclosed working chamber. Modular 2 or 3 tank system is offered for multistage washing and rinsing, and preservation processes. This is used for removing water based coolants, oils, & fine cleaning of assembly parts.

is 12 mm. Electropneumatics & Hydraulics (India) Pvt Ltd Pune - Maharashtra Tel: +91-2135-667500 Email: epchakan@electropneumaics.com Website: www.electropneumatics.com

DĂźrr Ecoclean Pune - Maharashtra Tel: 020-30585001/02 Email: info.india@ecoclean.durr.com Website: www.durr-ecoclean.com

Die forging systems The die forging systems provide precise positioning of the forging and allow automatic operation and repeatability of proven forging methods. The automatic forging installation produces forgings to close tolerances at high production rates. In addition, the actual steps are used for manufacturing the forging recorded for quality purposes. 166 MODERN MACHINE TOOLS - August 2012

Laser cutting machines The laser cutting machines are used in sheet metal processing industry. High precision of the dimensions and minimum heat distortion of the sheet parts are the advantages of these machines. Unprecedented parts output in the thin-sheet-metal range in high-tech fiber laser are combined with mature machine technology. Bystronic Laser India (Pvt) Ltd Pune - Maharashtra Tel: +91-020-67294800 Email: kavita.hatwalne@bystronic.com Website: www.bystronic.com

National - Products 2D laser machines The 2D laser machines, builtin control panel, window into the workpiece area and a barcode reader all make for easy operation. These deliver low running costs and eco-friendly features for power and gas consumption, and stable operation for up to 1.4 times greater productivity.

for up to 128 directly connected I/Os with CC-Link remote I/ Os. These have a high processing speed of 0.21 micro seconds as per Boolean instruction. Messung Systems Pvt Ltd Pune - Maharashtra Tel: +91-20-27102000 Email: marketing@ms.messung.com Website: www.messung.com

Waterjet cutting systems The waterjet cutting systems (Streamline PROI) avoids thermal stress on the material as well as material hardening or warping. Moreover, the systems provide burr-free cutting edges along with a cutting edge quality, so the expensive reworking of the work pieces is eliminated.

MC Craftsman Machinery Pvt Ltd Coimbatore - Tamil Nadu Tel: +91-422-6615200 Email: mccm@mccm.in Website: www.mccm.in

Programmable logic controllers The FX3G programmable logic controllers are designed to cater to a variety of applications that are performancecritical. These facilitate flexibility and control

Karolin Machine Tool (KMT) Pvt Ltd Mumbai - Maharashtra Tel: +91-022-28572494 Email: bhavin.mavani@kmt-waterjet.com Website: www.kmt-waterjet.com

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Products - National Cross shaft mechanical presses

Ferro Industries

The cross shaft mechanical presses have high torque, low noise and wet clutch brake. This has rigid frame with less deflection, high accuracy transmission gears, forced lubrication with feedback system and all function electric system. This has strong crank shaft with outstanding rigidity and quick responsive overload system.

Ghaziabad - Uttar Pradesh Tel: +91-120-4154384 Email: info@ferroindustriesindia.com Website: www.roll-formingmachines.com

CNC synchro press brakes The CNC synchro press brakes structure is precisely machined for long life and built in accuracy. The cylinders are connected with ram and piston is hard chromed with low friction and has long life sealing. The machine is equipped with delem controller to achieve ram parallelism within the defined accuracy.

Goodwill Imex Bangalore - Karnataka Tel: +91-080-26278815 Email: gwimex@gmail.com

Cross shaft power presses This cross shaft power press, bNX series, is used for blanking, forming piercing and drawing applications. This press offers the ultimate possible resistance to slide tipping and off centre loading. The guides are designed with extra length and surface area to provide better possible resistance.

Weldor Engineering Pvt Ltd Rajkot - Gujarat Tel: 0281-2360242 Email: weldor@weldor.com Website:www.weldor.com

Swastik Entech Pvt Ltd

Tube straightening machines

Gandhinagar - Gujarat Tel: +91-079-23287112 Email: info@swastikentech.com Website:www.swastikentech.com

The tube straightening machines are available in single speed, duel speed and with stepless speed variation. High speed of 120 metre per minute is easily achievable. The straightening is done without any marking inside and outside of the tube, giving it a good finish, thus imparting skin hardness to the tube.

Die protection system ProActive die protection - M1200 unit is equipped with 4 sensor inputs, 4 PLS outputs, 4 counters with electromechincal relays. This features broken resolver coupling/chain detection, resolver slippage & broken cable detection, built-in diagnostics, pre-built library of sensor names, choice of e-stop or top-stop, motion detector and brakewear monitor etc.

ITL Industries Ltd Indore - Madhya Pradesh Tel: +91-0731-3044400 Email: itlindia@sancharnet.in Website:www.itl.co.in

Taper pins AVG Electronics Pvt Ltd Bangalore - Karnataka Tel: +91-80-23193305,444111 Email: info-india@avg.net Website: www.avg.net

Hydraulic crimping presses The hydraulically operated press brake machine is steel fabricated. This machine is equipped with the side guides which are used to provide sufficient stroke, to the dies for bending the sheet into the desired shape. The upper die moves up and down in the vertical guides.

168 MODERN MACHINE TOOLS - August 2012

They are preferred for parts which have to be taken apart and when driving out the cylindrical pins would tend to wear the holes. These pins are also used to vary accurate constructed tools and gauges that have to be kept in proper alignment. They are manufactured as per DIN 1 and IS: 6688-1972. The taper pins are supplied soft condition from EN8 material and natural finish unless otherwise specified by the customer. R K Engineering Company Mumbai - Maharashtra Tel: +91-022-22671141 Email: rkeng@vsnl.net Website: www.rkengineeringco.com

National - Products Leak-test equipment Leak-test equipment is light weight leak test computer with aluminium housing single-knob operation. It is equipped with simple and clear menu with Windows technology. It has large date storage capacity that measures result and has data change & storage via memory stick. Its 100 test programs are programmable and storable. Innomatec India Pvt Ltd Pune - Maharashtra Tel: +91-020-24690055 Email: no_leak@innomatecindia.com Website: www.innomatec.com

2D laser cutting machines The high speed 2D laser cutting machines work with the flying optics principle. In this design, the raw sheet rests on the cutting table and the laser head moves in both X and Y direction. In these machines the

frame and the gantry are welded and then stress is relieved. Durmazlar Makina Sanayi Bursa - Maharashtra Tel: +90 -0224-2191800 Email: durma@durmazlar.com.tr Website: v1.durmazlar.com.tr

Servo controlled voltage stabilisers Servo controlled voltage stabilisers are designed to ensure that their output voltage remain constant irrespective of voltage swings in the incoming power supply. The standard input:340-480V; standard output: 415Âą1 per cent; response time: less than10 msec; rate of correction: 105V/sec etc. This is applied in pharma, automotive, steel, data centres etc. Neelkanth Power Solutions Mumbai - Maharashtra Tel: +91-022-25922511 Mob: 9867382364 Email: hm@neelpower.com Website: www.neelpower.com

August 2012 - MODERN MACHINE TOOLS 169

Products - International Multi-flute thread mills

Vertical turning centres

The expanded range of TMSD multi-flute, single point thread mills are supplied with cutting diameters from 13mm and up to 36.5mm, and in pitches from 0.5mm up to 8mm (48 to 3 TPI),adjustable overhang (up to 144mm) for optimal stability. It features through-tool cooling for fast chip evacuation and cool cutting–essential for deep hole applications. TMSD shell mill tools are also available from VARDEX and in cutting diameters up to 98mm and maximum thread lengths of 200mm.

These are double-column vertical turning centres available in model VTR160A. The doublecolumn design provides rigidity along with high machining capacity. Thermo-friendly concept provides outstanding thermo stability for highly accurate machining. Thermal deformation overtime is less than 20 μm. Cross rail travel is 600 mm, Z-axis travel is 900 mm and maximum load is 10,000 kg.

Vargus Ltd

Okuma Corporation Ltd Aichi - Japan

Nahariya-Israel Tel: +972-4-9855111 Email: mrktg@vargus.com Website: www.vargus.com

Tel: +81-58795-7825 Website: www.okuma.co.jp

Wire cutting EDMs Servo motor The Fanuc AC servo motor Beta-iS series is a high performance servo motor suited to feed axis of machine tools and industrial machines. It has optimized pole structure & mechanical design makes smooth rotation of feed axis possible. Compact and high-resolution pulse coder contributes to precise axis feed(resolution:128000/rev). The protection level is IP65.

The TP series wire cutting EDMs incorporate various innovative proprietary technology and patents. WEDM allows for non-streak surface for unmatched machining roughness and multi-cutting capabilities for high precision accuracy. In addition, also offered are two distinctive wire cutting EDM products based on the TP series, TP-W series and TP-SD series.

GE Fanuc Automation Europe SA, Germany

Troop Investments Pte Ltd

Germany Tel: +49-352-7279 79213 Email: ingo.kaiser@gefanuceur.ge.com Website: www.fanucrobotics.com

Singapore Tel: +65-67420778 Email: singapore@troop-online.com Website: www.troop-online.com

Electromagnetic chuck

Synthetic compressor lubes

This permanent electromagnetic chuck GLI type is suitable for CNC machine center. It magnetizes in 1.5 seconds and demagnetizes in 1.5 seconds, increasing working efficiency. The magnetism is able to last for a very long time. Instant power outages will not damage workpieces or hurt the operator. It saves electricity and gives no heat problems & has a long operating life. No deformation & provides high-accuracy performance (within 1 μm). Also, power shuts off automatically after magnetizing.

quality.

Guang Dar Magnet Industrial Ltd.

Rock Valley Oil & Chemical Co

Taichung City- Taiwan Tel: +886-4 2436 0757, Fax: +886-4 2436 6225 Email: info@guangdar.com.tw Website: www.guangdar.com.tw

Illinois - USA Tel: +1-0815-6542400 Email: sales@rockvalleyoil.com Website: www.rockvalleyoil.com

170 MODERN MACHINE TOOLS - August 2012

The PAO synthetic compressor lubes 3000 series are designed to meet the lubrication requirements of most compressors. The synthetic compressor lubes 3032, 3046, and 3068 are used in oil-flooded rotary vane and screw compressors. These are used in reciprocating compressors

Products - International Spindle motor

Tray-conveyer armature production line

The Fanuc spindle motor Beta-iI series is a high performance motor suited to spindle axis of machine tools. High efficiency & low heat generation is achieved by SPINDLE HRV control. Optimized winding design & effective cooling structure enables high power and high torque. The compact size of the motor is an added advantage.

S2 tray-conveyer armature production line is designed for ensuring high production efficiency, consistence quality of motor armature. Each machine in the line takes armature automatically from the tray conveyer, same function machine has separated conveyer to ensure the maximum production efficiency distribution, & operates with 7’’-10.4’’ touch screen.

GE Fanuc Automation Europe SA, Germany Germany Tel: +49-352-7279 79213 Email: ingo.kaiser@gefanuceur.ge.com Website: www.fanucrobotics.com

Ningbo Nide Mechanical Equipment Co Ltd Zhenjing - China Tel: +86-574-87295682 Email: sales@nide-international.com Website: www.nide-international.com

Modular boring system Cold forming machine Cold forming machines NedBase is relevant for a wire diameter of 10 mm and product lengths of 80 mm. This is kept running smoothly at speeds up to 240 products per minute, & allows producing fasteners (M5-M8). This offers tool protection in case of overload, variable AC speed motor etc. Nedschroef Herentals NV Herentals - Belgium Tel: +32 (0) 14 257100 Email: info@nedschroef.be Website: www.nedschroef.be

Plate bending machines Hydraulic plate bending machines of Akyapak AKBEND are produced with 3 and 4 rolls. With 2 mm200 mm thickness and width of 1000 mm 12000 mm sheet metal performs high quality twisting without having a difficulty. The control panel system is submitted with CNC and NC options. Akyapak Makina SanVeTic Ltd, Sti Bursa - Turkey Tel: +90-224-2807500 Email: info@akyapak.com.tr Website:www.akyapak.com.tr 172 MODERN MACHINE TOOLS - August 2012

The model B72 large diameter modular boring system is flexible. Its flexibility allows the system to easily adapt to process various more big sizes and depth of the hole of the diameter. The modular boring system assemble with taper shank, plate, large diameter body, balance holder, cutting insert holder and reverse cutting insert holder. It has two system, one is adjustable twin cutter roughing & semi-finishing boring system; and the other is finishing cutter fine boring system. Stanny Machine Tools Co Ltd Taichung Hsien - Taiwan Tel: +886-4-26710805 Email: stanny88@ms45.hinet.net Website: www.stanny-tool.com

Multi-spindle automatic lathe The multi-spindle automatic lathe is offered in CNC, non-CNC and partly CNC version. This machine is also available in 6-spindle and 8-spindle types right from 20 mm diameter to 67 mm diameter bar sizes. The machine is also equipped with chucking system together with automatic loading and unloading magazines. Tajmac-ZPS as Malenovice - Czech Republic Tel: 420-577-531111, Mob: 09845370604 Email: dwivedi@tajmac-zps.cz Website: www.tajmac-zps.cz

The information published in this section is as per the details furnished by the respective manufacturer/distributor. In any case, it does not represent the views of

List of Products

Looking For A Specific Product? Searching and sourcing products were never so easy. Just type MMT (space) Product Name and send it to 51818

eg. MMT EDM and send it to 51818 Product

Pg No

Product

Pg No

Product

Pg No

2D laser machine .................................167,169

Boring machine ...............................................161

CNC machine tool .........................................159

3 axes high speed machining centre .................13

Boring mill ......................................................151

CNC machining center..........................10,13, 18

5 axes high speed machining centre .................13

Boring tool system ..........................................156

CNC mill ..........................................................49

5 axis machining centre.....................................79

Buffing powder .................................................39

CNC milling machine ............................... 49,156

Abrasive .................................................... 153

Building automation .......................................116

CNC multi-tasking centre ................................10

Abrasive belt grinder .......................................162

Burnisher .........................................................131

CNC oxy fuel cutting machine.......................116

AC gear motor ..................................................26

C.I. Casting ............................................... 161

CNC plasma cutting machine ........................116

AC servo motor ................................................26

Cabinet ............................................................173

CNC precision lathe .........................................40

Advance cutting material ..................................29

Cable & hose carrier .......................................165

CNC punching software .................................155

Aerosol multispray ..........................................105

Cable carrier ......................................................12

CNC synchro press brake ...............................168

Air index .........................................................167

Cable conduit ....................................................31

CNC systems (open PLC & closed PLC type) ..109

Airline fluid .....................................................105

Cable connector ................................................12

CNC toolholder ................................................55

All geared auto feed pillar drilling machine ...169

CAM follower .................................................162

CNC turning center................................... 13,133

All geared planning machine ..........................161

CAM software ................................................154

CNC turn-mill centre .......................................10

Allen cap .........................................................163

Carbide endmill tool ....................................... BC

CNC vertical turning lathe ...............................10

Allen CSK .......................................................163

Carbide rod .....................................................113

Coating machine .............................................116

Analog timer ...................................................177

Carbide tool ......................................................95

Coating plant ..................................................116

Angle encoder ................................................BIC

Carpet extractor...............................................131

Coating system ................................................116

Anti-vibration mounts & pad .........................164

Casting ..............................................................63

Collet chuck ...........................................40, 55,76

Assembly & high temperature grease .............105

Ceramic ...........................................................183

Combination machine.....................................131

Auto feed radial drilling machine ...................169

Cermet ............................................................183

Commercial vacuum cleaner ...........................131

Automated guided vehicle ................................89

Chain.................................................................12

Complete locking at a stop .............................167

Automation .......................................35, 116, 153

Chain oil .........................................................105

Compressor oil ................................................105

Automation product ........................................127

Clamping tool ................................................. BC

Connector....................................................12, 53

Ball bearing ...........................................71,135

Cleaner ............................................................145

Control cabinet .................................................53

Ball screw ........................................................155

CMM ..............................................................179

Control panel ....................................................53

Ball screw support shaft ..................................155

CNC..............................................................5, 13

Control system ..................................................53

Ball screw support unit ...................................155

CNC cutting machine ....................................116

Controlling machine tool ...............................BIC

Ball speed reducer ...........................................167

CNC double column machining centre............10

Conventional phase failure relay .....................177

Bar feeder ..........................................................37

CNC equipment ...............................................33

Conventional precision lathe.............................62

Bearing ......................................................12, 135

CNC horizontal borer.......................................79

Conveyor lubricators and barrel pump .............83

Bench grinder cum polisher ............................162

CNC horizontal boring & milling machine .....10

Coolant pump .................................................162

Bending machine ............................................166

CNC horizontal machining centre ...................10

Coromill ........................................................FGF

Bengaluru Space Expo 2012 ...........................181

CNC horizontal turning centre ........................10

Corothread ....................................................FGF

BMT tool holder ............................................149

CNC laser cutting machine ............................116

Corrosion preventive .......................................145

Boring bar .................................................. 39,166

CNC lathe....6,11,13, 49, 62, 74, 79,133,149,165

Counters & power supplies........................ 15,177

174 MODERN MACHINE TOOLS - August 2012

List of Products Product

Pg No

Product

Pg No

Product

Pg No

Countersink ................................................FIC, 8

.................................................................167

Hydraulic chuck ................................................76

Cross shaft mechanical press...........................168

Flexible shaft grinder ......................................162

Hydraulic crimping press ................................168

Cross shaft power press...................................168

Floor plate .......................................................161

Hydraulic forging hammer..............................164

Crush blade .................................................50, 51

Form measurement ...........................................27

Hydraulic machine ............................................37

Customised tooling solution .............................76

Formdrill .........................................................156

Hydraulic press................................................164

Cutting fluid ...................................................145

Freewheel-one-way-clutch ..............................162

Hydraulic press brake .......................... 45,162,163

Cutting machine .............................................116

Fuel injection system.........................................76

Hydraulic shearing machine............................161

Cutting oil .........................................................39

Fully threaded bar ...........................................163

Hydraulic valve housing ....................................76

Cutting tool....43, 50, 51,73, 75, 93, 95, 113,183

Gantry and NC boring and milling machine .74

Imaging & vision system ............................ 116

Cyclone scrubber .............................................131

Gantry machining center ................................151

IMS 2012 ..........................................................20

Cylindrical grinding machine..................... 11,156

Gas spring ...................................................68, 14

IMTMA - finishing school summit ...............136

Damper ..................................................... 115

Gear box ....................................................14, 155

Indexable cutting tool .......................................39

Diamond tool .............................................FIC, 8

Gear hobbing machine....................................139

Inductive proximity switch ................................31

Didactic equipment for training .......................53

Gear milling solution for CNC milling

Industrial cleaning system ...............................166

Die coater ....................................................50, 51

& turn-mill machine .......................................107

Industrial control & sensing device ..................15

Die forging system ..........................................166

Glass ..................................................................16

Industrial grinding & cutting............................63

Die protection system .....................................168

Gomet bearing ..................................................71

Industrial vaccum cleaner ................................131

Digital laser scanner ........................................154

Graphic user interface .....................................166

Integrated machine safety solution .................125

Disc coupling ..................................................115

Grease......................................................105, 143

Intensifier pump system ..................................162

Drawing & forming compound ......................145

Grinding machine .......................16, 123,151,152

Iron & steel parts ........................................50, 51

Drill & Tap center ..........................................150

Grinding tool for hard material ................16, 123

Jewellery polisher ....................................... 162

Drilling machine .....................................141, 169

Grinding wheel .................................................39

Keyless transmisson element ...................... 162

Drilling tool ......................BC,FIC, 8, 43, 73, 95

Grooving & parting tool .................................113

Large part drilling machine ........................ 141

Drill .................................................................169

Gun drill.................................................... FIC ,8

Laser cutting machine .............................. 151,166

Drive technology ............................................BIC

Handling system module ..............................53

Laser exhibition.................................................99

EDM oil .................................................... 143

Heat exchanger machine .................................141

Laser shaping ............................................16, 123

Electronic level ................................................154

Heavy duty cycling duical bearing ....................71

Lathe ...................................................................5

Element shrink disc ........................................162

Helical gear box ................................................14

Lathe machine.................................................161

Encoder .............................................................15

Hex bolt ..........................................................163

Leak-test equipment .......................................169

Engineering slide chart ...................................152

High power UPS system.................................171

LED ..................................................................31

Exhaust brake system part ................................76

High precision machining service .....................76

Length gauge .................................................BIC

Exhibition..........................................................99

High precision tool holder ................................25

Lens mold ...................................................50, 51

Exhibition - Engineering Expo ..............134, 160

High speed drill tap centre ...............................79

Level controller .................................................15

Exhibition- IMTEX 2013 ................................22

Himtex 2012 ...................................................158

Line shaft ........................................................155

Exposed linear encoder ..................................BIC

HMC ..............................................................141

Linear bearing & shaft....................................155

Extruding ..........................................................63

Hold back ........................................................162

Linear guide ways ...........................................155

Factory automation .................................... 116

Holder ...............................................................39

Linear motion system .....................................155

Fastener ...........................................................163

Holemaking tool ....................................29,50, 51

Load break switch .............................................31

Fibre disc .........................................................155

Horizontal machining centre ................. 5, 13, 79

Locking element..............................................115

Fibre laser cutting machine ...............................45

Hydraulic & gear oil .......................................105

Lubricant .........................................................143

August 2012 - MODERN MACHINE TOOLS 175

List of Products Product

Pg No

Product

Pg No

Product

Pg No

Machine & tools lubricator ..........................83

Needle roller bearing .........................................71

Precision switches single & multiple ................31

Machine measurement ...................................BIC

Non backlash rack & pinion ...........................167

Press brake machines ........................................52

Machine tap ......................................................39

Non backlash speed reducer............................167

Process automation and control equipment......53

Machined casting ..............................................76

Non-sparking tool ...........................................161

Production grinder ..........................................156

Machining & grinding fluid ...........................145

Nut .................................................................163

Proximity sensor ................................................15

Machining centre ............................................139

Oil ........................................................... 143

Punching laser cutting ......................................45

Magnescale technology ...................................157

Optical measurement ........................................27

Punching shearing machine ..............................45

Magnetic chuck ...............................................152

Other automation accessories .........................109

Push buttons .....................................................31

Magnetic modular encoder ............................BIC

Pad printing machine ................................. 149

Rack .......................................................... 173

Material testing .................................................27

Panel bending machine .....................................45

Rack & pinion.................................................155

Measured value acquisition and display .........BIC

Panel meter .....................................................177

Radial drilling machine ............................ 161,169

Measurement equipment...................................27

Parallel & woodruff key ..................................153

Rail system ......................................................154

Measuring & monitoring relay for 1ph/3ph.....15

PCB drill .....................................................50, 51

Reamer .......................................................FIC, 8

Mechanical press .............................................165

PCD & CBN tool ..........................................183

Relay ................................................................177

Metal bellow coupling.....................................115

Pearldex ...........................................................167

Robotic bending machine ...............................166

Metal cutting tool .............................................61

Pedestal buffer .................................................162

Roll forming machine .......................................45

Metal working fluid ........................................143

Pedestal grinder (economy model)..................162

Roller bearing ..................................................135

Metrology equipment........................................27

Phase failure relay ...........................................177

Rolling oil........................................................145

Metrology instrument & solution ...................179

Photo electric sensor .........................................15

Rotary ..................................................................5

Micron drill .................................................50, 51

Photonic exhibition ...........................................99

Rotary damper...........................................68, 114

Milling......................................... 29, 43, 73, BIC

Pillar drilling machine.....................................169

Rotary encoder ...............................................BIC

Milling centre......................................................5

Pilot light ..........................................................31

Rotary joint & union ................................68, 114

Milling cutter .....................................FIC, 8, 113

Planner machine..............................................161

Rotary switch ....................................................31

Milling grade.................................................FGF

Plano-miller.....................................................161

Rotating union ..........................................68, 114

Milling machine ........................................49, 141

Plant lubrication system ....................................83

Rust preventive solution ........................... 143,145

Milling tool ...................................50, 51, 95, BC

Plasma cutter ...................................................154

Safety light curtain .......................................15

Mini machining centre....................................165

Plasma cutting machine ....................................45

Safety protection device ....................................31

Minidex & minitable series.............................167

PLC.......................................................... 127,167

Screw machine ..................................................49

Modular tooling system .............................FIC, 8

Plugs and socket................................................31

Screw press ......................................................164

Motor ................................................................14

Portable measurement arm .............................154

Scrubber dryer .................................................131

Motor protection circuit breaker.......................31

Portable radial drill .........................................156

Sealed linear encoder......................................BIC

Mould components .....................................50, 51

Power chucking cylinder ...................................11

Self tapping & machine screw ........................163

Moulding...........................................................63

Power source .....................................................91

Servo controlled voltage stabiliser ............ 162,169

Multi function turret .........................................37

Power tool .......................................................153

Servo drive.......................................................127

Multi functional tool .......................................113

Powerful index torque .....................................167

Servo mechanical press....................................162

Multi spindle head ..........................................152

Powerhouse for 5-axis machining ...................153

Servo motor & drive .......................................109

Multimedia union .....................................68, 114

Precision locknut .............................................155

Servo-insert coupling ......................................115

Neat cutting oil .......................................... 143

Precision steel ............................................16, 123

Shaping machine .............................................161

176 MODERN MACHINE TOOLS - August 2012

List of Products Product

Pg No

Product

Pg No

Product

Pg No

Shock absorber ..........................................68, 114

TCG (runner & ring) .....................................167

Vertical and horizontal machining centre.........74

Shrink fit adaptor ..............................................76

Temperature controller .............................. 15,177

Vertical boring machine ..................................161

Shrink fit technology ........................................39

Temperature indicator.....................................177

Vertical machining centre-single /

Simple air- driven control ...............................167

Tensioner nut ..................................................162

double column ....................................5,11, 79, 87

Single disc .......................................................131

Thermometer ..................................................164

Vertical turning lathe ......................................151

Single limit switch ............................................31

Thread mill .....................................................107

Vertical turning machine ......................... 139,161

Sinking EDM .................................................183

Thread milling cutter & taps holder ...........38,39

Vertical turnmill centre ...................................139

Siphon system ...........................................68, 114

Threading tool ................................................ BC

Vertical turret lathe ...........................................28

Slant / flat bed ..................................................79

Thrush ball bearing ...........................................71

Vision sensor .....................................................15

Sleeve bearing....................................................71

Timer.................................................................15

Visual optical system .......................................150

Small size ball bearing.......................................71

Tool holding system.............................. 39,76,149

VMC/HMC machine .......................................94

Solid carbide drill with IC ................................61

Tool setter .......................................................150

Vortex ..............................................................152

Solid carbide reamer with IC............................61

Toolholding collect ...........................................55

Waterjet cutting system.............................. 167

Solid carbide special mill ..................................61

Tooling system .......................................... 29, BC

Wear part ........................................................113

Solid carbide special reamer ..............................61

Toolings for EDM / WEDM / VMC-S

Wear resistant tool ......................................50, 51

Solid rotating tool .............................................39

/ HMC-S ..........................................................45

Wire cut EDM .........................................87, 183

Soluble cutting oil ...........................................143

Touch probe ...................................................BIC

Wire drawing lubricant ...................................143

Special induction hardening machine ...............91

Track roller......................................................162

World radio system .........................................150

Special purpose machine .................................139

Trade show........................................................99

Speciality oil ......................................................39

Transmission ...................................................153

INTERNATIONAL

Spindle nose tooling........................................113

Transparent gel ...............................................105

Association ........................................................64

Stacking system .................................................45

Tube straightening machine ...........................168

Cold forming machine ....................................172

Stainless steel & fastener ...............................163

Tubing accessory ...............................................53

Electromagnetic chuck ....................................170

Standard induction hardening machine ............91

Turbo charger part ............................................76

High speed double column milling

Static tool ........................................................149

Turning ....................................... 29, 43, 73, BIC

machining center ...............................................59

Steam cleaner ..................................................131

Turning center ................................................150

Linear motor thread & gear grinder ...............149

Stepper motor & drive ....................................109

Turning holder ................................................113

Modular boring system ...................................172

Strong type ball reducer ..................................167

Turning tool ........................................50, 51, BC

Multi-flute thread mill ....................................170

Super precision bearing .....................................71

Turret ................................................................11

Multi-spindle automatic lathe.........................172

Surface grinding machine .......................... 79,164

Turret punching machine .................................45

Plate bending machine ....................................172

Surface plate ....................................................161

Ultra high pressure apparatus ................. 50, 51

Professional high speed machine ......................59

Sweeper ...........................................................131

Universal grinding machine ............................163

Servo motor .....................................................170

Swiss rotary table ............................................161

Vacuum chuck .............................................37

Spindle motor..................................................172

Switching relay ..................................................15

Valve ..................................................................53

Synthetic compressor lube...............................170

Synthetics lubricant .........................................143

Valve terminal ...................................................53

Tray-conveyer armature production line.........172

Tap .................................................FIC, 8, 38

VDI tool holder ..............................................149

Vertical machine center.....................................59

Taper pin.................................................. 153,168

Vehicle lubricator ..............................................83

Vertical turning centre ....................................170

Tapping system .................................................55

Velocity & feed controller.........................68, 114

Wire cutting EDM .........................................170

COC - Cover on Cover FGF - Front Gate Fold FIC - Front Inside Cover BIC - Back Inside Cover BGF - Back Gate Fold BC - Back Cover

178 MODERN MACHINE TOOLS - August 2012

List of Advertisers Advertiser’s Name & Contact Details Accut Machinery Co. Ltd.

Pg No 151

Advertiser’s Name & Contact Details

Pg No

Drake Manufacturing

149

Advertiser’s Name & Contact Details Festo Controls Ltd

T: +86-411-84804589

T: +330-847-7291

T: +91-80-22894100

E: info@accutmachinetools.com

W: www.drakemfg.com

E: info_in@festo.com

W: www.accutmachinetools.com

Drass Mechatronics & Machinery Pvt

T: +91-80-23478764

Fullton Machinery Co Ltd

E: info@drassautomech.com

T: +86-411-82767678

E: customercare@acemicromatic.com

W: www.drassautomech.com

E: fullton@fulltontech.com

W: www.acemicromatic.net

Durga Bearing Pvt Ltd

T: +91-22-6876073

G W Precision Tools India Pvt Ltd

E: inquiry@durgabearings.com

T: +91-80-40431252

E: arizona.company11@gmail.com

W: www.durgabearings.com

E: info@gwindia.in

Austin Engineering Company Ltd

161

135

Dwij Consultants

149

T: +91-79-26760747

Ganesh Techmachinery Pvt Ltd

W: www.aec-bearings.com

E: info@dwijcon.com

T: +91-11-41612203

W: www.dwijcon.com

E: rajesh@ganeshmachinery.com

T: +91-20-25690044

EFD Induction Limited

E: autocnc@vsnl.com

T: +91-80-7820404

W: www.autotechcnc.com

E: sales@efdgroup.net.

Big Daishowa Seiki Co. Ltd

Electronica Hitech Machines Pvt Ltd

W: www.big-daishowa.com

T: +91-20-30435400 76

T: +91-22-67933000 W: www.indiantool.com

T: +91-20-39310000

Cenlub Industries Ltd

T: +91-129-4113701 W: www.cenlub.in

T: +91-09819552270 113

T: +91-33-24947146

E: jay@gentiger.com.tw 38

E: gskwang@hotmail.com 134, 160

E: info@guhring.in 52

W: www.guhring.in Haas Automation India Pvt Ltd

E: emre.ozkaya@ermaksan.com.tr

E: indiasales@haascnc.com Essor International Inc

W: www.coatecindia.com

W: www.essor.com.tw

119

W: www.haascnc.com Heidenhain Optics & Electronics (I)

181

Estern Petroeums (P) Ltd

143

T: +91-2225299990

E: info@heidenhain.in

E: rachna.jindal@cii.in

E: office@eastto.in

W: www.heidenhain.in

W: www.bsxindia.com

W: www.eastto.in Hi-Tech Robotic Systemz Ltd 10

Farmax Machines Private Limited

T: +91-80-42660122

T: +91-80-28435034

E: sandesh.kumar@doosan.com

E: skr@farmax.in

W: www.doosaninfracore.com

W: www.farmax.in

180 MODERN MACHINE TOOLS - August 2012

BIC

T: +91-44-30234000

T: +91-124-4014060

Doosan Infracore India Pvt Ltd

T: +91-22-61392800

W: www.ermaksan.com.tr

E: info@coatecindia.com

Confederation of Indian Industry

FIC

T: +91-80-40322500

W: www.engg-expo.com

T: +90-224-2947500

W: www.gsk.com.cn Guhring India Private Limited

E: engexpo@infomedia18.in

W: www.ceratizit.com

T: +91-172-5063436

T: +91-886835186

Ermaksan Sheet Metal Working Machinery

116

W: www.gentiger.com.tw GSK CNC Equipment Co. Ltd

E: info@ceratizitindia.co.in

Coatec India

T: +886-4-2683-6919

W: www.emugeindia.com Engineering Expo

W: www.gelco-world.com Gentiger Machinery Industrial Co. Ltd.

E: marketing@emugeindia.com

E: cenlub@cenlub.in

Ceratizit India Pvt Ltd

E: info@gelco-world.com 94

W: www.electronicahitech.com Emuge India Pvt Ltd

177

T: +91-79-22200902

E: marketing@electronicahitech.com

E: itmth@idiantool.com

W: www.ganeshmachinery.com Gelco Electronics Pvt Ltd

W: www.efd-induction.com

T: +81-729-828277

Birla Precision Technologies Ltd (B

W: www.gwindia.in

E: sales@aecbearings.com

Autotech Machine Tools Sales & Ser

W: www.fulltontech.com

T: +91-098230030618

Arizona Company

W: www.festo.com

T: +91-80-41492285

Ace Micromatic Group

Pg No

T: +91-124-4715100 E: marketing@hitechroboticsystemz.com W: www.hitechroboticsystemz.com

List of Advertisers Advertiser’s Name & Contact Details

Pg No

Hyderabad Intl Trade Expositions Lt

158

Advertiser’s Name & Contact Details Korloy India Tooling Pvt. Ltd.

Pg No 73

Advertiser’s Name & Contact Details Neway CNC Equipment (Suzhou)Co.,Ltd

T: +91-9000737325

T: +91-124-4930080

T: +(281)276-7100

E: sk@hitex.xo.in

E: sales.kip@korloy.com

E: newaycnc@gmail.com

W: www.himtexexpo.co.in

W: www.korloy.com

W: http://www.newaycnc.com

Hyundai Wia India Pvt. Ltd

159

Kyocera Asia Pacific India Pvt Ltd

Nikon India Pvt Ltd

T: +91-9940653703

T: +91-9650892692

T: +91-124-4688500

E: mvhari@gmail.com

E: r_ota@kyocera.net.in

E: nind.Inst@nikonoa.net

W: www.hyundai-wia.com

W: www.kyocera.com.sg

W: www.nikon-instruments.jp/eng/

Igus India Pvt Ltd

Larsen & Toubro Limited

T: +91-80-39127800

T: +91-22-67051093

E: info@igus.in

E: sm.haridas@larsentoubro.com

W: www.igus.in

W: www.larsentoubro.com

IMS Council

Larsen & Toubro Ltd

T: +91-9311903222

T: +1800-2335858

E: sachin.patil@ims2012.in

E: cic@lntebg.com

W: www.ims2012.in

W: www.larsentoubro.com

Indian Machine Tool Mfgr’S Association

136

Lexis Tooling Systems

T: +91-80-66246600

T: +91-422-3052110

E: augustin@imtma.in

E: sales@iexisindia.com

W: www.imtma.in

W: www.lexisindia.com

Nilfisk Advance India Ltd

Pg No 74

179

131

T: +91-22-61188188 E: balajnee.soundararajen@nilfisk.com W: www.nilfisk.com 127

Nmtg Mechtrans Techniques Pvt Ltd.

162

T: +91-79-22821527 E: nmtg@nmtgindia.com W: www.nmtgindia.com 55

Omron Automation Pvt. Ltd.

T: +91-22-42288400 E: in_enquiry@ap.omron.com W: www.omron-ap.com

Indian Machine Tool Mfgr’S Association

Maco Corporation India Pvt Ltd

68, 69 ,114

T: +91-33-24758371

OSG India Pvt Ltd

E: info@imtex.in

E: rdutta@macocorporation.com

T: +91-20-66304407

W: www.imtex.in

W: www.macocorporation.com

W: www.osg-india.com

T: +91-80-66246600

Isgec Heavy Engineering Ltd

Makson Machines Pvt Ltd

169

P R Sales Corporation Pvt Ltd

T: +91-120-3301001

T: +91-278-2446437

T: +91-20-25437591

E: trading@isgec.com

E: info@makwanaeng.com

E: info@prsales.in

W: www.isgec.com

W: www.makwanaeng.com

W: www.prsales.in

Jagdeep Foundry (Regd.)

161

Metrol Corporation India Branch Off

Pramet Tools India Pvt Ltd

T: +91-1871-242750

T: +91-80-42105031

T: +91-124-4703825

E: jagdeepfoundry@rediffmail.com

E: sales@metrolindia.com

E: pramet.info.in@pramet.com

W: www.jagdeepfoundry.in

W: www.toolsensor.com

W: www.pramet.com

Jyoti CNC Automation Pvt. Ltd.

Mitutoyo South Asia Pvt Ltd

Precihole Machine Tools Pvt Ltd

T: +91-2827-287081

T: +91-11-26372090

T: +886-3-329-9968

E: info@jyoti.co.in

E: delhi@mitutoyoindia.com

E: pshtech@gmail.com

W: www.jyoti.co.in

W: www.mitutoyoindia.com

W: www.peei.com.tw

Kabel Schlepp India Pvt. Ltd.

165

MMI India Pvt Ltd

T: +91-80-41158997

T: +91-9811090046

E: gm@kabelschlepp.in

E: bhupender.singh@mmi-india.in

W: www.kabelschlepp.com

W: www.photonicsindia.net

Kamo Seiko Corporation

167

Neri Engineering

T: +81-565-76-0021

T: +91-80-28374885

E: market@kamo.co.jp

E: sales@nerigroup.in

W: www.kamo.co.jp

W: www.nerigroup.in

182 MODERN MACHINE TOOLS - August 2012

Premier Ltd

139

T: +91-22-61179009 E: ericadesouza@premier.co.in W: www.premier.co.in 109

Quaker Chemical India Ltd T: +91-33-22822181 E: sales@quakerchemindia.com W: www.quakerchem.com

145

List of Advertisers Quickmill Inc.

Pg No 141

Advertiser’s Name & Contact Details Shuter Enterprises India Pvt. Ltd.

Pg No

Advertiser’s Name & Contact Details

Pg No

173

Tyrolit India Superabrasive Pvt. Ltd

123

T: +705-745-2961

T: +91-44-32407116

T: +91-80-40953259

E: info@quickmill.com

E: 32407116@shuter.in

E: subrahmanya.kumar@tyrolit.com

W: www.quickmill.com

W: www.shuter.in

W: www.tylolit.com

Raajratna Ventures Ltd

163

T: +91-79-27561915

Suhner India Pvt Ltd

W: www.raajfasteners.com 105

E: francis@rajgrp.com

153

164

W: www.unilineindia.com Vargus Limited

W: www.suhner.com

T: +91-9730028248 155

T: +91-22-61567567

T: +91-120-4261026

107

E: vishal@vargusindia.com W: www.vargus.com

E: sales@superslides.in

Vijay Machine Tools Pvt Ltd

W: www.superslides.in

T: +91-22-24950886

E: lasco@rightvision.biz BC

T: +91-80-27839111

W: www.elmacovijay.com

Ringfeder Power Transmission India Pvt. Ltd 115

E: sales@taegutec-india.com

Wendt India Ltd

T: +91-44-26791411

W: www.taegutec-india.com

T: +91-4344-405500

E: vijayvernekar@wendtindia.com

E: sales.india@ringfeder.com Taiwan Machine Tool & Accessory Builders’

W: www.ringfeder.com

Association

W: www.wendtgroup.com 64

T: +886-4-2350-7586

Wexper India Ltd

T: +91-120-4671694

E: tmba@tmba.org.tw

T: +91-124-2210020

E: dghosh@ra.rockwell.com

W: www.tmba.org.tw

E: rajan.vaid@wexper.com

125

183

W: www.wexper.com

W: www.rockwellautomation.com Takamatsu Machinery Co Ltd

T: +81-76-2741403

Wohlhaupter India Pvt Ltd

T: +91-2692-230430

E: h.nakagawa@takamaz.co.jp

T: +91-9810405242

E: info@rotomotive.com

W: www.takamaz.co.jp

Rotomotive Powerdrives India Ltd.

W: www.wohlhaupter.com Teknic 157

T: +91-44-23612310

31 YG Cutting Tools Corporation Pvt Ltd

T: +91-22-26592392

E: admin@yg1india.com

W: www.tecknic.co.in

W: www.yg1.co.kr

W: www.samkrish.com Trigon Tooling Solutions Pvt. Ltd. 133

T: +91-44-23612310

T: +91-124-2370250 E: info@trigontools.com

E: info@samkrishmachinetools.com

W: www.trigontools.com

W: www.samkrishmachinetools.com Tungaloy India Pvt Ltd Sandvik Coromant India

FGF

T: +91-20-27104800

E: seco.india@secotools.com W: www.secotools.com/in

T: +91-22-61248888 W: www.tungaloy.co.jp.in

W: www.sandvik.coromant.com/in

T: +91-2137- 667300

50, 51

E: info@tungaloyindia.com

E: rupali.kavi@sandvik.com

Seco Tools India Pvt Ltd

Tussor Machine Tools Ind P Ltd

Looking For A Specific Product? pe Searching and sourcing products were never so easy. Just type MMT (space)

Product Name

T: +91-422-3200183

and send it to 51818

E: info@tussorindia.com

eg. MMT EDM and send it to 51818

W: www.pinachoindia.com

FGF - Front Gate Fold FIC - Front Inside Cover BIC - Back Inside Cover

184 MODERN MACHINE TOOLS - August 2012

T: +91-80-43543636

E: teknic@vsnl.com

E: info@samkrish.com

Samkrish Machine Tools

E: keshav.khurana@wohlhaupter.com

W: www.rotomotive.com Samkrish

162

E: elmaco@elmacovijay.com Taegutec India Ltd

W: www.rightvision.biz

Rockwell Automation

171

E: uniline@uniline.in

E: automation.in@suhner.com

Superslides & Bushes Corporation

W: www.rajgrp.com

Uniline Energy Systems Pvt Ltd T: +91-11-46661111

T: +91-80-27831108

T: +91-44-42288900

Rightvision (India) Pvt. Ltd.

W: siemens.com/sinumerik

E: sales@raajfasteners.com

Raj Petro Specialities Private Limi

Siemens Ltd

BGF - Back Gate Fold BC - Back Cover

Our consistent advertisers

Advertiser’s Name & Contact Details

MODERN MACHINE TOOLS

Reg No: MH / MR / WEST / 235 / 2012 â&#x20AC;&#x201C; 2014 RNI No: MAHENG / 2008 / 24347 Licence to Post at Mumbai Patrika Channel Sorting Office, Mumbai GPO., Mumbai 400 001 Date Of Posting 5th & 6th Of Every Month / English & Monthly. Date Of Publication: 28th of Every Month

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186